Applies to

• All Lotem 800™
• Lotem Quantum
• Lotem Quantum Spectrum

Priority = Next failure
Release date = 13 Nov 2002

Component

Front and rear door gas spring pistons

Problem

The currently installed pistons do not open the doors properly, or have become weakened.

Solution

Replace the pistons with stronger ones.

Time needed to implement

1.5 hours for front and rear doors

Parts needed

FCO Kit #512-00254A (Front & Rear Doors "Gas Spring" Old Chassis Replacement Kit) includes the following parts:

Special Tools needed

Procedure

On old machines only, replace rear door pistons in addition to front door pistons.

Front door piston replacement procedure:

1. Remove the old pistons (right and left sides):
   Important Note: The new pistons will support the door in a wider open position than before. You must first disconnect the existing pistons on both sides, then temporarily support the door at its widest open position before installing the new pistons. You can use a wooden board to prop up the door or use duct tape (from front to back doors) until the new pistons are installed.
   1. Insert a small screwdriver between the piston head and the spring.
   2. Gently loosen the spring with the screwdriver and remove the spring by sliding it off with the screwdriver. Do not force the spring off.

Picture 1

The piston is released from the machine.
The ball head screw remains attached to the machine. Do not remove it.

Picture 2

2. Install the new pistons:

1. Grasp the two socket ends of the piston and rotate them so that they are facing 180º from each other.
2. Gently loosen the spring with the screwdriver and remove the spring by sliding it off with the screwdriver. Do not force the spring off.

3. Hold the body of the piston upwards.
4. Gently press the piston onto the ball head screw that is still attached to the machine after you removed the old piston. See Picture 1 above.
   Note: The new ball head screw that is provided with the new piston may be discarded.

5. Gently press the lower end of the piston onto the lower bolt.
6. Measure the gap between the upper bolt of the piston and the loading system. 

Picture 5

If the gap is less than 2mm, replace the upper bolt on the bearing housing of the XY loading system with the supplied screw (P/N 380X09070) from the FCO kit.

Picture 6

Rear door piston replacement procedure (old chassis only):

1. Remove the old pistons, as described in step 1 of the front door piston removal procedure above, then prop up the rear door before installing the new pistons.
2. Remove the old brackets (right and left sides) by unscrewing 4 screws in each bracket. Keep these screws and their lock washers.

Picture 7

The upper ball head screw remains in the machine; the lower ball head screw is removed with the bracket.

3. Separate the ball head screw from the gas piston.
4. On a work table, assemble the new bracket:
   1. Insert the bolt into the bracket.
   2. Place a lock washer on the bolt.
   3. Place a lock nut on the bolt over the lock washer and tighten it.

Picture 8

5. Reattach the bracket to the machine using the 4 screws and lock washers that were removed during step 2.
   The orientation of the left and right brackets is fixed, due to the asymmetric arrangement of the holes in the bracket.
6. Attach the new piston to the machine with the body of the piston held upwards.

Picture 9

Logistics

Approved quantities:

Schedule supplies for first lots:

Lead Time: 20 days

Technical contact

Itai Peperovich

Product Support Manager:Yaron Soffer
Approval Date: 24 Dec 2002
Rev B

Modified by

Dennis Kaliser

Date submitted