3
Assembly
Warning! As a precaution before you begin to
assemble the gas spring, gently place the piston
rod into the tube. Be careful not to damage the
safety plug in the bottom of the gas spring. If the
gas spring is equipped with a safety plug the piston
rod top should be raised 1-2 mm from the tube top.
If there is no safety plug the piston rod top should
be flush with
the top of the tube.
12) Unpack the repair kit. Make sure the correct repair kit is
being used.
13) Fit the rod seal (O), guide ring (N), scraper (L) and O-
ring (M) onto the guide.
14) Lightly oil the seals and the guide ring on the guide (D).
15) Fit the guide (D) on the piston rod (A).
16) Oil the inside of the upper tube end to prevent damage
to the guide O-ring.
17) Fill the tube with the appropriate oil volume (see table
below),
18) 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
19) 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.
20) Pull out the piston rod (A) and the guide (D) using the
T-handle. Pull until the guide stops against the lock ring
(C) and is flush with the tube end.
Warning! If the top of the guide is not in line with
the top of the cylinder tube, the assembly is
incorrect. DO NOT charge the spring. Charging an
incorrectly assembled spring could result in
serious injury.
21) Using the valve tool fit the valve (K) into the charging
port. Finger strength is enough to tighten the valve.
22) Oil and fit the dirt protection ring (B) so it snaps into to
the groove in the guide (see picture below).
The function of the dirt protection ring is to prevent dirt from
coming into the gas spring and also prevent the guide from
falling into the tube when the spring is uncharged.
For gas charging see Gas Charging Instruction
8200-1873 available at kaller.com
Model
Oil
SPC 750
30 ml
SPC 800
30 ml
SPC 1500
40 ml
SPC 3000
60 ml
SPC 5000
120 ml
Correct
Incorrect
