Dismantling the refrigeration unit in the tractor cab DAF XF 105 is a task that many truck drivers face. Most often, the need for this arises when a system breaks down, requiring complex repairs, or when the unit is completely replaced with a more modern analogue. Unlike household models, refrigerators in trucks are integrated into the general electrical network and the cab mounting system, which requires a special approach.
The removal process cannot be called trivial, since it affects not only mechanical components, but also high-power electrical circuits. Improper dismantling can lead to damage to the wiring, loss of interior sealing, or even a short circuit. That is why it is important to strictly follow the algorithm of actions and understand the structure of a particular unit.
In this article we will analyze in detail all stages of work: from preparing the tool to the final removal of the compressor unit. We will pay attention to the nuances specific to the series DAF XF 105, since the layout of the berth and the location of technical niches here have their own characteristics. Proper execution of the work will extend the life of the rest of the equipment and ensure safety.
Preparation of the workplace and the necessary tools
Before taking active steps, it is necessary to organize a safe workspace. The cabin DAF 105 is quite spacious, but access to the rear wall, where the refrigerator is usually located, may be limited by the berth or additional equipment. You will need to provide good lighting, since most fasteners and connectors are in darkened niches.
A basic set of tools should include a ratchet socket set, a set of screwdrivers (phillips and slotted), pliers and a multimeter. Pay special attention to the insulation of tools, since the work will be carried out in close proximity to the electrical circuits of the truck. A rag is also useful for wiping contacts and a container for collecting possible condensation or refrigerant residues if the system has not been completely drained.
⚠️ Attention: Before starting any work on electrical equipment, be sure to turn off the power to the car by switching the ground to the on-board power switch. Working under voltage in a confined space in the cab is life-threatening.
It is important to clear the space around the refrigerator compartment. If food or personal items are stored in a niche, they must be removed. In some configurations, access to the mounting bolts may be blocked by elements of the sleeping area furniture. In this case, it may be necessary to partially dismantle the casing or lift the bed, which should be done carefully so as not to damage the plastic fasteners.
Diagnostics and turning off the power supply
The first technical stage is to completely disconnect the device from the on-board network. In trucks DAF the refrigerator can be powered through a separate fuse or directly through a terminal block located behind the rear wall of the cab. It is necessary to find an electrical diagram for your specific modification, since the location of the blocks may differ depending on the year of manufacture.
The shutdown process begins with checking the voltage at the terminals. Use the multimeter in DC current mode to ensure there is no potential before disconnecting the contacts. Drivers often forget that some systems can be energized even when the ignition is turned off, if the main ground switch is not activated.
- 🔌 Find the main wiring harness going to the back wall of the refrigerator and visually assess the condition of the insulation.
- 🔌 Disconnect the power connector, having first secured the clips so as not to break the plastic latches.
- 🔌 Check that there is no short circuit between the positive wire and the vehicle ground after disconnecting.
If your DAF XF 105 has a climate control system integrated with the refrigerator, make sure that you are turning off the cooling circuit and not the ventilation. An error in wire identification may result in malfunction of the cabin heating system. After disconnecting the wires, it is better to immediately insulate their ends with electrical tape or cover them with caps to prevent accidental contact.
Removing fasteners and clamps
Refrigeration units in trucks are mounted rigidly enough to withstand vibrations and shaking on the roads. The model DAF 105 most often uses a combination of bolted connections and special guides. They are usually accessed through technological hatches or after removing the decorative panel of the rear wall.
The main difficulty is that the mounting bolts often sour due to changes in temperature and humidity. Before unscrewing, it is recommended to treat the threaded connections with a penetrating lubricant (for example, WD-40) and wait 10-15 minutes. The use of an impact tool (a screwdriver with an impact mechanism) may be justified, but requires caution so as not to damage the body of the refrigerator itself or the wall of the cabin.
The sequence of unscrewing the bolts:1. Upper guides (2 pcs.)
2. Lower support bar (2 pcs.)
3. Side clamps (if available)
When removing fasteners, it is important to hold the unit itself. Despite its small dimensions, the weight of the compressor unit can be significant, and its fall can damage the plastic lining of the niche or damage the heat exchanger tubes. If access is difficult, use a magnetic holder or extension for the wrench.
☑️ Check before removing fasteners
Removing the compressor unit and heat exchanger
After freeing the fasteners and wires, the most crucial moment comes - physically removing the unit. In design DAF 105 the refrigerator is often a modular system where the compressor, condenser and evaporator can be combined or separated. If your goal is to remove the entire module, proceed smoothly, without jerking.
Carefully monitor the copper tubes connecting the parts of the system. Even if the freon has been removed, residual pressure may remain in the pipes. A sudden break in the tube may cause oil or refrigerant residue to splash out, which should not come into contact with the skin or eyes. Carefully remove the unit from the niche, controlling the angles.
| Element | Weight (approximate) | Mounting type | Risks during removal |
|---|---|---|---|
| Compressor | 4-6 kg | Rubber pads | Broken wires |
| Capacitor | 2-3 kg | M6 bolts | Deformation of the lamellas |
| Control unit | 0.5 kg | Latch | Damage to the board |
| Fan | 1 kg | Screws | Blade breakage |
If the refrigerator is built into a furniture box, it may be necessary to remove the entire back panel of the bed. In this case, proceed with caution with chipboard and plastic, as they can be fragile. In DAF XF 105 high-roof Space Cab models, access is often through a hatch in the ceiling of the sleeping area, which requires working in an awkward position.
Features of working with the cooling system
When When dismantling, it is important to understand what kind of system you are dealing with. Modern trucks use compressor refrigerators running on freon or absorption systems. In DAF 105 compressor models that require circuit tightness are more common. If you plan to reinstall the same unit, the tubes must be immediately plugged with special caps to prevent moisture and dust from getting inside.
Moisture in the cooling system is the main enemy of the compressor. This leads to acid formation and oil failure. Therefore, the open ends of the tubes must be closed immediately after disconnection. If you notice traces of oil around the connections before removal, this is a sure sign that the seal was previously broken.
What to do with the remaining freon?
If there is pressure left in the system, you cannot bleed it off indoors. Refrigerant is heavier than air and can displace oxygen. It is better to carry out work in a ventilated hangar or outside.
It is also worth inspecting the condition of the vibration-isolating rubber bands on which the compressor is attached. When installing a new or reinstalling an old unit, it is better to replace them. Old rubber loses its elasticity, and vibrations from the operation of the compressor will be transmitted to the cab body, creating unpleasant noise and hum during parking.
Installing a new unit or preserving the place
If removal was carried out for replacement, installation of a new refrigerator is done in the reverse order. It is critically important to check the compliance of the electrical parameters of the new device. DAF XF 105 has an on-board 24 V network, and connecting a 12-volt unit without a converter will lead to instant burnout of the fan motor or compressor.
During installation, make sure that all wires are laid in corrugation or cable channels and do not have contact with moving parts or sharp metal edges. The vibration of the truck will eventually wear down the exposed insulation, causing a short. All connections must be securely tightened and, preferably, treated with contact lubricant to prevent oxidation.
- 🔧 Check the tightness of all fastening bolts after the first 100 km.
- 🔧 Make sure that the ventilation holes are not blocked by personal belongings.
- 🔧 Test the operation of the thermostat and the inclusion of the fan immediately after assembly.
If the refrigerator is completely removed and there are no plans to install a new one, the resulting niche must be preserved. The wiring compartments should be closed with plugs, and the hole in the cabin wall with a sealed plate with insulation. This will prevent noise, dust and cold from getting into the cabin from the street, which is especially important in winter.
Common mistakes during dismantling
One of the common mistakes is neglecting to mark the wires. When reconnecting, drivers often rely on memory, which in the case of complex harnesses DAF can lead to errors. Always label wires or take photos before unplugging. This will save you hours of searching in the future.
Another mistake is using excessive force when unscrewing soured bolts. In pursuit of speed, you can tear off the head of a bolt or, worse, damage the threads in the aluminum body of the refrigerator. Restoring threads in such conditions is extremely difficult and often requires replacing the entire assembly.
⚠️ Attention: Do not use open fire to warm frozen or soured connections near plastic elements of the cabin and wiring. This can lead to a fire or melting of the insulation.
It is also worth mentioning the mistake of ignoring cleanliness. Chips or dirt that got inside the system during installation can jam the compressor in the first minutes of operation. Wipe down the seats and make sure that the work area is clean.
Do you need to pump out freon before removal?
Yes, if you are planning repairs or disposal. Simply releasing freon into the atmosphere is prohibited by environmental standards, and to reuse it, it must be collected in a cylinder using special equipment. If the refrigerator is being disposed of, it is still better to depressurize the system in a ventilated place.
Is it possible to remove the refrigerator without removing the entire back panel?
In most cases, the DAF XF 105 allows access to the main fasteners through technological holes. However, for complete dismantling, especially if it is necessary to disconnect the heat exchanger tubes, removal of the decorative panel is often necessary to ensure safe access.
What tools are needed for DAF electrics?
You will need contact test leads, a multimeter with a continuity function, a set of high quality insulating tape and possibly a terminal crimping kit if old connectors are damaged. A standard automotive tool kit usually does not include specialized feeler gauges for deep pads.