Nitrogen Gas Spring Maintenance Instructions 90.5B2
Contents
1. 3A 3B 3A While holding the cartridge vertically tap the Assembly Cap to drive the cartridge down the rod Be careful not to force the cartridge at an angle as the seal could become damaged 3B The cartridge is now below the Assembly Cone Remove Assembly Cone from the rod 7 Insert the C Style Retaining Ring 90 285 x in the retaining ring groove using a DADCO C Ring Installation Tool 90 350 x 90 351 x or 90 352 or standard bench tools Be sure C Style Retaining Ring is fully seated in retaining ring groove Linked Mode 1L Pipe all gas springs back to the control panel making sure that all connections are tight and that gas spring rods are extended 2L Attach Charging Assembly 90 310 040 or 90 310 045 to the quick disconnect filler valve on the control panel 4 Lubricate the inside wall of the tube with entire contents of the bottle of assembly oil 8 Thread T Handle 90 320 x into the end of the piston rod Pull up on T Handle until the top of the cartridge is past the c ring The rod must seat cartridge assembly fully with the housing flush with end of cylinder Make sure rod is extended to its proper stroke length Depress cartridge valve to facilitate full rod extension 4 Set the desired charging pressure on the regulator 5 Slowly open the shut off valv2. sticking proceed to step 2 If the valve does not need replacing proceed to Ill C Ring Removal 2 Remove valve using the Port Servicing Tool 90 320 8 Cartridge Valve 90 265 requires a T40 drive or bit Compact Valve 90 260 requires a T20 drive or bit Linked Mode 3 Replace the damaged valve Use the Port Servicing Tool 90 320 8 to thread the new Valve into the port until it fits snugly on the seat Avoid over torquing the valve 1 Check the port for deposits or burrs and clean thoroughly Inspect the service fitting and replace if it shows signs of damage Lubricate threads and seals on the fitting and thread the service fitting into the gas spring port lll C Ring Removal 1 Stand the gas spring upright Make sure the rod is retracted in the tube Place a Removal Sleeve 90 340 x over the rod Tap the sleeve until the Dust Cover 90 246 x is loosened Remove the Dust Cover and discard IV Rod amp Cartridge Removal 1 To remove the Cartridge Assembly thread a T Handle 90 320 x into the rod end V Cleaning amp Inspection 1 Lightly polish the rod surface with an emery cloth 600 grit Inspect the finish of the rod for any scratches or gouges If the rod is damaged it must be replaced If present the Rod Safety Ring should remain in place 2 Reposition the Removal Sleeve and continue tapping unti
3. that are worn or damaged All DADCO replacement parts are available from factory stock Typically DADCO Nitrogen Gas Springs can be rebuilt in less than ten minutes by replacing only one part the factory pre assembled cartridge assembly After reviewing this maintenance guide if you require any additional training or have any questions please contact DADCO for assistance Please Note Nitrogen Gas Spring repair varies Slightly from model to model and by mode of operation self contained or linked As you proceed through the basic steps outlined in this bulletin take care to follow the instructions pertaining to your model All DADCO Gas Springs are permanently marked with model and serial number Please refer to these numbers when performing repair work and when ordering replacement parts DADCO Inc 2015 All Rights Reserved 90 5B2 Series Parts List Piston Rod oe 90 215 10 Zaai 7 215 5B2 Modal Stroke GE l Model Stroke Dust Cover AAK W ky area 90 246 10 TEE Rod Wiper sri j Model C Style Retaining Ring Rod Guide C Style Retaining Ring 90 285 iN 90 285 Model A Model O ring Backup Ring Rod Seal Ht O ring Backup Ring O rin i O ring j Tube Assembly f Cartridge Assembly Cartridge Assembly 90 205 5B2 __ Iaa 90 10 Series Moner ieee A Ae ET Rod Safety Ring ar 90 10RX Series 90 284 __ 90 230 10RX ____ Retainer Wear Ring Rod Retainer 90 225A Model Port Plu
4. the control panel Rod Wiper Rod Guide Rod Seal 90 8 Series Parts List Tube Assembly 90 205 8 Model Stroke Rod Safety Ring 90 284 Model Retainer Wear Ring 90 242 Model od Valve Compartment Self Contained Included in the Repair Kit Included in the Cartridge Assembly Port Plug 90 505 110 90 10 90 10RX Series Parts List Piston Rod Rod Wiper 90 215 8 l Model Stroke Rod Guide Dust Cover ala Model Tube Assembly a l 90 205 10 C Style Retaining Ring waaa 90 285 Model _ O ring Backup Ring Rod Seal O ring Cartridge Assembly 90 230 8 Rod Safety Ring Model 90 284 Model Retainer Wear Ring 90 242 Rod Retainer 90 225A Self Contained Model 90 242 Model Rod Retainer If Nitrogen Gas Spring port requires maintenance verify valve type that was removed lI Self Contained T Model Model 90 225A Model Port Plug Valve Compartmentt 90 505 110 Self Contained Included in the Repair Kit Included in the Cartridge Assembly Valve Compartmentt 90 8 90 10 90 10RX 90 5B2 o an i l lI l l lI l l lI l l lI l l lI l l lI l I a II l l lI l Cartridge Valve Port Adapter l 90 265 a 90 506 119 i l l l l l l l l l l l and replace with the same valve Please note valves are not interchangeable f l e a E ee E a ee E Repair Tools Cartridge Starte
5. 90 8 90 10 90 10RX 90 5B2 Series Gas Spring Repair Instructions I Exhausting Pressure Self Contained Mode 1 When exhausting pressure position the gas spring horizontally with the port up for safety Linked Mode 1 Exhaust nitrogen gas by opening the bleed valve on the control panel 2 Remove the Port Plug 90 505 110 located at the base of the spring Retain parts for use during reassembly 2 Verify that all pressure is relieved by manually retracting the piston rod into the tube If the rod will not fully retract release the remaining pressure If still unsuccessful STOP and contact DADCO 3 Keeping face and hands clear of the port use the Valve Bleed Tool 90 360 4 or the 4 After all of the gas pressure is exhausted be sure that the piston rod will freely extend and Port Servicing Tool 90 320 8 retract into the tube manually to depress the Cartridge Valve If not try depressing the valve 90 265 or Compact Valve again If still unsuccessful 90 260 Cover the port with STOP and contact DADCO a cloth to absorb discharge 3 Unthread the service fitting and wipe with a clean cloth Proceed to Il Port Maintenance Linked Mode step 1 Il Port Maintenance Self Contained Mode 1 Generally the valve does not need replacing If the valve appears damaged is leaking pressure or is
6. e and allow gas spring to reach the desired charg ing pressure After the gas spring has been charged to the desired pressure CLOSE THE HOSE SHUT OFF VALVE AND THE TANK SHUT OFF VALVE Self Contained Mode 8S Verify the pressure with a DADCO Load Cell using a Portable Test Stand 90 305 3 or an arbor press 9S Make sure the valve is in place and thread Port Plug 90 505 110 securely over top 6 Disconnect the charging assembly from the charging nipple The small amount of nitrogen trapped between the shut off valve and filler valve will bleed off as you disconnect the fitting Self Contained or Linked 10 Install the new Dust Cover 90 246 x Tap with a soft mallet until the top of the Dust Cover rests flush with the top of the can The rod wiper should be visible Self Contained Mode 1S To increase spring pressure thread the Quick Disconnect Charging Nipple 90 310 111 into the port set the regulator to the desired pressure and fill DADCO s Pressure Analyzer 90 315 5 may also be used to adjust pressure 2S To decrease gas spring pressure depress the valve stem using a Valve Bleed Tool 90 360 4 Linked Mode 1L To increase system pressure set the regulator on the nitrogen tank to the desired level and fill the system through the control panel To release pressure open the drain valve on
7. eve 90 340 00500 00750 01500 03000 05000 07500 To position the cartridge below the C ring groove when assembling or disassembling a gas spring C Ring Installation Tool 90 352 01500 07500 Models 90 352 10000 10000 Model To insert the C style retaining ring into the retaining ring groove C Ring Removal Tool 90 355 00500 03000 Models 90 356 00750 7500 Models To remove the C style retaining ring safely in a single controlled motion 90 355 90 356 DADCO Pressure Analyzer 90 315 5 Use the DADCO Pressure Analyzer to easily charge discharge and gauge the pressure in DADCO s Nitrogen Gas Springs Charging Assembly 90 310 040 Use the DADCO Quick Disconnect Charging Assembly with the Charging Nipple or Pressure Analyzer to charge self contained gas springs The 90 310 040 can also be used with a DADCO control panel for charging linked systems Portable Test Stand 90 305 3 Use the Portable Test Stand in conjunction with a Standard Load Cell for precise measurement of gas spring force For more information request bulletin 97B121 Bulletin No BO6124E Comprehensive Guide This service manual is a simple step by step maintenance guide for DADCO Nitrogen Gas Spring models including the 90 8 90 10 90 10RX and 90 5B2 Series Proper repair requires careful examination of all component parts and replacement of any
8. g 90 505 110 Valve Compartmentt Self Contained Included in the Repair Kit Included in the Cartridge Assembly Nitrogen Gas Spring Maintenance Instructions 90 8 90 10 90 10RX 90 5B2 Series WABCO 43850 Plymouth Oaks Blvd Plymouth Michigan USA 48170 1 734 207 1100 800 323 2687 Toll Free 800 DADCO USA Fax 1 734 207 2222 www dadco net
9. l the rod cartridge assembly is slightly below the Retaining Ring groove DO NOT force the cartridge down further into the Tube Assembly 4 Once the hooked end of the tool is firmly seated below the using the C Ring Removal Tool c ring begin pushing it toward 90 355 or 90 356 Position the outside of the gas spring the correct hooked end of the can The handles will close C Ring Removal Tool below the naturally and the c ring will be c ring For best results locate extracted as you complete this the tool near either end of the motion c ring 3 Remove the C style Retaining Ring 90 285 x 2 Pull the entire assembly out of the tube Depress the cartridge valve to relieve any back pressure 3 Once the cartridge and rod are removed from the Tube Assembly slide the cartridge off of the rod and discard Retain rod for inspection and possible reuse 2 Inspect the Tube Assembly for any damage especially around the mouth of the Tube Assembly Polish out any scratches at the mouth of the tube assembly to avoid damaging seals during the reassembly process If damage to the Tube Assembly is severe it must be replaced 3 Wash clean and dry the inside of the Tube Assembly thoroughly VI Cartridge Replacement and Reassembly 1 Choose the appropriate repair kit 90 201 x or 90 208 x for the specific model you are repairing The repair kit n
10. r Kit 90 335 00500 00750 01500 03000 05000 07500 The Cartridge Starter Kit includes an Assembly Cap and an Assembly Cone The Assembly Cone is used to start the cartridge assembly onto the rod without damaging the seal the Assembly Cap is used to set the cartridge at a proper depth for C Ring installation C Ring Installation Tool 90 351 00500 00500 Model 90 350 00750 00750 Models To insert the C style retaining ring into the retaining ring groove T Handle 90 320 2 M8 thread 90 320 10 M10 thread To remove the piston rod when disassembling and position correc when reassembling Valve Bleed Tool 90 360 4 Use the DADCO Valve Bleed Tool to slowly discharge a spring to the desired pressure Port Servicing Tool 90 320 8 To perform all necessary servicing to the valve compartment Quick Disconnect Charging Nipple 90 310 111 G 1 8 Use the DADCO Quick Disconnect Charging Nipple to charge Nitrogen Gas Springs Standard Load Cell 90 300 00500 00750 01500 03000 05000 07500 10000 The Standard Load Cell gives precise measurement of gas spring charging pressure Each model requires its specified load cell Load cells for 00500 07500 Models may be used with the Portable Test Stand the load cell for the 90 10 10000 may be used with an arbor press For more information request bulletin 97B119G Removal Sle
11. umber is laser marked on the back of the tube assembly 5 Place the rod and cartridge assembly into the spring To release any back pressure depress the cartridge valve Use the Assembly Cap 90 330 x to drive the rod and cartridge assembly into the tube assembly 2 Thread Assembly Cone 90 331 x from Cartridge Starter Kit 90 335 x onto rod Slide Cartridge Assembly over the Assembly Cone making sure that the wiper end marked TOP is facing up Place Cartridge Assembly Cap 90 330 x from Cartridge Starter Kit 90 335 x on top of Cartridge Assembly 6 Position the top of the cartridge just below the retaining ring groove The assembly cap is designed to locate the cartridge in this position Vil Charging Quick Disconnect Filling Method Self Contained Mode 1S Thread the Quick Disconnect Charging Nipple 90 310 111 into the port of the gas spring Connect the female end of the Charging Assembly 90 310 040 or 90 310 045 to the charging nipple The DADCO Pressure Analyzer 90 315 5 can also be used for charging discharging and gauging the pressure Self Contained or Linked Mode 3 Open the main valve on the nitrogen tank Self Contained or Linked 7 Check for leaks at the top of the tube around the rod and at the base around the valve compartment using vegetable oil or water Vill Adjusting Gas Spring Pressure
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