II. Port Maintenance I. Exhausting Pressure III. C-Ring
Contents
1. T Handle 90 320 2 M8 thread To remove the piston rod when disassembling and position correctly when reassembling C Ring Removal Tool 90 356 To remove the C style retaining ring safely in a single controlled motion Valve Bleed Tool 90 360 4 Use the DADCO Valve Bleed spring to the desired pressure Tool to slowly discharge a _ Port Servicing Tool 90 320 8 necessary servicing to the valve compartment DADCO Pressure Analyzer 90 315 5 Use the DADCO Pressure Analyzer to easily charge discharge and gauge the pressure in DADCO s 90 5B Series Gas Springs To perform all Quick Disconnect Charging Nipple 90 310 111 G 1 8 Series Gas Springs Use the DADCO Quick Disconnect Seem tale Charging Nipple to charge 90 5B Standard Load Cell 90 300 00750 01500 03000 05000 07500 When used with a Portable Test Stand the Standard Load Cell gives precise measurement of gas spring charging pressure Request bulletin 97B119G 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 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 It can also be used with a2. of 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 extracted as you complete this motion Retaining Ring 90 285 x using C Ring Removal C Ring Removal Tool below c ring For best results locate tool near either end of c ring 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 If present rod safety ring should remain in place 2 Inspect tube assembly for damage especially around opening Polish scratches at mouth of tube assembly to avoid damaging seals during reassembly If damage to tube assembly is severe it must be replaced 3 Wash clean and dry inside of tube assembly thoroughly 1 Choose appropriate repair kit 90 105 95x for specific model you are repairing The repair kit number is laser marked on back of tube assembly NOTE Repair kits are not interchangeable among models Self Contained Mode 2 Position 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 Linked Mode f 3 Lubricate the inside wall of t
3. 5 may also be used to adjust pressure 1L To increase system pressure set regulator on nitrogen tank to desired level and fill system through control panel To release pressure open drain valve on control panel 90 5B Series Parts List Rod Wiper Rod Guide Tube Assembly 90 205 5B Model Stroke Rod Safety Ring 90 284 Model Retainer Wear Ring 90 241 Model Included in the 90 5B Series Repair Kit Included in the Cartridge Assembly Repair Tools Assembly Cap 90 330 00750 01500 03000 05000 07500 Used to hold the rod and position the cartridge below the C ring groove when assembling the gas spring Cartridge Valve 90 265 Self Contained Piston Rod 90 215 5B Model Stroke Dust Cover 90 246 5B Model C Style Retaining Ring 90 285 Model O ring Backup Ring O ring Rod Seal Cartridge Assembly 90 230 5B _ __ Model Rod Retainer 90 225 Model Port Plug 90 505 110 Removal Sleeve 90 340 00750 01500 03000 05000 07500 To position the cartridge below the 1 C ring groove when assembling or disassembling a gas spring C Ring Installation Tool 90 350 00750 00750 Models To insert the C style retaining ring into the retaining ring groove C Ring Installation Tool 90 352 To insert the C style retaining ring into the retaining ring groove
4. DADCO control panel for charging linked systems DADCO Inc 2012 All Rights Reserved Port Adapter 90 505 115 Linked NANCO Nitrogen Gas Spring Maintenance Instructions 90 5B Series Bulletin No BO6125C Comprehensive Guide This service manual is a simple step by step maintenance guide for DADCO 90 5B 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
5. I Exhausting Pressure Self Contained Mode 1 When exhausting pressure position gas spring horizontally with port up for safety 2 Remove Port Plug 90 505 110 located at the base of the spring Retain parts for use during reassembly ll Port Maintenance Self Contained Mode g 3 Keeping face and hands clear of port use Valve Bleed Tool 90 360 4 or Port Servicing Tool 90 320 8 to depress Cartridge Valve 90 265 Cover port with a cloth to absorb discharge 4 After all gas pressure is exhausted be sure piston rod will freely extend and retract into tube manually If not try depressing valve again If still unsuccessful STOP and contact DADCO Linked Mode Linked Mode 1 Exhaust nitrogen gas by opening bleed valve on the control panel Ill C Ring Removal 2 Verify all pressure is relieved by manually retracting piston rod into tube If rod will not fully retract release remaining pressure If still unsuccessful STOP and contact DADCO 3 Unthread service fitting and wipe with a clean cloth Proceed to Il Port Maintenance Linked Mode step 1 n i 4 gt 9 lt j Ahi j 4 ant Lf 1 The valve usually does not need replacing If it appears damaged is leaking or sticking proceed to step 2 If valve does not need rep
6. he tube with entire contents of the bottle of assembly oil 1 1S Thread the Quick Disconnect Charging Nipple 90 310 111 into the port 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 may also be used 1L Pipe all gas springs back to control panel making sure that connections are tight and that gas spring rods are extended 2L Attach Charging Assembly 90 310 040 or 90 310 045 to quick disconnect filler valve on the control panel 4 Thread assembly cap onto rod Place rod and cartridge assembly into spring To release any back pressure depress cartridge valve Position top of cartridge just below retaining ring groove Tap assembly cap to drive rod and cartridge assembly into tube assembly 5 Position the top of the cartridge just below the retaining ring groove The assembly cap is designed to locate the cartridge in this position 6 Insert C Style Retaining Ring 90 285 x into retaining ring groove using C Ring Installation Tool 90 350 00750 or 90 352 or standard bench tools Be sure C Style Retaining Ring is fully seated in retaining ring groove 7 Thread T Handle 90 320 2 into end of piston rod Pull up on t handle until top of cartridge is past c ring The rod must seat cartridge assembly fully with the housing flush with end of cylinder Make sure rod
7. is extended to its proper stroke length Depress cartridge valve to facilitate full rod extension 3 Open main valve on nitrogen tank 4 Set desired charging pressure on regulator 5 Slowly open shut off valve and allow gas spring to reach desired charging pressure After charging CLOSE HOSE SHUT OFF VALVE AND 6 Disconnect charging assembly from control panel The small amount of nitrogen trapped between the shut off valve and filler valve Vill Adjusting Gas Spring Pressure Self Contained Mode TANK SHUT OFF VALVE will bleed off as you disconnect fitting Linked Mode 7 Check for leaks at top of tube around rod and at base around valve compartment using vegetable oil 8 Verify pressure with a DADCO Load Cell using a DADCO Portable Test Stand 90 305 3 or an arbor press 9 Make sure Cartridge Valve is in place and thread Port Plug 90 505 110 securely over top 10 Install new Dust Cover 90 246 5B x Tap with a soft mallet until top of Dust Cover rests flush with top of can 2S To decrease gas spring pressure depress valve stem using a DADCO Valve Bleed Tool 90 360 4 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
8. lacing proceed to Ill C Ring Removal 2 Remove Cartridge Valve 90 265 using Port Servicing Tool 90 320 8 IV Rod amp Cartridge Removal 3 Replace damaged Cartridge Valve Use Port Servicing Tool 90 320 8 to thread new Cartridge Valve into the port until it fits snugly on the seat Avoid over torquing the valve 1 To remove cartridge assembly thread a T Handle 90 320 2 into the rod end 2 Pull entire assembly out of tube Depress cartridge valve to relieve any back pressure 3 Once cartridge and rod are removed from tube assembly slide cartridge off of rod and discard Retain rod for inspection and possible reuse VI Cartridge Replacement amp Reassembly Vil Charging 1 Check port for deposits or burrs and clean thoroughly Inspect service fitting and replace if shows signs of damage Lubricate threads and seals on fitting and thread into gas spring port 1 Stand 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 x is loosened Remove dust cover and discard 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 Assembly V Cleaning amp Inspection 3 Remove C style Tool 90 356 Position correct hooked end
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