Kaller SPC 750 Original operating manual

SERVICE INSTRUCTION
8100-3016-B
Gas Spring Models
SPC 750
SPC 800
SPC 1500
SPC 3000
SPC 5000
Strömsholmen AB
P.O. Box 216,
SE-573 23 Tranås, Sweden
Visiting Address:
Verkstadsgatan 16, Tranås
Phone: [phone]
Email: [e-mail]
kaller.com

2
SERVICE INSTRUCTION
Please Note!
Actual gas spring design may appear different from what
shown here.
A) Piston rod
B)* Dirt protection ring
C)* Lock ring
D)** Guide
E) Tube
F) Piston
G)* Guide ring
H)* Oil
J)* Cover screw
K)* Valve
L)* Scraper
M)* O-ring
N)* Guide ring
O)* Rod seal
* = Parts included in the
repair kit
**=Separate repair kit
including the guide
also is available
Warning!
•Always read the permanently marked information
on the side of the tube before service to make sure
you use the correct repair kit.
•Failure to exhaust all gas pressure prior to
disassembling could result in serious injury.
•The maximum charging pressure is150 bar (2175 psi)
•Use only pure nitrogen gas (N2) for charging.
•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.
•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.
•Always wear protective equipment incl. safety goggles
and rubber gloves, whilst servicing the gas spring in a
well ventilated area. Avoid direct contact with gas
spring lubricants and inhalation of any exhausting
gases.
•Only specially trained personnel with good knowledge
of the products should carry out the maintenance.
Disassembly
1) To obtain an easy working position, clamp the spring in
a vice (use protective jaws). Clamp the gas spring in a
leaning position (about 30°) with the piston rod
upwards. Point the valve port upwards to prevent oil
from leaking out during the service.
2) Unscrew the cover screw (J) on the tube using 5 mm
Allen key.
3) Empty all gas from the spring. Release it by screwing
the threaded end of the valve tool into the gas port until
the valve opens.
Warning! The valve (K) must not be unscrewed
until the piston rod can be pushed down by hand or
with a rubber mallet.
Once the gas is released use the opposite end of the
valve tool to unscrew the valve. Pull the valve from the
port with a pair of needle nose pliers.
4) Tap the guide (D) into the tube, using a socket and
rubber mallet, until the lock ring (C) is exposed.
Remove the dirt protection ring (B) which becomes
loose during the procedure.
Note! For model SPC 1500, the dirt protection ring
must be removed first before the guide is tapped
down into the tube.
5) Remove the lock ring (C) using the lock ring tool.
Warning! The lock ring could fly out, be sure to
wear safety goggles.
6) Pull out the piston rod (A) including the piston (F) and
the guide (D), using the T-handle.
7) Remove the guide ring (G) and the guide (D) from the
piston rod.
8) Remove the guide ring (N), rod seal (O), scraper (L)
and O-ring (M) from the guide (D).
9) Save the piston rod (A), the tube (E), the piston (F) and
the guide (D).
Inspection
10) Thoroughly clean the tube, the piston rod, the piston
and the guide.
11) Closely inspect the piston rod, the piston, the guide and
the tube. There should be no scratches or dents on the
inside surface of the tube, the piston rod or the lock
ring grooves. If these parts are scratched or damaged
in any way, then the gas spring cannot be repaired and
has to be replaced.

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