DAF CF65, CF75, CF85 Series . Manual — part 1069

©

200424

5-1

Disassembly and assembly

HYDRAULIC LIFTING GEAR

ΧΦ65/75/85 series

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5. DISASSEMBLY AND ASSEMBLY

5.1 DISASSEMBLY AND ASSEMBLY, PUMP UNIT

Disassembling the pump unit
1.

Remove the pump unit from the vehicle, see

the chapter "Removal and installation".

2.

Let the oil run from the reservoir.

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HYDRAULIC LIFTING GEAR

5-2

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200424

Disassembly and assembly

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ΧΦ65/75/85 series

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3.

Clean the entire pump unit and the

surroundings before disassembly. Work in

very clean conditions.

4.

Remove the pressure relief valve, the 4/2

valve and the 2/2 valve, see chapter

"Removal and installation".

5.

The built-in non-return valve (28) is very

difficult to remove from the valve block

because a very strong locking and sealing

compound has been applied to the screw

thread of the plug (29). Leave the non-return

valve in the valve block, if it is not necessary

to remove it.

6.

Remove the pressure switch (40).

7.

Loosen the clamping strip (19) and take the

reservoir (23) from the valve block (27).

8.

If necessary, remove the return lines (35)

and (45) from the valve block (27). The lines

are clamped to the couplings (36) and (44).

9.

Loosen the hose clamp (48) and take the

suction filter (50) out of the coupling (47).

10. Mark the position of the pump (32) relative to

the valve block (27) to facilitate installing the

pump. Remove the two attachment bolts (34)

at the back of the pump and remove the

pump (32) from the valve block (27).

11. Mark the position of the motor (24) relative to

the valve block (27). Remove the two

hexagonal socket screws (31) and remove

the motor from the valve block.

12. Remove the coupling disc (28) from the

valve block.

Assembling the pump unit
1.

Check the components for signs of wear

and/or damage.

Check the suction pipe carefully.

When installing the parts, use new gaskets

and/or O-rings. Apply some grease to the O-

rings prior to installation.

2.

Apply plenty of oil to the coupling disc (26)

and install the coupling disc in the valve

block (27). Make sure that the groove for the

motor is pointing towards the motor side.

3.

Install the motor (24) on the valve block (27).

Tighten the attachment bolts (31) to the

specified torque. See "Technical data".

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200424

5-3

Disassembly and assembly

HYDRAULIC LIFTING GEAR

ΧΦ65/75/85 series

8

9

4.

Install the pump (32) on the valve block (27).

Make sure that the pump drive shaft

engages the coupling disc (26). Check

whether the front of the pump is flush against

the valve block before tightening the

attachment nuts (34). Tighten the

attachment bolts to the specified tightening

torque, see "Technical data".

5.

Install the pressure relief valve, the 4/2 valve

and the 2/2 valve, see chapter "Removal and

installation".

6.

Install the pressure switch (40).

7.

Connect the oil return lines (35) and (45).

8.

Fit the filter (50). The cam on the filter must

fall into the groove of the pump cover.

Tighten hose clamp (48) securely.

9.

Install the O-ring (20) and the reservoir (23).

The filler opening of the reservoir (23) is on

the side with the valves (40) and (43).

Tighten the reservoir using the clamping

strip (19).

10. Plug the line connections.

11. After installation of the pump unit in the

vehicle, the operation and adjustment of the

valves and the pressure switch should be

checked, see chapter "Inspection and

adjustment".

Check for external leakage.

HYDRAULIC LIFTING GEAR

5-4

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200424

Disassembly and assembly

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ΧΦ65/75/85 series

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5.2 DISASSEMBLY AND ASSEMBLY, 2/2 SOLENOID VALVE

Disassemble the valve only to check

and/or to clean the internals. The

internal parts cannot be obtained

separately. In case of a fault, the

valve as a whole should be replaced.

Repair and maintenance activities

should be carried out in very clean

conditions as even the smallest

impurity can cause internal leakage

or can result in jamming of the valve.

Disassembling the 2/2 solenoid valve
1.

Remove the valve from the pump, see the

chapter "Removal and installation".

2.

Clamp the valve casing (1) with the

hexagonal head in the vice and remove the

holder (8).

3.

Remove the holder (8) with the valve (7) from

the valve casing (1). Make sure that the

adjusting rings (3) are kept together.

4.

Remove the spring (6) from the magnet-

core (4) pin.

5.

Remove the magnet core (4) with the bush

(5) from the valve casing (1). Note down the

distance of the bush (5).

Assembling the 2/2 solenoid valve
1.

Check the sealing surfaces of the valve (7),

the holder (8) and the magnet-core (4) pin.

2.

Check the freedom of movement of the

valve (7) in the holder (8).

3.

Check the freedom of movement of the pin in

the magnet core (4).

4.

Replace the O-ring (2) of the valve core (1)

and the O-ring (9) of the holder (8). Apply a

layer of grease to the O-rings.

5.

Install the magnet core (4) with the bush (5)

into the valve casing (1). Make sure that the

bush (5) is fitted in its original position.

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