FIBRO 2486.22 Series Especificaciones técnicas

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MAINTENANCE INSTRUCTIONS

GAS SPRING DS

2486.22.

Maintenance instructions Gas spring DS

Document: Maintenance instructions

Document number: 2.7539.00.0915.0100000

Revision: R04-2020

Version: V01

Language:

In the German language, this document is the original version in the EU language of the manufacturer and is labelled

with the German national flag.

In the language of a country of use, this document is a translation of the original version and labelled with the national

flag of the country of use.

This document is referred to as "instructions" in the following text.

Number of pages in this manual including the title page: 30

These instructions are valid for the product

2486.22.

Gas spring DS

This document was created by

FIBRO GMBH

August-Läpple-Weg

DE 74855 Hassmersheim

Phone: +49 (0) 62 66 73 0

Fax: +49 (0) 62 66 73 237

E-mail: [email protected]

Internet: www.fibro.de

Without the prior written permission of FIBRO GMBH, this document must not be copied or

reproduced, either in full or in part.

The instructions are intended only for the operator of the described only

and must therefore not be made available to uninvolved third parties - in particular to competitors.

Maintenance instructions Gas spring DS 3/30

Contents

1 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.2 Safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.3 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.4 Residual risks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.1 Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.2 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.2.1 Check gas pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.3 Repairs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.3.1 Required spare parts, tools and tool kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

2.3.2 Evacuating gas pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.3.3 Dismantle gas spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

2.3.4 Clean and check components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

2.3.5 Assemble gas spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.4 Fill with nitrogen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

3 Indexes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.1 Third-party products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.2 Glossary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.3 Index of figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3.4 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4 Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.1 Personal notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4/30 Maintenance instructions Gas spring DS

Safety

1SAFETY

1.1 Safety information

The statements contained in this document only apply to the maintenance of the stated gas

springs and are only for the use by trained and authorised staff.

Staff has to have the necessary training, experience and product knowledge as well as specialist

tools in order to carry out maintenance work correctly.

Staff has to have fully read and understood this document prior to carrying out any maintenance

work.

Replacement of spare parts without special training or knowledge of the maintenance instruc-

tions and without the specialist tools can be dangerous and may lead to accidents causing se-

vere injuries or even death.

Most accidents during maintenance occur due to disregarding the basic safety regulation.

Noticing a potential danger can prevent accidents from happening. Safety information in this

document warn about potential risks. FIBRO GMBH can not foresee all situations which may

potentially cause risks. The warnings in this document are therefore not all encompassing.

If a work material, an act, a work method or work technique is used which has not been specif-

ically suggested by FIBRO GMBH, then the user has to ensure the safety for himself and other

persons.

The information, descriptions and illustrations in this documents are based on the information

on the basis of information which was available at the point of creation of this document.

Illustrations show examples of a potential gas spring and are not to scale.

Descriptions, tightening torques, operating pressures, measuring methods, illustrations and oth-

er points are subject to change at any time. The changes can have an influence on the compo-

nent's properties. Prior to starting any work, obtain the currently available information.

Maintenance instructions Gas spring DS 5/30

Safety

1.2 Safety instructions

These instructions contain safety notices intended to draw attention to possible dangers that

should be observed to prevent injury.

The pertinent text describes

• the type of danger

• the source of danger

• the options for preventing injuries

• the consequences in case of non-observance of the warning notices

The safety instructions are emphasised by a colour signal bar with warning triangle and signal

word.

The signal bars have the following meaning:

DANGER!

A safety notice on a red signal bar with the signal word DANGER designates a hazard

with a high risk level which, if not avoided, will result in death or severe injury.

WARNING!

A safety notice on an orange signal bar with the signal word WARNING designates a haz-

ard with a medium risk level which, if not avoided, might result in death or severe injury.

CAUTION!

A safety notice on a yellow signal bar with the signal word CAUTION designates a hazard

with a low risk level which, if not avoided, could result in minor or moderate injury.

1.3 General instructions

In addition to the safety notices, these instructions contain information that must be observed to

prevent property damage.

The pertinent text describes

• the possible reason for property damage

• the possibilities for preventing property damage

Notices of possible property damage are emphasised by a blue signal bar and the signal word

ATTENTION.

NOTICE

Notices for the prevention of property damage are not related to possible injuries.

Furthermore, these instructions contain general information on use.

General information on use and tips for certain applications are emphasised with a blue

information symbol.

6/30 Maintenance instructions Gas spring DS

Safety

For safe maintenance further, applicable documents are necessary. The information in these

documents have to be adhered to.

1.4 Residual risks

WARNING!

Filled gas springs are under high internal pressure.

Before repairing, drain the nitrogen completely.

To drain, open the valve carefully and only slightly

Wear safety glasses. Eye injuries due to nitrogen leaks

After removing the locking screw, never bend directly over the valve. Never direct the fill

opening towards persons

Only unscrew the valve when there is no more nitrogen flowing out and the piston rod can

be pushed in by hand. Injuries due to valve flying out.

If assembled incorrectly, parts may be propelled out after filling. Observe the precise instal-

lation position of the spare parts. Never direct the piston rod towards persons. Injuries pos-

sible due to parts flying out.

WARNING!

Use of incorrect spare parts

Installing the incorrect spare parts results in a loss of safety.

After filling with nitrogen, parts may be propelled out due to internal pressure.

Before repair, always ensure that the correct set of spare parts is being used.

Injuries possible due to parts flying parts.

NOTICE

Damages during repair

Always use protective jaws when clamping a gas spring into a vice. Ensure a clean environment.

Grooves, bumps or other damages can cause leakages.

Never exercise undue force to the gas spring during repair. Protect against damages.

Let nitrogen flow in slowly during the filling process. The valve of the gas spring can be dam-

aged.

For the filling process, only use pure nitrogen N2 of Grade 5.0 purity or higher.

Highest permissible filling pressure: 150 bar (2175 psi).

Gas spring operating instructions

Safety data sheet "Exchange of spare parts"

Operating instructions filling and control fitting.

Maintenance instructions Gas spring DS 7/30

Maintenance

2 MAINTENANCE

2.1 Components

Fig. 2-1 Components of the gas springs

1 Piston rod

2 Guide

3 Dirt ring guard

4 Circlip

5 Warning tape

6 Locking screw on service port

7 Separated piston disc

8 Guide ring

9 Filter screen

10 DS piston seal

11 Flow restrictor

12 DS piston

13 Sealing ring

14 Non-return valve

15 Circlip halves

16 DS piston O-ring

17 G 1/8 Fill opening locking screw

18 Valve

The components marked * are included in the spare parts set.

8/30 Maintenance instructions Gas spring DS

Maintenance

2.2 Inspection

2.2.1 Check gas pressure

NOTICE

Use the tools given below for the test. The tools are available from FIBRO GMBH. Damage to

the gas springs when using other tools.

Pos. Description Article number

[A] Filling and checking equipment 2480.00.32.21

[B] G1/8" filling adapter 2480.00.32.11

[C] Filling hose 2480.00.31.02

Cylinder pressure reducer (optional) 2480.00.32.07

Observe the operating instructions for the filling and checking equipment

2480.00.32.21.

G1/8“

A B C

Maintenance instructions Gas spring DS 9/30

Maintenance

1) Prepare filling and checking equipment.

– Turn the small knob (a) to the left as far as it will go. This will move the release pin (b)

into the retracted position.

– Close the outlet valve (c).

– Screw the filling adapter onto the M6 thread on the fittings. In the process, ensure that

the washer seal is located on the M6 thread.

2) Carefully unfasten the G1/8" locking screw via the fill opening of the gas spring using an

Allen wrench.

3) Unscrew and remove the locking screw.

4) Screw the filling and checking equipment into the fill opening of the gas spring by turning the

large knob.

5) Turn the small knob inwards. The release pin opens the valve. Caution! Do not turn the re-

lease pin inwards too far. Otherwise the valve may be damaged.

6) Read the filling pressure on the manometer display.

The permissible filling pressure is printed on the gas spring. If the filling pressure is too low, the

nitrogen must be topped up (see chapter 2.4 "Fill with nitrogen" on page 24).

2. 5.

10/30 Maintenance instructions Gas spring DS

Maintenance

7) After checking, turn the small knob to the left as far as it will go. The release pin moves into

the retracted position and closes the valve.

8) Slowly open the knob on the outlet valve and bleed the fittings.

9) Unscrew the fittings from the gas spring by turning the large knob.

10) Unscrew the filling adapter.

11) Screw the G1/8" locking screw into the fill opening of the gas spring.

– Tighten using a tightening torque of 15 - 18 Nm (11-13 lb-ft).

The locking screw has a sealing function and must always be fitted.

9. 11.

10.

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