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
