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  9. Kaller M2 Original operating manual

Kaller M2 Original operating manual

SERVICE INSTRUCTION
8100-2003-B
Gas spring models
M2
MM2
MC3
MC3-SP
Strömsholmen AB
P.O. Box 216,
SE-573 23 Tranås, Sweden
Visiting Address:
Verkstadsgatan 16, Tranås
Phone: +46 140 571 00
Email: info@kaller.com
kaller.com
2
SERVICE INSTRUCTION
Please Note!
Actual gas spring design may appear different from that shown
here.
A) Piston rod
B)* Color coded ring
C)* Lock ring
D)* Guide
E) Tube
F)* Oil
G)* Valve
* = Parts included in the
repair kit
Warning!
•Make sure to use the correct repair kit.
•Make sure the correct internal components are being
used.
•Failure to exhaust all gas pressure prior to
disassembling could result in serious injury.
•The maximum charging pressure is180 bar (2610 psi)
•Use only pure nitrogen gas (N2) for charging.
•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 against 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.
•Always wear protective equipment incl. safety goggles
and rubber gloves, whilst servicing the gas spring in a
well ventilated area. Avoid direct contact with gas
spring lubricants and inhalation of any exhausting
gases.
•Only specially trained personnel with good knowledge
of the products should carry out the maintenance.
Disassembly
1) To obtain an easy working position, clamp the spring in
a vice (use protective jaws). Clamp the gas spring with
piston rod pointing downwards. Make sure not to
damage the tube.
2) For MC3-SP, unscrew the cover screw on the tube
using a 3 mm Allen key.
3) Empty all gas from the spring. Release it by screwing
the threaded end of the valve tool into the gas port until
the valve opens.
Warning! The valve (G) must not be unscrewed
until the piston rod can be pushed down by hand or
with a rubber mallet.
Once the gas is released use the opposite end of the
valve tool to unscrew the valve. Pull the valve from the
port with a pair of needle nose pliers.
4) Reposition the spring in the vice so the piston rod (A)
points upward. Note: Oil will drain from the bottom of
the spring. Tap the guide (D) into the tube, using a
socket and rubber mallet, until the lock ring (C) is
exposed. Remove the color coded ring (B) which
becomes loose during the procedure.
5) Remove the lock ring (C) using the lock ring tool.
Warning! The lock ring could fly out, be sure to
wear safety goggles.
6) Pull out the piston rod (A) and the guide (D), using the
piston rod removal tool (4017910).
7) Remove the tool from the piston rod (A). Remove the
guide (D) from the piston rod (A).
8) Save the piston rod (A) and the tube (E).
Inspection
9) Thoroughly clean the tube and the piston rod.
10) Closely inspect the piston rod and the cylinder tube.
There should be no scratches or dents on the inside
surface of the tube or on the piston rod. If these parts
are scratched or damaged in any way, then the gas
spring cannot be repaired and has to be replaced.
3
Assembly
11) Unpack the repair kit. Make sure the correct repair kit is
being used.
12)
Using the valve tool fit the valve (G) into the
charging port. Finger strength is enough to tighten
the valve.
13) Clamp the tube (E) in a vice with the opening upwards
14) Fit the guide (D) on the piston rod (A) so that the small
diameter of the guide is positioned toward the top of
the piston rod (see picture below).
15) Oil the inside of the upper tube end to prevent damage
to the guide O-ring.
16) Fill the tube with 2 ml oil.
Note! Be careful not to apply too much oil since
that may lead to high gas pressure increase.
17) Insert the piston rod with guide into the tube. Tap down
the guide (D) using a socket and rubber mallet until the
lock ring groove is exposed
18) Fit the lock ring (C) into the groove in the tube by
pushing one of the lock ring ends into the groove,
steadying it with your thumb and then hit the ring
inwards until it snaps into the groove. You can hear a
clicking sound when the ring snaps into position.
19) Pull out the piston rod (A) and the guide (D) using the
piston rod removal tool (4017910). Pull until the guide
stops against the lock ring (C).
If the guide not will stay up, there is vacuum inside the
gas spring. Eliminate this vacuum by temporarily
opening the valve (G) with the valve tool.
Note! Check to make sure the top edge of the guide
is flush with the upper edge of the tube. If it is not
flush, the guide is not fit correctly.
DO NOT charge the spring if the guide is not in the
correct position. Charging an incorrectly
assembled spring could result in serious injury.
20) Oil and fit the color coded ring (B) so it snaps into to
the groove in the guide.
Charging
For gas charging see Gas Charging Instruction
8200-1873 available at kaller.com
Correct
Incorrect

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