Atlas Copco Service & Maintenance Instructions

Rod Clamp Spring Unit

 Contents
Introduction ....................................................................................3

Safety Regulations .........................................................................4

Disassembly Instructions ..............................................................5

Assembly Instructions ...................................................................8

Nitrogen gas charging .................................................................14

Repair Kit (3719000567) contents ...............................................17

Tool Kit (3719000568) contents ...................................................17

 Atlas Copco Service & Maintenance Instructions

Introduction

The purpose of this manual is to describe how to service the Kaller Rod Clamp Spring Unit (RCSU).

The manual contains step-by-step instructions; showing you how to disassemble the RCSU, replace all
seals, reassemble the RCSU and finally charge the RCSU with nitrogen gas to the correct charging
pressure.

A repair kit, part number 3719000567, is available containing all seals, replenishing valve, lubricating
oil, etc. necessary to service the RCSU.

A tool kit, part number 3719000568, is available containing specialised tools necessary to carry out the
service.

It is our recommendation that this manual is read thoroughly and both the repair kit and the tool kit are
purchased before attempting to service the RCSU.

When servicing the RCSU, we recommend you replace the whole unit if there are signs of excessive
wear shown on any gas-sealing surface, such as the Piston (Item 1) and Cylinder (Item 2). If there is
hydraulic oil leakage, then the Piston Rod (Item 3) can be replaced.

All Safety Regulations must be followed when servicing the RCSU – read the section on
Safety Regulations thoroughly before you start.

Guide 5 1 Piston 2 Cylinder

4 Bottom

Mounting Plate 6

3 Piston Rod

KALLER Rod Clamp Spring Unit

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Atlas Copco Service & Maintenance Instructions

Safety Regulations

This symbol indicates WARNING of the risk of personal injury!

• Read all instructions carefully before you service the RCSU

• Do not attempt to service the RCSU if you are unfamiliar with the procedure.

• Do not remove the gas valve until all gas pressure has been released.

• Never lean over the gas valve. Direct the charging port away from you and other people when
working with the valve plug and valve.

• Never use unnecessary force when working on the RCSU and protect the unit from mechanical
damage.

• Do not attempt to modify the unit in any way.

• Do not attempt to recharge the RCSU until you are sure everything is correctly assembled.

• When recharging the RCSU, use only nitrogen (N2) gas. The use of other gas types could result
in personal injury or failure of the RCSU.

• Never charge the RCSU with nitrogen pressure above a maximum 150 bar (2175 psi).

• Always use the correct torque setting when fitting the mounting screws.

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 Atlas Copco Service & Maintenance Instructions

Disassembly Instructions

1. Fix the Rod Clamp Spring Unit (RCSU)

in a vice fitted with protective jaws as
shown and remove the valve plug using a
5mm Allen key. Using the valve tool ,
carefully release the gas pressure by
screwing the G1/8” threaded end of the
tool into the gas port. When all gas
pressure is released use a plastic mallet to
tap on the bottom to make sure that it
moves when tapped. Remove the valve
using the other end of the valve tool.

Never attempt to remove the valve

until all gas pressure is released. Avoid
leaning over the valve when removing
it in case it should fly out.

2. Using a mounting sleeve, tap in the

bottom of the RCSU to expose the lock
ring. Remove the lock ring using the lock
ring tool as follows. Hold the lock ring
steady in the groove opposite to the lock
ring opening with your left hand and with
the lock ring tool in your right hand,
hook the tip of the tool under the left
edge of the lock ring. Push down on the
tool against the edge of the cylinder and
remove the lock ring. Remove the RCSU
bottom using a G1/8” threaded
T-handle in the gas port.

3. Drain the assembly oil from the RCSU

into a suitable container. Remove the two
M12 screws from the mounting plate
using a hook spanner to prevent the plate
from rotating.

4. Remove the circlip from around the top

of the RCSU. Then using an O-ring hook
or small screwdriver remove the dirt
cover.

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Atlas Copco Service & Maintenance Instructions

5. Push down the guide using the mounting

sleeve and plastic mallet until the lock
ring is exposed. Remove the lock ring as
previously described.

6. Using the two M12 screws for grip,

remove the piston rod assembly and
guide. You may need to first loosen the
assembly from the tube using the mount-
ing sleeve and the plastic mallet on the
underside of the piston.

7. Fix the piston rod assembly in a vice

using protective jaws to prevent damage
to the chromed piston rod. Remove the
circlip and unscrew the piston from the
piston rod using a hook spanner.

8. Remove and discard all seals, wear rings

and back-up rings from the piston both
externally and internally.
Make sure not to scratch the sealing
grooves when removing the seals. The
piston should be replaced if scratches are
found on any sealing surface.

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 Atlas Copco Service & Maintenance Instructions

9. Remove the piston rod wiper from the

guide using a plastic hammer and flat-
headed screwdriver for leverage. Carefully
remove the two wear rings and piston rod
seal, avoiding damage to the seal groove.
Remove the external O-ring and back-up
ring also.
The guide should be replaced if scratches
are found on any sealing surface.

10. Wash all parts thoroughly and check for

scratches and damage to sealed surfaces.
Damaged or scratched parts should be
replaced.

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Atlas Copco Service & Maintenance Instructions

Assembly Instructions

1. Before assembling the piston seals make

sure the piston has been washed thor-
oughly. Lightly lubricate all O-rings, wear
rings and back-up rings with assembly
oil. Assemble the piston seals using the
piston assembly tools making sure they
are assembled according to the drawing.

Guide Ring
Dynamic
Dynamic Seal
Seal
O-Ring

O-Ring
Back-up Ring
O-Ring

O-Ring

Back-up
Ring

2. Secure the piston rod in a vice fitted with

protective jaws and assemble the piston.
Fit the small circlip around the end of the
piston rod.

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 Atlas Copco Service & Maintenance Instructions

3. Check to make sure the guide has been

washed thoroughly. Using a piston rod
wiper assembly tool, press in the wiper
until the metal casing fits flush into the
groove. Lightly lubricate all O-rings,
wear rings and back-up rings with assem-
bly oil. When fitting the piston rod seal
make sure it is assembled according to
the drawing shown here.

Back-up Ring O-Ring

O-Ring

Piston Rod Wiper

Dynamic Seal

Guide Rings

4. Using a mounting sleeve and plastic

mallet, fit the guide onto the piston rod
assembly making sure the piston rod
wiper faces upwards.

5. Lubricate the inside opening of the cylin-

der using assembly oil at the end closest
to the hydraulic oil connection.

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Atlas Copco Service & Maintenance Instructions

6. Using a the two M12 threaded screws,

lower the complete assembly into the
lubricated end of the cylinder.

7. Remove the M12 screws and tap down

the assembly using the mounting sleeve
until the lock ring groove is fully ex-
posed. Initially you may need to apply a
fair amount of force to tap down the
assembly.

8. Fit the lock ring by first positioning one

edge of the lock ring into the groove
whilst holding the lock ring as flat to the
cylinder as possible. With the lock ring
held down as flat as you can manage, hit
the other free end of the lock ring side-
ways with a plastic mallet until you hear
the lock ring snap into place.

9. Use the two M12 screws again to help

pull out the assembly against the lock
ring.
The groove in the guide should be in-line
with the end of the cylinder.

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 Atlas Copco Service & Maintenance Instructions

10. Press the dirt cover into the gap around

the top of the cylinder and fit the circlip
into the groove in the guide.

11. Hold the RCSU in a vice fitted with

protective jaws as shown and fill with
40ml of assembly oil.

12. Make sure the RCSU bottom is clean

before lightly lubricating and fitting the
O-ring and back-up ring as shown here.
Note! The back-up ring should sit
closest to the threaded holes in the
base.

13. Position the RCSU in the vice. Use the

mounting sleeve and plastic mallet to fit
the bottom into the cylinder with the four
M10 holes facing upwards. Tap down on
the bottom until the lock ring groove is
exposed.

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Atlas Copco Service & Maintenance Instructions

14. Fit the lock ring using the same technique

as before.

15. Screw the T-handle into the G1/8” gas

charging port and pull out the bottom
against the lock ring. Remove the T-
handle from the gas port.

16. Use the valve tool to fit the valve into the
gas port. Only finger strength is required
to tighten the valve.

17. Assemble the front mounting plate. Use

Loctite 242 thread lock and apply 135
NM torque with the help of a hook span-
ner to fasten the M12 screws.

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 Atlas Copco Service & Maintenance Instructions

18. The two M12 threaded holes in the front

90
mounting plate and two opposing M10

90
˚

˚
holes in the bottom should be aligned in
the same plane. This plane must be
perpendicular to the hydraulic G3/8” oil
connection port. Use M12 and M10
screws together with a long screwdriver
to help line up the holes.
Front View Rear View

19. The RCSU is now ready to be charged

with nitrogen (N2) gas.

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Atlas Copco Service & Maintenance Instructions

Nitrogen gas charging

Before attempting to charge the RCSU,

give consideration to the following
safety points:

• For safety reasons, never lean over the

charging port.

• Do not attempt to charge the RCSU unless

you are familiar with gas charging.

• We recommend your nitrogen gas bottle be

fitted with a pressure regulator to control
the output pressure from the bottle.

Charging instructions

1. Secure the RCSU firmly in a vice fitted

with protective jaws with the bottom
facing upwards. Pressure
release valve Small knob
2. Before connecting the replenishing arma-
ture to the bottom plate make sure the
sealing washer and G1/8” adapter are in Large knob
place. Next attach the armature to the
charging port by screwing the larger knob
clockwise. Make sure the smaller knob has
not been twisted clockwise to expose the Pressure
valve pin. Gauge

Sealing
Note! Washer
Twisting the smaller knob clockwise
pushes out the valve pin from inside the G1/8”
armature. This valve pin can be used to Shut off Charging
open the valve when the armature is in valve Adapter
place but is not needed when charging.

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 Atlas Copco Service & Maintenance Instructions

3. Close the armature’s pressure release

valve by screwing it clockwise.

4. With the nitrogen gas bottle regulated to

deliver 110 bar, slowly open the shutoff
valve.

5. Slowly charge the RCSU until the pres-

sure gauge fitted to the armature reads
110 bar.

6. Close the shutoff valve and then open the

pressure release valve until the pressure
gauge reads 0 bar.

7. With the pressure release valve closed,

slowly twist the small knob clockwise to
open the valve. The moment the pressure
gauge displays the pressure in the RCSU
stop twisting the small knob.

8. By opening and closing the pressure

release valve, reduce the pressure to 107
bar. Twist the small knob anticlockwise to
close the valve.

9. Open the pressure release valve before

removing the armature by twisting the
larger knob anticlockwise.

10. Fit the G1/8” protective plug to the gas

charging port and the G3/8” plug to the
oil connection port. The RCSU is now
ready for service once again.

11. In order to make sure all seals have been

correctly assembled, allow the RCSU to
stand on its Mounting Plate end for 24
hours. After 24 hours, compress the
RSCU in a suitable Test Rig to measure
the initial force of the RCSU.

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Atlas Copco Service & Maintenance Instructions

19 15

20 2 20 5 1 13 14 6 4 6
18 10 9 6 7 8 3 14 13 1

11

12

7
5
9
8

1 2

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 Atlas Copco Service & Maintenance Instructions

Repair Kit (3719000567) contents

Pos. Quantity Description Dimension

1 2 Lock ring Ø7

2 1 Circlip SgA95

3 1 Circlip SgA35

4 1 Piston guide ring Ø100/95 x 9.7

5 1 O-ring Ø89.1 x 5.7

6 3 Piston seal Ø100/84.9 x 6.3

7 1 Back-up ring Ø35/39.8 x 1.3

8 1 O-ring Ø35.5 x 3

9 1 Back-up ring Ø50/54.8 x 1.3

10 1 O-ring Ø49.5 x 3

11 1 Valve Vg5

12 1 Plug VSTI G1/8"

13 2 Back-up ring Ø95/100 x 1.3

14 2 O-ring Ø94.5 x 3

15 1 Plug VSTI G3/8"

16 1 Label 98 x 70

17 2 Oil OY 95

18 1 Piston rod wiper Ø50/60 x 10

19 1 Piston rod seal Ø50/65.1 x 6.3

20 2 Piston rod guide ring Ø50/55 x 9.7

21 1 Service and Maintenance instructions

Tool Kit (3719000568) contents

Pos. Quantity Description Dimension

1 1 Lock ring tool

2 1 T-handle G1/8"

3 1 Needle nose pliers

4 1 Valve tool

5 1 Mounting sleeve Ø71.5/86

6 1 Wiper mounting tool

7 1 Piston seal mounting sleeve

8 1 Piston seal guide sleeve

9 1 Piston seal distance sleeve

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 6991 1252 01

Atlas Copco Craelius AB

SE-195 82 Märsta, Sweden
Tel: +46 8 587 785 00 Fax +46 8 591 187 82
www.atlascopco.com