90.9 Series Nitrogen Gas Spring Repair Instructions
Contents
1. 5 Insert C Style Retaining Ring 90 285 x into retaining ring groove using C Ring Installation Tool 90 352 or standard bench tools Be sure C Style Retaining Ring is fully seated in retaining ring groove 6 Thread T Handle 90 320 2 into end of piston rod Pull up on T Handle until top of cartridge is completely past c ring The rod must seat cartridge assembly fully before charging The housing should be flush with end of cylinder Make sure rod is extended to its proper stroke length Depress the compact valve to facilitate full rod extension 1L Pipe all gas springs back 2L Attach the Charging to the control panel making Assembly 90 310 040 or sure that all connections are 90 310 045 to the quick tight and that gas spring rods disconnect filler valve on the are extended control panel 1S Thread the Quick Disconnect Filler Valve 90 310 143 or 90 310 111 into port of gas spring Connect female end of charging assembly to charging nipple The DADCO Pressure Analyzer 90 315 5 can also be used for charging discharging and gauging pressure Self Contained or Linked Mode Self Contained or Linked Self Contained Mode 5 Slowly open shut off valve and allow gas spring to reach the desired charging pressure After spring has been charged to desired pressure CLOSE HOSE SHUT OFF VALVE AND TANK SHUT OFF VALVE 6 Disconnect charg2. 90 9 Series Nitrogen Gas Spring Repair Instructions I Exhausting Pressure Self Contained Mode Linked Mode 1 When exhausting 2 Remove Port Plug pressure position gas 90 607110 or 90 505 110 spring horizontally with port Retain parts for use during up for safety reassembly Il Port Maintenance Self Contained Mode 3 Keeping face and hands clear of port use Valve Bleed Tool 90 360 4 or Port Servicing Tool 90 320 8 to depress Compact Valve 90 260 Cover port with a cloth to absorb discharge 4 After all gas pressure is 1 exhausted be sure piston rod will freely extend and retract into tube manually Exhaust nitrogen gas by opening bleed valve on control panel 2 Verify all pressure is relieved by manually retracting piston rod into tube If rod will If not try depressing valve again If still unsuccessful STOP and contact DADCO not fully retract release remaining pressure If still unsuccessful STOP and 1 The compact valve usually does not need replacing If it appears damaged is leaking or sticking proceed to step 2 otherwise leave the valve undisturbed and proceed to Ill C Ring Removal 2 Remove Compact Valve 90 260 by unscrewing it with the Port Servicing Tool 90 320 8 IV Rod amp Cartridge Removal 3 Replace damaged C
3. ing assembly from charging nipple The small amount of nitrogen trapped between shut off valve and filler valve will bleed off as you disconnect fitting 7 Check for leaks at top of tube around rod and at base around valve compartment by using vegetable oil or water 10 Install new Dust Cover 90 246 9 x Tap with a soft mallet until top of Dust Cover rests flush with top of can The rod wiper should be visible 8S Verify pressure with 9S Make sure Compact a DADCO Load Cell using Valve 90 260 is in place a Portable Test Stand and thread Port Plug 90 305 3 or arbor press 90 607110 or 90 505 110 securely over top 2 Position the Cartridge Assembly over the rod making sure wiper end marked TOP is facing up While holding cartridge vertically slide it down the rod to the rod retainer Be careful not to force cartridge at an angle as seal could become damaged Self Contained or Linked Mode 3 Lubricate the inside wall of the tube with entire contents of the bottle of assembly oil 3 Open main valve on nitrogen tank 4 Set desired charging pressure on regulator Vill Adjusting Gas Spring Pressure 1 To increase spring pressure thread Quick Disconnect Filler Valve 90 310 143 or 90 310 111 into port set regulator to desired pressure and fill DADCO s pressure analyzer 90 315 5 may also be used to adjust pressure 2 To decrease ga
4. ompact Valve Use Port Servicing Tool 90 320 8 to thread new Compact Valve 90 260 into the port until it fits snugly on the seat Avoid over torquing the valve V Cleaning amp Inspection Linked Mode 1 Check port for deposits or burrs and clean thoroughly Inspect service fitting and replace if it shows signs of damage Lubricate threads and seals on fitting and thread into the gas spring Ill C Ring Removal contact DADCO 3 Unthread service fitting and wipe with a clean Port Maintenance Linked Mode cloth Proceed to ll step 1 1 Stand the gas spring upright Make sure rod is retracted in tube Place removal sleeve 90 340 x over rod Tap sleeve until Dust Cover 90 246 9 x is loosened Remove Dust 2 Reposition Removal Sleeve and continue tapping until rod cartridge assembly is slightly below retaining ring groove DO NOT force the cartridge down further into the Tube port Cover and discard Assembly 3 Remove C style Retaining Ring 90 285 x using C Ring Removal Tool 90 356 Position hooked end of tool below c ring For best results locate tool near either end of c ring Vi Cartridge Replacement amp Reassembly es lll 4 Once hooked end of tool is firmly seated below c ring begin pushing it toward outside of gas spring can The handles will close naturally and c ring will be ex
5. ring Valve Bleed Tool 90 360 4 Use the DADCO Valve Bleed Tool to slowly discharge a spring to the desired pressure C Ring Removal Tool 90 356 To remove the C style retaining ring safely ina single controlled motion Standard Load Cell 90 300 01500 03000 05000 07500 When used with a Portable Test Stand the Standard Load Cell gives precise sss measurement of gas spring p m charging pressure Request F _ bulletin 97B119G if T Handle 90 320 2 M8 thread To remove the piston rod when disassembling and position correctly when reassembling Quick Disconnect Charging Nipple 90 310 143 M6 Model 01500 90 310 111 G 1 8 Models 03000 07500 Use the DADCO Quick Disconnect Charging Nipple to charge 90 9 Series Gas Springs 90 310 143 90 310 111 Port Servicing Tool 90 320 8 To perform all necessary servicing to the valve compartment Charging Assembly e 90 310 040 Use the DADCO Quick Disconnect Charging Assembly with the charging nipple or pressure analyzer to charge self contained gas springs It can also be used witha 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 DADCO Inc 2010 All Rights Re
6. s spring pressure depress valve stem using a Valve Bleed Tool 90 360 4 90 9 Series Parts List 90 9 03000 90 9 07500 Dust Cover 90 246 9 Model C Style Retaining Ring 90 285 Model Cartridge Assembly 90 230 9 Model Tube Assembly 90 205 9 Model Stroke 90 260 90 9 01500 Compact Valve 90 260 Compact Valve Piston Rod 90 215 9 Model Stroke Rod Wiper 90 248 9 Model O ring Backup Ring 90 249 Model O ring 90 245 Model G 1 8 Port Plug 90 505 110 M6 Port Plug 90 607 110 Replacement Part Ordering Example Models 01500 03000 05000 07500 Piston Rod 90 215 9 017500 025 Part Number Series Model NOTE DADCO s 90 9 Series Nitrogen Gas Springs are permanently marked with model number serial number and repair kit number Please refer to these when ordering replacement parts Stroke mm The 90 9 Series Repair Kit includes Cartridge Assembly 90 230 9 Included in Cartridge Assembly M DustiCover 90 246 9 Model Assembly Oil 90 289 1 A step by step maintenance manual is also included Repair Tools C Ring Installation Tool 90 352 To insert the C style retaining ring into the retaining ring groove SS Removal Sleeve 90 340 01500 03000 05000 07500 To position the cartridge below the C ring groove when assembling or disassembling a gas sp
7. served DADCO Pressure Analyzer 90 315 5 Use the DADCO Pressure Analyzer to easily charge discharge and gauge the pressure in DADCO s 90 9 Series Gas Springs Bulletin No BO02111A Nitrogen Gas Spring Maintenance Instructions 90 9 Series Comprehensive Guide This service manual is a simple step by step maintenance guide for DADCO 90 9 Series Nitrogen Gas Springs 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 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
8. tracted as you complete this motion 1 To remove Rod and Cartridge Assembly thread a T Handle 90 320 2 into rod end Pull entire assembly out of tube The spring body can be held in a vise with soft jaws while pulling out the assembly VI Cartridge Replacement amp Reassembly continued 2 Once cartridge and rod are removed from Tube Assembly slide cartridge off of rod and discard Retain rod for inspection and reuse 1 Lightly polish rod surface with emery cloth 600 grit Inspect finish of rod for scratches or gouges If rod is damaged it must be replaced 2 Inspect Tube Assembly for damage especially around opening Lightly polish scratches at mouth of Tube Assembly to avoid damaging seals during reassembly If damage to Tube Assembly is severe it must be replaced Wash clean and dry the inside thoroughly 1 Choose appropriate repair kit 90 109 x for specific model you are repairing The repair kit number is laser marked on back of the Tube Assembly NOTE Repair kits are not interchangeable among models Vil Charging Self Contained Mode Linked Mode 4 Place rod and cartridge assembly into the tube To release any back pressure depress compact valve Position top of cartridge just below retaining ring groove DO NOT force the cartridge down further into the tube Vil Charging continued
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