SERVICE INSTRUCTIONS
Please Note!
Actual gas
spring design
may appear
different from
what shown
here.
C
D
E
F
G
H
J
K
A
L
B
A)
Piston rod
B)* Dirt protection ring
C)* Lock ring
D)* Guide
E)
Tube
F)
Piston
(consists of two halves)
G)* Guide ring
H)* Oil
J)*
Cover screw
K)* Valve
L)** Grease
* = Parts included in the repair kit
** = included only for repair kit models:
TU/LCF/TL/TUS 3000-7500 and TU/TUR 10000
Warning!
Always read the permanently marked information on
the side of the tube before service to make sure you
use the correct repair kit.
Failure to exhaust all gas pressure prior to disassembly
could result in serious injury.
The maximum charging pressure is 150 bar (2175psi),
for HT 750, 120 bar (1740 psi).
Use only pure nitrogen gas, N
2
for charging.
A
lways wear safety goggles, when servicing
the gas spring.
Only specially trained personnel with good knowledge
about the products should carry out the maintenance.
Once the cover screw is removed, never lean directly
over the valve. Always direct the valve port away from
yourself and others.
Never use extreme force on the gas spring. Charged
gas springs are under high internal pressure and should
be protected from damage.
Always use protective jaws when clamping the
spring in a vice.
To achieve maximum service life, keep the gas spring
protected from dirt, drawing fluids, and grinding dust.
In some models there is a safety plug in the bottom
of the gas spring. This plug should under no
circumstances be removed. If the safety plug is
releasing gas the complete gas spring must be
replaced. Ensure the cause of the overstroke or
overpressure before a new gas spring is installed in
the tool. If uncertain, contact your distributor.
Disassembly
1) To obtain an easy working position, clamp the spring
in a vice (use protective jaws). Clamp the gas spring
in a leaning position (about 30°) with the piston rod
upwards. For all models except 750, the valve port
should point upwards. For the 750, the valve port
should point downwards to prevent oil from leaking
out during the service.
2) Unscrew the G 1/8" cover screw (J) from the tube
using a 5 mm Allen key.
3) Empty the gas in the spring by screwing the threaded
end of the valve tool into the gas port until the valve
opens.
Warning! The valve (K) must not be unscrewed
until the piston rod can be pushed down by hand or
with a rubber mallet.
Once the gas pressure is released use the opposite
end of the valve tool to unscrew the valve. Pull the
valve from the port using the needle-nose pliers.
4) Tap the guide (D) into the tube, using a socket and
rubber mallet, until the lock ring (C) is exposed.
Remove the dust cover (B) which becomes loose
during the procedure.
Note! For model TU 3000 PED, the dirt protection
ring must be removed first before the guide is tapped
down into the tube.
5) Remove the lock ring (C) using the lock ring tool.
Warning! The lock ring could fly out, be sure to wear
safety goggle
s
.
6) Pull out the piston rod (A) including the piston halves
(F) and the guide (D), using a T-handle.
7) Remove the guide ring (G), the two piston halves (F)
and the guide (D) from the piston rod.
8) Save the piston rod (A), the tube (E) and the two
piston halves (F).
Inspection
9) Clean the tube, the piston rod and the piston halves.
10) Visually inspect piston rod and the tube. There should
be no scratches or dents on the inside surface of the
tube, the piston rod or the lock ring grooves. If defects
exist, replace the parts.