Kaller CU4 1000 User manual

MOUNTING INSTRUCTION
8200-1109-B
SP and SPRM Plates
Gas Spring Models
CU4 1000, CU4 1800,
CU4 2900, CU4 4700,
CU4 7500, CU4 11800,
CU4 18300
Strömsholmen AB
P.O. Box 216,
SE-573 23 Tranås, Sweden
Visiting Address:
Verkstadsgatan 16, Tranås
Phone: [phone]
Email: [e-mail]
kaller.com

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Parts List - SP
A) *SP plate CU4 1000-18300
B) *SP adapter 1800 - 18300
C) *Socket head cap screw
D) *Cap screw plug
E) *Valve
F) *Cover screw
G) Bottom
H) Tube
* = Parts incl. in the CU4-SP kit.
For CU4-SP 1000 the SP adapter is integrated in the
SP plate.
Torque according to Table A.
Required Tools
I) Charging Hose with Control Armature
J) Needle Nose Pliers
K) Charging Adapter G1/8”
L) Valve Tool G1/8”
M) Valve Tool M6
Parts List - SPRM
A) *SPRM plate
B) *SPRM adapter
C) *Screw bolt
D) *Upper flange
E) *G1/8-M6 adapter with valve
F) *Port plug
G) Bottom
H) Tube
I) *Cover screw (do not remove or use)
J) *Lock ring halves
* = Parts incl. in the CU4-SPRM kit.
Torque according to Table A.
I
K
L
M
J

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Warning!
•Only specially trained personnel with good
knowledge of the products should carry out the
following procedure.
•Before mounting or dismounting the SP or SPRM
plate, make sure all gas pressure is exhausted.
•Once the cover screw is removed, never lean
directly over the valve. Always direct the valve port
away from yourself and others.
•Never use extreme force on the gas spring.
•Charged gas springs are under high internal
pressure and should be protected against damage.
•Use only pure nitrogen (N2) for gas charging.
•Maximum charging pressure is 150 bar (2175 psi).
•Always use protective jaws when clamping the
spring in a vice.
•To achieve maximum service life, keep the gas
spring protected from dirt, drawing fluids, and
grinding dust.
Table A
Mount
Type Gas Spring Size Thread Size Torque [Nm]
SP CU4 1000 – 1800 M6 17
SP CU4 2900 – 7500 M8 40
SP CU4 11800 – 18300 M10 85
SPRM CU4 4700 – 7500 M8 33
SPRM CU4 11800 – 18300 M10 65
Instructions SP
1) Clamp the gas spring in a vice (fitted with protective
jaws) with the piston directed downwards.
2) Unscrew the cover screw (O), M6 (for CU4 1000) or
G1/8” (for CU4 1800 up to and including 18300). If
there is no gas pressure inside the spring the bottom
plate (G) may rotate.
3) If there is gas pressure inside the spring, release it by
screwing the threaded end of the valvetool into the
charging port until the valve needle opens.
Warning! The valve (N) must not be removed
until the bottom plate can be pushed into the
spring by hand or be tapped in using a plastic
mallet.
4) Unscrew the valve with the opposite end of the valve
tool and remove it by using the needle nose pliers.
Warning!Thevalve must be removed before
mounting the SP plate onto the gas spring.
Otherwise the gas spring cannot be discharged
through the SP plate.
5) Unpack the SP plate.
6) Mount the SPRM adapter (B) onto the spring bottom
using a 4 mm Allen key (except for CU4 1000)
7) We recommend applying Loctite 2701 on the SP
adapter´s threaded end to secure it firmlyto the bottom
plate.
8) Lubricate the O-ring on the SP adapter as well as the
hole in the SP plate with some oil.
9) Mount the SP plate onto the SP adapter and center by
hand.
Warning! Do not use excessive force.
Misalignment of the SP adapter and bottom
plate can result in damage to the bottom plate
and/or O-ring.
10) Mount the cap screws (C) by hand and use the
prescribed torque (see table A) to tighten the screws.
Warning! If incorrect torque is used,a fatigue
type failure may occur.
11) Due to the high strain on the screws, it is recommended
that these are replaced after 400,000 strokes to ensure
the function (class 12.9).
12) Mount the cap screw plugs (D) in the hex sockets of
the cap screws (C).
13) For self-contained gas springs, mount the valve (E) into
the charging port using the valvetool. Finger strength is
enough to tighten the valve.
Warning! Do not mount the valve when the gas
spring is to be linked to a hosed system.
Otherwise the gas spring cannot be discharged
through a control block.
For gas charging instructions, see Service Instruction
8200-1364.

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Instructions SPRM
1) Clamp the gas spring in a vice (fitted with protective
jaws) with the piston directed downwards.
2) Unscrew the cover screw (O), G1/8” (for CU4 4700 up
to and including 18300). If there is no gas pressure
inside the spring the bottom plate (G) may rotate.
3) If there is gas pressure inside the spring, release it by
screwing the threaded end of the valvetool into the
charging port until the valve needle opens.
Warning! The valve (N) must not be removed
until the bottom plate can be pushed into the
spring by hand or be tapped in using a plastic
mallet.
4) Unscrew the valve with the opposite end of the valve
tool and remove it by using the needle nose pliers.
Warning!Thevalve must be removed before
mounting the SPRM plate onto the gas spring.
Otherwise the gas spring cannot be discharged
through the SPRM plate.
5) Unpack the SPRM plate.
6) Mount the SPRM adapter (B) onto the spring bottom
using a 4 mm Allen key.
7) Werecommend applying Loctite 2701 on the SP
adapter´s threaded end to secure it firmlyto the bottom
plate.
8) Mount the upper flange (D) onto the gas spring tube.
9) Position the lock ring halves (J) in the lower C-groove of
the gas spring. Make the sure the upper flange is above
the lock ring halves.
10) Lubricate the O-ring on the SPRM adapter as well as
the hole in the SPRM plate with some oil.
11) Mount the SPRM plate onto the SPRM adapter and
center by hand.
Warning! Do not use excessive force.
Misalignment of the SPRM adapter and bottom
plate can result in damage to the bottom plate
and/or O-ring.
12) Mount the screwbolts (C) by hand and use the
prescribed torque (see table A) to tighten the screws.
Warning! If incorrect torque is used,a fatigue
type failure may occur.
13) Mount the upper flange (D) onto the SPRM plate (A)
using the assembly screws and tighten.
14) For self-contained gas springs the charging valve is
included in the plug insert. Remove the M6 cover
screw and charge the gas spring. Do not use the M6 port
located below the plug insert as there is no valve behind.
Warning! When linking the gas spring to a
hosed system remove the valve if this
connection port is to be used. Otherwise the
gas spring cannot be discharged through a
control block.
For gas charging instructions, see Service Instruction
8200-1364.