Nitrogen Gas Spring Maintenance Instructions
Contents
1. Connect the female end of the charging assembly to the charging nipple The DADCO Pressure Analyzer 90 315 5 can also be used for charging discharging and gauging pressure in self contained gas springs 4 After the spring has been charged to the desired pressure CLOSE THE HOSE SHUT OFF VALVE AND TANK SHUT OFF VALVE 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 VIII Adjusting Gas Spring Pressure 1 To increase the spring pressure thread the Quick Disconnect Filler Valve 90 310 143 or 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 IX Linked Systems Open Flow Mode 1 Thread the DADCO Pressure Analyzer 90 315 5 into the port of the gas spring and open the valve For a detailed explanation of how to use the DADCO Pressure Analyzer see bulletin B01133D Connect the female end of the charging assembly to the male quick disconnect 5 Check for leaks at the top of the tube around the rod and at the base around the valve compartment by using mineral oil or water to test for leaks Verify the pressure of self contained spring models 2600 6600 with a DADCO Load Cell using a DADCO Portable Test Stand 90 3052. 3 Verify the pressure of self contained spring models 9600 and 20000 using a DADCO Load Cell and an arbor press NOTE If spring is open flow mode then a DADCO Pressure Analyzer 90 315 5 may be used to verify pressure and must remain in place during testing 3 Lubricate the inside wall of the tube with all of the DADCO Assembly Oil 2 Open the main valve on the nitrogen tank Set the desired charging pressure on the regulator Do not exceed the maximum charging pressure of 150 bar 2175 psi 6 Install the new Dust Cover 90 246 U 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 4 Place the rod and cartridge into the Tube Assembly Use the Valve Bleed Tool 90 360 4 or Port Servicing Tool 890 320 8 to depress the needle valve to release any back pressure Position the top of the cartridge just below the retaining ring groove 3 Slowly open the shut off valve at the end of the charging hose and allow the gas spring to reach the desired charging pressure Self Contained 7 Securely re install the Protective Screw 90 505 110 or 90 296 2 To decrease the gas spring pressure depress the valve stem using a DADCO Valve Bleed Tool 90 360 4 or a DADCO Pressure Analyzer 90 315 5 After testing all sp
3. M6 Port 90 310 111 G 1 8 Port Use the DADCO Quick Disconnect Charging Nipple to charge DADCO Nitrogen Gas Springs lt 5 90 310 143 90 310 111 Digital Load Cell 90 305 BG Meter 90 305 LC 50 222 kN Load Cell The DADCO Digital Load Cell Meter can display force in Newtons Kg or Ibs The 90 305 LC 50 supplied with the connector may be used to measure gas spring force up to 50 000 Ibs Other digital load cell units are available for more information request bulletin B04106B Bulletin No B06127A Comprehensive Guide This service manual is a simple step by step maintenance guide for DADCO s Ultra Force and Ultra Force Extended Nitrogen Gas Springs Models U 2600 U 20000 UH 2600 UH 6600 UT 2600 UT 9600 UX 2600 UX 20000 Proper repair requires careful examination of all component parts and replacement of any 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 Note All DADCO gas springs are permanently marked with model and serial number Please refer to these numbers for corresponding repair kits and when ordering replacement parts All DADCO b
4. of damage Lubricate threads and seals on the fitting and thread the service fitting into the gas spring port VI Cartridge Replacement and Reassembly 1 Choose the appropriate repair kit The repair kit number needed is laser marked on the back of the Tube Assembly NOTE Repair kits are not interchangeable among models 2 Reposition the DADCO Removal Sleeve and only continue tapping until the rod cartridge assembly is slightly below the retaining ring c ring 3 Remove the C style Retaining Ring 90 285 x using a C Ring Removal Tool 90 356 Position the hooked end of the tool below the c ring For best results locate groove the tool near either end of the V Cleaning amp Inspection 2 Once the cartridge and rod are removed from the Tube Assembly slide the cartridge off the rod and discard Retain the rod for inspection and reuse 1 Lightly polish the rod surface with an emery cloth 600 grit Inspect the finish of the rod for any scratches or gouges Ifthe rod is damaged it must be replaced 4 Once the hooked end of the tool is firmly seated below the c ring begin pushing it toward the outside of the gas spring can The handles will close naturally and the c ring will be extracted as you complete this motion For a detailed explanation of c ring removal see bulletin 97B110 2 Inspect the Tube Ass
5. Service Tools C Ring Removal Tool C Ring Installation Tool 90 356 90 352 U 2600 U 9600 90 352 10000 U 20000 To remove the C style retaining ring safely in a single controlled To insert the C style retain ing ring motion into the retaining ring groove a Valve Bleed Tool 90 360 4 Port Servicing Tool 90 320 8 Use the DADCO Valve Bleed Tool to slowly discharge a spring to the desired pressure the valve compartment T Handle 90 320 2 M8 90 320 10 M10 Removal Sleeve 90 340 01500 Models U UH UT UX 2600 90 340 03000 Models U UH UT UX 4600 90 340 05000 Models U UH UT UX 6600 90 340 07500 Models U UT UX 9600 To perform all necessary servicing to To remove the piston rod when disassembling and position To position the cartridge assembly below the C ring groove when assembling or disassembling a gas spring Parts List All DADCO gas springs are permanently marked with model and serial number Please refer to these numbers for corresponding repair kits when ordering replacement parts Dust Cover 90 246 U Model O Ring Backup Ring O Ring UltraPak Cartridge 90 200 U Model Tube Assembly 90 205 Series Model Stroke U 4600 U 9600 UH 2600 UH 6600 UT 2600 UT 9600 Compact Valve 90 260 Port Plug 90 505 110 T20 6 Lobe Drive 90 296 Compact Valve Sealing Washer 90 260 90 252 U 20000 U
6. X 2600 UX 20000 e7 Port h a 90 505 110 Cartridge Valve 90 265 correctly when reassembling Piston Rod 90 215 Series Model Stroke Wiper C Style Retaining Ring Model Part Number 2600 90 285 01500 4600 90 285 03000 6600 90 285 05000 9600 90 285 07500 20000 90 285 10000 Repair Kits ee rarer Includes a fully assembled cartridge dust cover bottle of assembly oil and a maintenance manual Model Kit Number 2600 90 108 2600 4600 90 108 4600 6600 90 108 6600 9600 90 108 9600 20000 90 108 20000 Ordering Example Models 02600 04600 06600 09600 20000 90 215 U 2600 025 Part No Series Model Stroke mm Standard Load Cell 90 300 2600 Models U UH UT UX 2600 90 300 4600 Models U UH UT UX 4600 90 300 6600 Models U UH UT UX 6600 90 300 9600 Models U UT UX 9600 90 300 20000 Models U UX 20000 When used with a Portable Test Stand the Standard Load Cell gives precise measurement of gas spring charging pressure Each model requires its specified load cell For more information contact DADCO Quick Disconnect Charging Assembly 90 310 040 Use the DADCO Quick Disconnect Charging Assembly with the Filler Valve or Pressure Analyzer to charge self contained gas springs or with a DADCO Control Panel for charging linked systems For more information contact DADCO Quick Disconnect Charging Nipple Self Contained 90 310 143
7. embly for any damage especially around the mouth of the Tube Assembly Lightly 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 Wash clean and dry the inside thoroughly 5 Insert the C Style Retain ing Ring in the retaining ring groove using a DADCO C Ring Installation Tool 90 352 or 90 352 10000 Be sure the C Style Retaining Ring is fully seated in the retaining ring groove 2 Position the Cartridge Assembly over the rod making sure that the wiper end is facing up While holding the cartridge vertically slide the cartridge down the rod to the rod retainer Be careful not to force the cartridge at an angle as the seal could become dislodged 6 Thread the T Handle 90 320 2 or 90 320 10 into the end of the piston rod Pull up on the T Handle until the top of the cartridge is completely past the c ring The rod must seat the cartridge assembly fully before charging The housing should be flush with the end of the cylinder Make sure the rod is extended to its proper stroke length Depress the needle valve to facilitate full rod extension Vil Charging Self Contained Self contained spring with a 90 310 143 shown 1 Thread the Quick Disconnect Filler Valve 90 310 143 or 90 310 111 into the port of the gas spring
8. ntact DADCO Nitrogen Gas Spring Maintenance Instructions Ultra Force and Ultra Force Extended Models U 2600 U 20000 UH 2600 UH 6600 UT 2600 UT 9600 UX 2600 UX 20000 NADICO 43850 Plymouth Oaks Blvd Plymouth Michigan USA 48170 1 734 207 1100 1 800 323 2687 Toll Free 1 800 DADCO USA Fax 1 734 207 2222 www dadco net U Series Nitrogen Gas Spring Repair Instructions I Exhausting Pressure Self Contained Mode 1 When exhausting pressure position the gas spring with the port up for safety Open Flow Mode 1 Exhaust nitrogen gas by opening the bleed valve on the control panel ll Port Maintenance Self Contained 1 Generally the valve does not need replacing Only if the valve appears damaged is leaking pressure or sticking proceed to step 2 otherwise leave the valve undisturbed and proceed to Ill C Ring Removal lll C Ring Removal 1 Stand the gas spring upright Place a removal sleeve 90 340 x longer than the stroke over the rod Tap the sleeve until the Dust Cover 90 246 U x is loosened Remove the Dust Cover and discard IV Rod amp Cartridge Removal 1 To remove the Rod and Cartridge Assembly thread a T Handle 90 320 2 or 90 320 10 into the rod end Pull the entire assembly out of the tube The spring body can be held in a vise with soft jaws
9. rings for leaks the open flow springs are ready to be re linked in the system If possible once the springs are all linked back to the control panel leave the system to sit fully charged overnight If pressure has dropped indicating a leak verify that each connection is tight and test each fitting for a leak Contact DADCO for information on converting a self contained DADCO Nitrogen Gas Spring to a linked system NOTE DADCO U UH UT UX Series Nitrogen Gas Springs should not be linked with the valve installed
10. ulletins and catalogs are available for download from our web site www dadco net DADCO Inc 2013 All Rights Reserved 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 on contact Excludes use with the U 9600 and U 20000 For more information request bulletin 97B121 DADCO Pressure Monitor 90 421 1 120 VAC bulletin BO0136 2 240 VAC bulletin BO1115A 2D 24 VDC SPDT bulletin B00134A The DADCO Pressure Monitor indicates if pressure drops below a pre set level alerting the press controller to shut down the press The shutdown point is adjustable between 15 and 200 bar 200 3000 psi For additional information request the appropriate bulletin DADCO Pressure Analyzer 90 315 5 M6 and G 1 8 bits Use the DADCO Pressure Analyzer to easily charge discharge and gauge the pressure in DADCO s U Series This tool can take the place of the Valve Bleed Tool Standard Load Cell Quick Disconnect Filler Valve and Portable Test Stand For more information request bulletin BO1133D DADCO Electronic Pressure Monitors DADCO s Electrical Pressure Monitors indicate if pressure drops below a preset level alerting the press controller to shut down the press They are available in a variety of configurations to suit a variety of applications For more information request bulletin B10105 or co
11. while pulling out the assembly 2 Remove the Protective Screw 90 505 110 or 90 296 Retain parts for use during reassembly 3 Keeping face and hands clear of the port use the Valve Bleed Tool 90 360 4 or Port Servicing Tool 90 320 8 to depress the Compact Valve stem 90 260 or Cartridge Valve 90 265 Cover the port with a cloth to absorb discharge 3 Unthread the service fitting and wipe with a clean cloth Proceed to Il Port Maintenance Open Flow Mode step 1 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 2 Remove the Compact Valve 90 260 or Cartridge Valve 90 265 by unscrewing it Valve 90 265 into the with the Port Servicing Tool port until it fits snugly on the 90 320 8 seat Avoid over torquing the valve 3 Thread a new Compact Valve 90 260 or Cartridge 4 After all of the gas pressure is exhausted be sure that the piston rod will freely retract into the tube manually If not try depressing the valve again If still unsuccessful stop and contact DADCO Open Flow Mode 1 Check the port for deposits or burrs and clean thoroughly Inspect the service fitting and replace if it shows signs
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