Cargo Floor CF500 SL-2 Replacement Instructions Manual Download Page 2 | Manualshive

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Cargo Floor B.V.
Byte 14
NL-7741 MK COEVORDEN
Phone:+31 (0)524-59 39 00

[email protected]

www.cargofloor.com

Replacing a cylinder CF500 SL-2 / CF500 SL-C

10-12-2013

/ NL 2 van 16

R

eplacing a cylinder CF500 SL-2 / CF500 SL-C



You have received a cylinder to replace a defective one. Please follow the instructions given below carefully
to exchange the cylinder correctly and as quickly as possible.



The total de / installation time of the old / new cylinder will take a maximum of 4 hours, where for every
extra cylinder 1 extra labour hour extra is needed.

(this means for a complete set of cylinders, = 3 pieces, maximum 6 hours.)

Before replacing the cylinder check the system number, if it is a CF500 SL-C that it has a different
measurement than the CF500 SL-2.

The cylinder is supplied in a sturdy crate with all the seals and fastening materials.

Parts number

parts

supplied

Cylinder CF500

1

4105007

Guide block for piston rod

1

500216090.9

Hexagon bolt M16x90

6

500216100.9

Hexagon bolt M16x100

6

500916.9

Tob washer with long tab M16 steel

12

9309021

Instructions “important information”

1

7376001

CF500 seals for common rail

13

500208060.9

Hexagon bolt M8x60

24

5002008.9

Spring washer M8

24

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Summary of Contents for CF500 SL-2

Page 1: ...Replacement instructions CF500 SL 2 CF500 SL C cylinder ...

Page 2: ...ery extra cylinder 1 extra labour hour extra is needed this means for a complete set of cylinders 3 pieces maximum 6 hours Before replacing the cylinder check the system number if it is a CF500 SL C that it has a different measurement than the CF500 SL 2 The cylinder is supplied in a sturdy crate with all the seals and fastening materials Parts number parts supplied Cylinder CF500 1 4105007 Guide ...

Page 3: ...m in the future could be avoided IMPORTANT Always check that the selected loading or unloading direction is actually activated and occurring If the system fails to start turn off the Cargo Floor system and the hydraulic pump and follow the recommendations and guidelines provided below Do not repeatedly try to start the system as this may result in damage to your Cargo Floor system and or vehicle A...

Page 4: ... The Cargo Floor system must however be turned on in unloaded condition and the person performing the check must place his finger half on the floor profile and half on the bolt There should be no appreciable movement space between the floor profile and bolt Failure to check these bolts may lead to damage to the Cargo Floor system During this check a second person must also be present to switch off...

Page 5: ...em and the vehicle BB Always return emergency control s to their original non activated position after use CC During the operation of the system test the temperature of the oil by touching the side of the tank If the oil is so hot that you cannot continue to touch the tank switch off the pump to allow the oil to cool off and determine what is causing the overheating Stop loading or unloading if th...

Page 6: ...ded rod can be removed from the end of the threaded rod fig 1 Turn the system back on and the cylinders will eventually pull in fully and at the end of the ingoing stroke the pressure relieve valve will be activated At that time the system must be turned off For your safety it will be advisable to disconnect the hoses between pump and system and disconnect the electrical connections Demounting the...

Page 7: ... rails Unscrew all the bolts with which the common rails are attached to the cylinders by using a spanner wrench 13 mm or a tacker with cap 13 mm fig 7 en 8 These common rails can be removed by pushing away the pipes that are fitted into the screw in couplings If this is not successful by hand then can alternatively a tire iron or crowbar be used fig 9 en 10 Fig 7 Fig 8 Fig 9 Fig 10 Fig 5 Fig 6 ...

Page 8: ... The M16 bolts can be removed fig 13 after this with a open end spanner 24 mm or air wrench with cap 24 mm Now the clamping plates fig 14 can be removed but one clamp of the moving cross members has to remain This is so that the cylinder can stay in it s place for a short while longer The two bolts of clamping plate that remains in place must be loosened till so far that the clamping plate still r...

Page 9: ...he fixed clamping plate To release the cylinder you can use a tire iron or crow bar and push the cylinder loose out the clamp fig 17 2 persons need to support the cylinder when removing it When supporting the cylinder the last clamping plate can be removed Then the cylinder can be lowered and removed A sideways movement needs to be made to pass the hydraulic pipes that run underneath the cylinders...

Page 10: ...so grease the thread of all the M16x100 bolts beforehand Equip all new bolts M16x100 of the clamping plates and the bolts M16x90 of the piston rod bearing with a tob washer with long tab fig 19 en 20 With the help of two people the new cylinder can be hung on his place now Again you will have to make a sideways movement to get past the hydraulic pipes that run underneath the cylinders First mount ...

Page 11: ...linder should be given its proper place in the clamping plates The cylinder itself should be in about the same place as the cylinder next to it Compare for this the front surfaces of the cylinder lids fig 26 If all cylinders are replaced they should line up but the first cylinder should in the first place be situated in about the middle of the thread of the cylinder If the cylinders have the corre...

Page 12: ...n rod fig 28 If the thread is in the right place you can move the sleeve back and forward so the thread falls into the thread of the fixed clamping plates in the right order fig 28 The securing is done later Now the surfaces of the cylinders to which the common rail is mounted need to be aligned You can use the common rail itself When the surfaces are not aligned the cylinder can be rotated with t...

Page 13: ...on rails can be mounted with the new seals Pay attention to that the plugs in the common rail are at the right spot fig 32 The common rails are also asymmetrical of shape Put the spring washers on the bolts of the common rail and grease these a little with copper grease The bolts 24x of the both common rail must now being tightened at 30 Nm torque wrench 13 fig 33 Fig 31 Fig 32 Fig 33 ...

Page 14: ...cker these need to be fastened with a torque wrench The bolts of the clamping plates at 150 Nm fig 34 en 35 and the bolts of the guide block with a torque of 100 Nm fig 36 To prevent the M16 bolts loosening the other tob washers with long tab also need folded over with the help of a hammer The long side of the tob washer needs to be bend over the fixed base by hitting it with a hammer The edge of ...

Page 15: ...aulic hoses and electric wiring between truck and system Start the pump and system The command lip around the threaded rod will move directly towards the headboard If the commando lip is far enough stop the system and place the steel spring on the treaded rod Then place back the roll pin or bolt in the commando lip to keep the treaded rod on his place fig 41 en 42 After this a full function test c...

Page 16: ...y prepaid post A copy of the Cargo Floor packing slip for the new component must be included in the package This packing slip must include the following information the Cargo Floor system number the number of articles which are being returned with their associated article numbers and a description of the nature of the failure In addition you must include the name and the telephone number of the co...

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