Cargo Floor CF500 Power speed Reference guide

GB
Repair regulations
CF500 Cylinder disassembly

Cargo Floor B.V.
P.O. Box 271
7740 AG COEVORDEN
The Netherlands
Phone: [phone] www.cargofloor.nl
Fax: [phone] [email protected]
CF500 cylinder repair regulations, Article No. 9305003 03-09-2008 / GB 2 of 26
GB
CF500 Cylinder disassembly
•You have received a cylinder from Cargo Floor as an exchange for a defective cylinder. Please
follow the instructions given below carefully to exchange the part correctly and as quickly as
possible.
•The total disassembly/assembly time for the old/new cylinder shall not exceed 4 hours. Each
additional cylinder will involve 1 hour’s work.
(This represents a maximum of 6 hours for a complete set of cylinders = 3 units.)
Required parts Supplied Reuse
CF500 cylinder 1
Bolt M16 x 90 12
Tab washer M16 12
Rod guiding block 1
Box 1
Instructions for shipping parts back 1
•Tools required:
•3.5 mm screwdriver
•Open-end spanner 10;
•Open-end spanner 17 (2x);
•Open-end spanner 19;
•Open-end spanner 22;
•Open-end spanner 24;
•Open-end spanner 32;
•Open-end spanner 36;
•Open-end spanner 41;
•Open-end spanner 46;
•Torque wrench 0-50 Nm with cap 13
•Torque wrench 0-200 Nm with cap 24
•Copper grease
•Steel brush;
•Hammer;
•Chisel.
Important information:
-When possible draw in the cylinders to prevent damages to the cylinder rods;
-The warranty will not apply if prior permission has not been obtained from Cargo Floor B.V.! The
system number must be mentioned in all correspondence when under warranty;
-Always replace, when exchanging a cylinder, the supplied rod guiding set.
-The pump and electrical installation must always be switched off and the hoses and/or pipes
between the pump and the Cargo Floor drive unit must have been disconnected;
-Also disconnect the electrical connection (light coil of the lorry);
-When the cylinders are being installed, the floor must be empty! Should this be impossible, the
bolts must be tightened immediately after having used the torque wrench;
-Check the oil level after assembly;
-Check/replace the pressure filter!
-When sending back “defective” cylinders, follow the instructions given!

Cargo Floor B.V.
P.O. Box 271
7740 AG COEVORDEN
The Netherlands
Phone: [phone] www.cargofloor.nl
Fax: [phone] [email protected]
CF500 cylinder repair regulations, Article No. 9305003 03-09-2008 / GB 3 of 26
Remove the plug caps from the coils of the GS02 (on=unload/off) and
G02 (load) valves. Use a 3.5 mm screwdriver.

Cargo Floor B.V.
P.O. Box 271
7740 AG COEVORDEN
The Netherlands
Phone: [phone] www.cargofloor.nl
Fax: [phone] [email protected]
CF500 cylinder repair regulations, Article No. 9305003 03-09-2008 / GB 4 of 26
P-pipe disassembly
Position an oil trough under the valve block to catch any leak-off oil.
First, loosen the coupling screw on the front of the control valve; figure 1.0 (spanners 32 + 36).
Disassemble the pressure filter of the support (4 x M8 x 25, spanner 13) and remove the pressure filter
with the P-pipe. Ensure that dirt cannot enter the pipe when putting it aside. Cap off the outlet of the
valve to avoid contamination; figure 3.0.
Figure 1.0
Figure 2.0
Figure 3.0

Cargo Floor B.V.
P.O. Box 271
7740 AG COEVORDEN
The Netherlands
Phone: [phone] www.cargofloor.nl
Fax: [phone] [email protected]
CF500 cylinder repair regulations, Article No. 9305003 03-09-2008 / GB 5 of 26
T-pipe disassembly
Position an oil trough under the valve block to catch any leak-off oil.
First, loosen the coupling screw on the side of the control valve; figure 4.0 (spanners 41 + 46).
Next, loosen the bolts of the pipe bracket (2 x M6 x 40, spanner 10) and remove the pipe.
Ensure that dirt cannot enter the pipe when putting it aside. Cap off the outlet of the valve to avoid
contamination; figure 6.0.
Figure 4.0
Figure 5.0
Figure 6.0

Cargo Floor B.V.
P.O. Box 271
7740 AG COEVORDEN
The Netherlands
Phone: [phone] www.cargofloor.nl
Fax: [phone] [email protected]
CF500 cylinder repair regulations, Article No. 9305003 03-09-2008 / GB 6 of 26
Threaded rod disassembly
Remove the bolts from the command lips; figure 7.0 (M6 x 50, 2 x spanner 10).
Loosen the nut on the mechanical front control plunger (Ø 16 mm) of the control valve. To achieve
this, position a spanner 17 on the back of the control valve and another spanner 17 on the front of the
valve; figure 8.0. Turn the threaded rod and remove it from the mechanical pre steering plunger; figure
9.0. If this is not possible because the spring is pressing against the command lip, first turn the 2 M10
(2 x spanner 17) nuts slightly back (away from the command lip).
Figure 8.0
Figure 7.0
Figure 9.0

Cargo Floor B.V.
P.O. Box 271
7740 AG COEVORDEN
The Netherlands
Phone: [phone] www.cargofloor.nl
Fax: [phone] [email protected]
CF500 cylinder repair regulations, Article No. 9305003 03-09-2008 / GB 7 of 26
Remark/Warning:
If the bolt on the back turns loose, but not the nut on the threaded rod, screw a bolt without a spacer in
the mechanical pre steering plunger(Ø 16 mm, figure 10.0). Next, position a spanner 13 on the flat
sides of the cartridge. The bolt ensures that the hollow shaft cannot be compressed when a spanner is
positioned on the flat sides.
Figure 10.0

Cargo Floor B.V.
P.O. Box 271
7740 AG COEVORDEN
The Netherlands
Phone: [phone] www.cargofloor.nl
Fax: [phone] [email protected]
CF500 cylinder repair regulations, Article No. 9305003 03-09-2008 / GB 8 of 26
Removing the G02 cartridge (load)
First, loosen the nut with which the coil has been mounted (spanner 19) and remove the coil (to ensure
that the pins and the cartridge are not damaged); figure 11.0.
Next, unscrew the cartridge from the control valve (spanner 22).
Seal the opening again using the GS021 plug, which can be found next to the test connections in the
block (spanner 24) (the code can be found on the valve); figures 12.0 and 13.0.
Figure 13.0
Figure 11.0
Figure 12.0

Cargo Floor B.V.
P.O. Box 271
7740 AG COEVORDEN
The Netherlands
Phone: [phone] www.cargofloor.nl
Fax: [phone] [email protected]
CF500 cylinder repair regulations, Article No. 9305003 03-09-2008 / GB 9 of 26
Removing pipes
Loosen pipe P5 (see: the pipes figure below and also the assembly instructions, page H1, hydraulic
diagram and the instructions of use) on the side of the control valve (channel 4); spanners 32 + 36.
Next, loosen the pipe on the side of the common rail (rod side of the cylinder).
Remove the ¾”-20 screw-in coupling from the control valve and cap off the channel.
Loosen pipe S5 on the side of the control valve (channel A1); spanners 32 + 36.
Next, loosen the pipe on the side of the common rail (bottom side of the cylinder).
Cap off the A1 openings and the openings in the common rail.
Slightly loosen the coupling screw of pipe Q5 on the side of the control valve (channel A1); spanner
32/36 (leave the nut positioned but in such a way that the pipe can turn in the coupling).
Next, loosen the nut on the side of the common rail (rod side of the cylinder) in such a way that it can
be unscrewed immediately manually). The pipe will remain attached to the valve block to ensure it can
be presently used as a “handle”; figure 15.0.
Next, loosen the bolts of the common rail bottom side connection (4 x M8 x 75, spanner 13). Note:
remove 3 bolts and allow the last bolt to somewhat remain in the thread.
Now, support the valve with your hand and unscrew the last M8 bolt from the common rail.
Subsequently, loosen the coupling screw on the common rail rod side.
The control valve can now be removed.
Cap off the channels of both common rails; figure 16.0
P5
Q
5S5
Figure 13.1

Cargo Floor B.V.
P.O. Box 271
7740 AG COEVORDEN
The Netherlands
Phone: [phone] www.cargofloor.nl
Fax: [phone] [email protected]
CF500 cylinder repair regulations, Article No. 9305003 03-09-2008 / GB 10 of 26
Figure 14.0
Figure 16.0
Figure 15.0

Cargo Floor B.V.
P.O. Box 271
7740 AG COEVORDEN
The Netherlands
Phone: [phone] www.cargofloor.nl
Fax: [phone] [email protected]
CF500 cylinder repair regulations, Article No. 9305003 03-09-2008 / GB 11 of 26
Figure 18.0Figure 17.0
Figure 20.0Figure 19.0
Common rail disassembly
First, disassemble the common rail on the rod side of the cylinder. You have to loosen the 12 M8 x 75
bolts (spanner 13); figure 17.0. The common rail can now be removed.
Cover or cap off the channels of the common rail and of the cylinders to prevent dirt entering the
system; 18.0.
Next, disassemble the common rail at the bottom of the cylinder. You have to loosen the 12 M8 x 75
bolts (spanner 13); figure 19.0. The common rail can now be removed, figure 20.0.
Cover or cap off the channels of the common rail and of the cylinders to prevent dirt entering the
system; figure 21.0.
Figure 21.0

Cargo Floor B.V.
P.O. Box 271
7740 AG COEVORDEN
The Netherlands
Phone: [phone] www.cargofloor.nl
Fax: [phone] [email protected]
CF500 cylinder repair regulations, Article No. 9305003 03-09-2008 / GB 12 of 26
Cylinder disassembly, (note: this should be done by 2 persons)
Hit back the vertical edge of the tab washers of the bolts (M16 x 90) of the clamping plate on the
bottom (2x), of the triple clamping plate on the rod side (4x), of the clamping plate located at the frame
foot of the cylinder concerned (4x) and of the rod guide set (2x). Use a hammer and a chisel for this;
figures 22.0 and 23.0.
Figure 22.0
Figure 23.0

Cargo Floor B.V.
P.O. Box 271
7740 AG COEVORDEN
The Netherlands
Phone: [phone] www.cargofloor.nl
Fax: [phone] [email protected]
CF500 cylinder repair regulations, Article No. 9305003 03-09-2008 / GB 13 of 26
The bolts of the triple clamping plate (4 x M16 x 90) can be unscrewed and removed; figure 24.0.
Next, the bolts of the rod guide can be unscrewed and removed
Now loosen the bolts of the single cylinder (bottom); figure 25.0.
Do not remove these bolts yet but ensure that these can be unscrewed manually.
Next, loosen the bolts of the clamping plate of the frame foot; figure 26.0.
Figure 25.0
Figure 24.0
Figure 26.0

Cargo Floor B.V.
P.O. Box 271
7740 AG COEVORDEN
The Netherlands
Phone: [phone] www.cargofloor.nl
Fax: [phone] [email protected]
CF500 cylinder repair regulations, Article No. 9305003 03-09-2008 / GB 14 of 26
Remove one clamping plate and loosen the other bolts in such a way that they can be removed
manually.
Next, 2 persons should grab the cylinder (figure 27.0; you can also use a jack or a pit lift as an
alternative) and remove the last bolts and clamping sleeves.
The cylinder can now be removed; figure 28.0.
Remove the rod guiding by unscrewing the 2 M16 bolts.
Figure 27.0
Figure 28.0

Cargo Floor B.V.
P.O. Box 271
7740 AG COEVORDEN
The Netherlands
Phone: [phone] www.cargofloor.nl
Fax: [phone] [email protected]
CF500 cylinder repair regulations, Article No. 9305003 03-09-2008 / GB 15 of 26
Cylinder assembly (note: this should be done by 2 persons)
When assembling the cylinder, all the seatings in which the cylinder falls and the thread on the piston
rod must be cleaned well and must be greased using copper grease; figures 29.0 and 30.0.
Position the 2 clamping plates with the bolts (4 x M16 x 90 that have the tab washers) so that they are
ready and within reach.
Slide the plastic rod guiding on the piston rod.
Figure 29.0
Figure 30.0
Figure 31.0
Warning:
Remove all caps before
installation and ensure
that the holes have been
properly cleaned.
Also properly clean the
flat side on which the
common rail will be
installed.

Cargo Floor B.V.
P.O. Box 271
7740 AG COEVORDEN
The Netherlands
Phone: [phone] www.cargofloor.nl
Fax: [phone] [email protected]
CF500 cylinder repair regulations, Article No. 9305003 03-09-2008 / GB 16 of 26
Two persons should lift the cylinder and position it at the correct location. Ensure that the thread is
correctly positioned in the plate. It must be positioned approximately in the centre of the supporting
plate (this is the sleeve that has been mounted on the frame foot); figure 32.0.
First, mount a clamp around the piston rod at the frame foot and tighten both bolts a few turns; figure
32.0.
Figure 32.0
Figure 33.0

Cargo Floor B.V.
P.O. Box 271
7740 AG COEVORDEN
The Netherlands
Phone: [phone] www.cargofloor.nl
Fax: [phone] [email protected]
CF500 cylinder repair regulations, Article No. 9305003 03-09-2008 / GB 17 of 26
Next, install the single clamping sleeve on the cylinder bottom and tighten both bolts a few turns;
figure 33.0.
Now, install the triple clamping plate and the rod guide. Do not yet tighten the bolts.
Check whether the slit that is located in the sleeve around the piston rod is in a horizontal position;
figure 34.0.
Figure 34.0

Cargo Floor B.V.
P.O. Box 271
7740 AG COEVORDEN
The Netherlands
Phone: [phone] www.cargofloor.nl
Fax: [phone] [email protected]
CF500 cylinder repair regulations, Article No. 9305003 03-09-2008 / GB 18 of 26
Install a trimmed tab washer under the bolt head of the single clamping plate. (Refer to figure 35.0.)
Turn over the protruding tab and hit one side of the ring against the surface of the hexagon-head bolt
(refer to figure 36.0).
Remove all caps from the cylinders and from the common rail.
Figure 35.0
Figure 36.0

Cargo Floor B.V.
P.O. Box 271
7740 AG COEVORDEN
The Netherlands
Phone: [phone] www.cargofloor.nl
Fax: [phone] [email protected]
CF500 cylinder repair regulations, Article No. 9305003 03-09-2008 / GB 19 of 26
Next, pull the cylinder as close as possible in the sleeves by tightening the bolts but also ensure that the
cylinder is not yet clamped.
Check whether the surfaces of the common rail are all in parallel to each other.
You can use the common rail for this; figure 37.0.
Warning:
Check that the surfaces on which the common rail is being mounted are really clean and that all plugs
have been removed.
If they are correctly positioned, mount the common rail on both sides; figure 38.
Figure 38.0
Figure 37.0

Cargo Floor B.V.
P.O. Box 271
7740 AG COEVORDEN
The Netherlands
Phone: [phone] www.cargofloor.nl
Fax: [phone] [email protected]
CF500 cylinder repair regulations, Article No. 9305003 03-09-2008 / GB 20 of 26
To correct the position of the cylinder, should this be necessary, you can position a spanner 17 on the
bolts of the cover of the cylinder and turn it. Note: Do not position a spanner on the (hexagon) plug
next to the piston rod. It is very easy to damage the piston rod should the spanner slip; figure 39.0
Figure 39.0