Hydraulic Cylinder PT 1 CV01

HYVA CYLINDER
715 04 196 I
leVA
Front end cylinder with outer cover type FC 129 -3- 03460- 594A -K0162
equivalent to FC 5.5 -3 -136
II
tipping weight 34 -60 ton / 74 -132 x1000 lbs
page #1 /2 ' closed length (K) 157 -192 mm / 6.18- 7.56"
front & side view cylinder U.S. Metric
I
1/2 1/2
i
clearance for service
A 9.02"/8.82" 229/224 mm
B 7.01"/7.09" 178/180 mm
N C 5.87" 149 mm
u: D 7.68" 195 mm
'
E
D ca- --- G'

_ __I H* 58.43" 1484 mm
_ _ - p - - II 2.56" 65 mm
A2 Al J 3.59" 91 mm
Ira
K* 6.38" 162 mm
L
M'
N
O
P
Q
R
S 4.16" 106 mm
11/16" 11/16"
-
T UNF
U 1.87" 47.6 mm
V 2" 50.8 mm
W 1.87" 47.6 mm
B2 B1 X 1.26" 32 mm
Y
z
*incl. 0.79"[-0.20";+1.21 pull out on piston
specifications II
technical notes
weight cylinder only 386 lbs 175 kg This cylinder is a lifting device only and may not be used as
total volume 10 gallon 37 L
structural member or be subject to side load. Working pressure
depends on application; never exceed maximum pressure.
working volume 9 gallon 34 L
Cylinder painted with Akzo Air drying Enamel (RAL9005).
maximum pressure 2756 psi 190 bar Max duration of extension 2 hours (excluded HC).
maximum pump flow 36 gal /min 137 L /min See mounting instruction CYL -0019.
maximum cylinder angle to front 5° 5° See oil specification sheet OIL -0002.
The smallest stage is Hard Chromed.
maximum thrust first stages" 55116 lbs 25 ton
"when I. mounted at a large angle, thrust first stage may become too high: see Hyva Tipper Program
extension 1 2 3 4 5 6 7 8 9 total
t
effective diameter [inch] 5.08 4 33 3.58
effective diameter [mm] 129 110 91
stroke [inch] 44 9 45.7 45.7 136.0

stroke [mm] 1140 1160 1160 3460
tipping weight
tipping weight at maximum pressure of 2756 psi or 190 bar and C is 7.01 inch or 178 mm
BL (body length); BL 185" 175" 165"
OH (rear overhang);
OH 8" 16" 24" 8" 16" 24" 8" 16" 24"
Ycog (vert. pos. centre of
I gravity); At 44 46 48 46 49 51 49 52 55
\ Qo (pivot length); Ycog
II 1
C (bracket length);
--
16" 74 80 88 76 84 94 79 88 101
}
........ . .:
_r_ lik
"' "/
-~
o;- At = stroke x 60 / Qo 28" 81 89 101 85 95 110 90 103 122
I-- BL 39" 89 100 117 95 110 132 103 123
Subject to change without notice. DO-U 715 04 196 / 07-11-06 / RV AE
Information for reference only no other conditions are expressed or implied
PDF compression, OCR, web optimization using a watermarked evaluation copy of CVISION PDFCompressor
HYVA CYLINDER
eTh 715 04196
Front end cylinder with outer cover type
H*A
FC 129-3-03460-594A-K0162
FC 5.5-3-136 I
page #212
CD c) - - - (4-6
-
100 120 -
g O-- 122 123
® @
o --
44,:,
30 102
- 20 Ea
-
103 0°^i
o
Q -
0 cD -
21
t121
CI)
- --- 101
-
31
- 1
21
4p
e
--- 104
- 125
Q - 22
C'i-32
(:;)
C'j ---
33
34
o
G
o
-- 105
106
107
108
(0-23
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4
- 24
°a a -6 5
Spare part list Spare part list

Pos Part no. Description Qty. Pos Part no. Description Qty.
0 71802149 K PACKSET 149 01 100 71831091 PISTON HEAD 091 MACHINED 01

72505370R1105 BASE 149 -1399-1 1 /16UNF- 000- 90 -C195 01 101 72402371 PISTON S 091- 13651C
"a\ 01
1
2 71870030 K SEAL BOTTOM PLATE 149 01 102 71875010 PIN ROUND HEAD GROOVED 6x15 mm 01
3 71821149 BOTTOM PLATE 149 01 103 71870115 K 0 -RING PISTON TOP 091 01
4 71820149 LOCKING PLATE 149 03 104 71807091 K SLIDER 091 (2 X 1/2) 01
5 01732559 K SPRING WASHER M8 SET 01 105 71807091 K SLIDER 091 (2 X 1/2) 01
6 01732055 K BOLT M8 X 1.25 X 20 SET 01 106 71870215 O -RING PISTON BOTTOM 091 01
107 71822091 BOTTOM PLATE PISTON 091 01
108 71814091 SNAPRING FOR PISTON 091 01
20 71802129 K PACKSET 129 01
21 72604370 STAGE 129 -1360 01
22 NOT APPLICABLE
23 71807129 K SLIDER 129 (2 X 1/2) 02
24 71812129 K LIFTRING 129 01
30 71802110 K PACKSET 110 01 120 01702907 TOPNUT NYLOC M48x3 DIN 985 ZP 01
31 72603370 STAGE 110-1360 01 121 71704544 COVER 195 -1325 PIN47 01
32 NOT APPLICABLE 122 01702956 WASHER M48 DIN 1258 ZP 01
33 71807110 K SLIDER 110 (2 X 1/2) 02 123 NOT APPLICABLE
34 71812110 K LIFTRING 110 01 125 NOT APPLICABLE
Seal kit complete: i 1
I
Part no. Description
71901430 K Seal kit complete:

consists of all packsets with packset
grease, 0 -rings and Pin (pos 102)
Subject to change without notice DO-U 715 04 195 /07-1106 /RVAE
mounting instructions
front -end cylinders
F.L.A.S.H. series
111VXxroRauucs
Mounting Instructions
Front -End (FC, FE and FEE) Cylinder
F. L.A. S. H. series
Table of contents
1. Introduction 3
1.1. Scope of use 3
1.2. General remarks 3
1.3. Safety 4
1.3.1. Explanation of guidance 4
1.3.2. Precautions 4
2. Guarantee ............._ 6
Hyva International Terms of Warranty 6
3. Mounting Instructions 8
3.1. General 8
3.1.1. Components 8
3.1.2. Mounting position and clearances 9
3.1.3. Cross members 10
3.2. Sub -frame mounting the cylinder 10
3.3. Cradle mounting the cylinder 11
3.3.1. Mounting the cradle 11
3.3.2. Mounting the chassis brackets into the cradle 12
3.4. Fixing the cylinder into the chassis brackets 13
3.5. Attaching the cylinder to the tipper body 14
3.5.1. FC cylinder 14
3.5.2. FE cylinder 14
3.6. Connecting and testing the cylinder 15
3.6.1. Connection of the hydraulic system 15
3.7. Final Checks
. 16
3.8. Painting the cylinder 16
4. Tables
.
18
4.1. Table 1: Bolt and nut specifications 18
4.2. Table 2: Recommended Cross Member Profiles and Dimensions 18
5. Service points 20
"Th
page 1 of 20
Subject to change without room
CITE CYL-0017 / 06-06 -141 RV AB
F.L.A.S.H. series
1
Introduction Scope of use
This section gives an overview of the use of this manual. General remarks
It also gives some basic advice on safety and precautions to be
taken before and during installation. Safety
Intended for experienced fitters that are new to Hyva Hydraulic
equipment and also as a refresher for those already familiar with
Precautions
Hyva products.
The advice given in these pages is by no means complete and

should not be used as an alternative to common sense.
page 2 of 20
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011.E CYL-0017106-06-141 RV AB
Front-End (FC, FE and FEE) Cylinder
F.L.A.S.H. series
1. Introduction
1.1. Scope of use
This manual is for work -preparation and workshops and has been written to assist with the planning and
installation of the Hyva front -end cylinder and associated equipment.
The Hyva Front -end cylinder range includes cylinders with Outer Cover (FC), with Eye (FE) and with
Eye /Eye (FEE).
1.2. General remarks

Where a tipper is to be built-up with no sub -frame on the chassis, we strongly advise that a Hyva cradle be
used to mount the cylinder. Instructions for cradle mounting of the Hyva cylinder are also given in this manual.
If the cylinder is to be fitted above the gearbox, splitter box or any part that needs periodic service, clearance
must be provided between this part and the bottom of the cylinder.
It is important that the gear is fitted in the correct position, to ensure the safe and /or legal axle loading,
Specification sheets are available for all Hyva cylinders; these sheets contain all relevant dimensional and
application information about your cylinder.
The Hyva cylinder has been developed for lifting purposes only and its use for any other purpose is prohibited.
The cylinder is not to be used as a stabiliser and any kind of side -load must be avoided whenever possible.
Warning
Applying side -load to any cylinder is dangerous.
The cylinder should be mounted with a minimum pull out of 15 mm and a
maximum pull out of 50 mm (the closed length of the cylinder on the Hyva
specification sheet already includes 20 mm pull out).
If you have any questions concerning the application, installation, operation or repair of any Hyva product -
please contact your nearest Hyva Service Point.
Hyva cylinders are also compatible with biodegradable oils such as the following synthetic ester based oils:
BP - Biohyd SE -S
Castrol - Carelube HES
Texaco - Hydra
Elf - Hydrelf Bio Safety
page 3 of 20
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CH -E CYL -0017 /06-06.141 RV AB
F.L.A.S.H. series
1.3. Safety
1.3.1. Explanation of guidance

Tip
i
Gives the reader advice in order to simplify certain tasks or warns of potential
problems.
Warning
Warning of danger to the operator or product. The operator can be seriously
hurt or the equipment severely damaged if the recommended procedure is
not followed.
Danger
There is a serious threat to the life of the operator.
1.3.2. Precautions
Ensure there is enough free working space for mounting the cylinder.
i
If the tipper body is on the truck chassis, lift the body using an overhead crane so that the cab protector is well
clear of the cylinder.
If the tipper body is raised to create working space, support the body using body props before mounting the
cylinder.
Danger
Working under an unsupported tipper body is a danger to life. - --
To avoid damage to the truck cabin, cover the rear of the cab with a tarpaulin.
If necessary tilt the vehicles cabin (see the truck manual for details).
Disconnect the vehicle's battery leads before any welding.
While lifting a cylinder the other stages can extend, to avoid this use a sling around the cover or piston and
base tube (between the trunnion and anti -rattle ring). Extend the cylinder until the sling is locked and transport
f the cylinder using a suitable lifting device (see chapter 3.4).
Warning
Not using the appropriate equipment when lifting parts (such as the proper
sling for a cylinder) is a danger to life.
Ensure any oil, spilt during installation and testing, is disposed of in an environmentally friendly way.
page 4 of 20
OH -E CYL -0017 106-06 -14 I RV AB
F.L.A.S.H. series
2
Hyva International Terms of Warranty
Guarantee
This section contains an overview or guide to Hyva terms of
warranty.
It is not complete or contractual, so in the event that you do have a

problem with a Hyva product you should contact your nearest Hyva
service point.
page 5 of 20
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OR.E CYL-0017 106-06-14 1 RV AB
I
F.L.A.S.H. series
,ri
2. Guarantee
Hyva International only issues warranty to products under agreed conditions.

The following products are covered by warranty:
1. Hydraulic Cylinder
2. PTO & Pump
3. Tipping valve & Air Control
4. Oil Tank
5. Body
The warranty is only valid under the following conditions:
01) All Hyva products must be installed, operated, maintained and repaired in accordance with the
relevant Hyva guidelines.
02) For the parts listed above, the warranty period covering is valid 12 months from date of delivery or up
to a maximum, whichever comes first, of:
20.000 tipping cycles for the cylinder, tipping valve, control
and body.
300 running hours for the PTO and pump.
100.000 km for the oil tank.
03) The warranty period does not cover:
Wear of parts during normal operation (e.g. sealing set),
parts made of rubber or with limited lifetime.
Paint coatings.
Damage caused by forces beyond our control.
Damage caused by incomplete or erroneous installation.
Damage caused by abusive or inappropriate operation.
Damage as a result of service not carried out in accordance
with the Hyva Operating & Maintenance Instructions.
04) This warranty is valid only in accordance with the Hyva General Terms unless otherwise specified
(document FO- E00000130/050721/RV AB).
05) A completed Claim Report shall be delivered with every claim.
06) All broken parts shall be kept for inspection, these parts will be returned to Hyva International for
inspection on request (transportation costs to be met by end user).
07) Where warranty is granted, Hyva International will meet the cost of the following:
All necessary spare parts.
A replacement part where the original cannot be repaired.
08) Hyva International does not accept any liability for transport costs or travel expenses.
09) During the warranty period the equipment must be serviced at the appropriate periods (costs to be met
by the end user). Checks listed in the Hyva Operating & Maintenance instructions must be completed.
10) Drivers must be trained to operate the Hyva equipment with the appropriate operating instructions
made available.
11) Drivers should include the Hyva equipment in their daily vehicle inspection and arrange service for the
vehicle /equipment as described in the Maintenance Instructions.
Any variation from the conditions listed above must be agreed with Hyva
prior to the operation of the equipment.
page 6 of 20
CH -E CYL-0017 /06-06 I RV AB
F.L.A.S.H. series
3
Mounting Instructions General
This section makes up the main body of the mounting instructions.
Components
It is separated into sections to enable you to go directly to areas you
are unsure about or work through in sequence as a 'fitting course'. Mounting position and clearances
It is separated into sections based on possible fitting arrangements
i.e. with cradle or without/ FC and FE. Cross members
The remainder of the section covers mounting of the cylinder on to
Sub -frame mounting the cylinder
the vehicle or trailer, attaching to the body and connection & testing.
Cradle mounting the cylinder
Mounting the cradle
Mounting the chassis brackets into the cradle
Fixing the cylinder into the chassis brackets
Attaching the cylinder to the tipper body
FC cylinder
FE cylinder
Connecting and testing the cylinder
Connection of the hydraulic system
Final Checks
Painting the cylinder
page 7 of 20
OH.E CYL -0017 ! 06-06 -141 RV AB
F.L.A.S.H. series
3. Mounting Instructions
3.1. General
3.1.1. Components
The basic components of the Hyva front end cylinders are as shown in Figure 1:
Cylinder FEE type
Cylinder FE type
Cylinder FC type
FIGURE 1
FC type (Front -end Cover) FE type (Front -end Eye) FEE type (Front -end Eye-Eye)
1. Cylinder (Cover) 1. Cylinder 1. Cylinder
2. Cylinder (Main Body) 2. Piston Eye 2. Piston Eye
3. SAE Oil Inlet 3. SAE Oil Inlet 3. SAE Oil Inlet
4. Right Hand Body Bracket 4. Chassis Brackets 4. Base Eye
5. Left Hand Body Bracket 5. Bracket Cradle
6. Chassis Bracket
7. Bracket Cradle
page 8 of 20
OH.E CYL-0017 106-06.14 I RV AB
F.L.A.S.H. series
3.1.2. Mounting position and clearances

The mounting position of the cylinder will depend on the application requirements of the cylinder and the
safe/legal axle loading of the vehicle.
The application requirements (lifting capacity and tipping angle) of the cylinder are governed by the load
capacity of the vehicle and the physical shape of the body (overhang, body -length, pivot point, etc.). The axle
loading for the vehicle is governed by legal requirements in the country of use and the specification of the
vehicle manufacturer.
Tip
For minimum body weight use:

body volume (L `w *h -in metres) * specific mass of sand (1.6 ton/m3)
If you are -
unsure of any of these details please contact you nearest Hyva Service Point, who will advise on
suitable fitting position for your application.
Additional factors that may affect the mounting position:

1. Cab clearance - ensure enough clearance is left between the body and cab, allow for tilting of the cab,
movement of the body during tipping and access to other equipment in the mounting area
2. Rotation clearance - during tipping the cylinder rotates about it's lower bracket, ensure there is enough
clearance around the lower part of the cylinder body, cab and gearbox
3. End of stroke clearance - check there is at least 50mm clearance between the front of the body and the
stages of the cylinder at the end of it's stroke
4. Maintenance access - remember to allow space for the use of tools, connection of hoses and so on during
fitting and service
Caution
The maximum build -in angle for FC cylinders depends on cover length.
As a rule of thumb:
Cylinders with long cover (small closed length) can be build in up to 10°
Cylinders with short cover (big closed length) can be build in up to 20°
(angle from the vertical)
For more detailed information see cylinder specification sheet.
The maximum build-in angle for FE/FEE cylinders is 30° from the vertical
plane.

Where a 'knock -offor other end of stroke device is to be used remember to allow
150mm of stroke for front -end cylinders to activate the device.
page sain
OH -E CYL -0017 /06.06.14 /RV AB
f Front -End (FC, FE and FEE) Cylinder
r
3.1.3. Cross members
See the cylinder specification sheet for the minimum distance
between the support cross members. Allow free distance for
rotation of the cylinder during tipping (rotation is approximately
half the tipping angle).
( ( Cross members for the chassis brackets (see Figure 2), must
1
be of sufficient cross section to withstand the cylinder load.
I See manufacturer's guide and table 2 for recommended cross
member profiles and dimensions.
FIGURE 2
Allow maximum 2mm clearance between the cylinder and
chassis brackets for assembly and removal.
I 3.2. Sub -frame mounting the cylinder

Position one of the chassis brackets, hand -tighten the required bolts, self -locking nuts and washers, (see
bracket specification sheet). See Figure 3 for position and orientation of chassis brackets.
--
FIGURE 3: MOUNTING THE CYLINDER INTO THE SUB FRAME
Ensure there is enough clearance between the top of the cross member and the bottom of the cylinder at full
extension. See specification sheet for details.
For sequence see section 3.4.
page 10 of 20
0HE CYL-00I7 106-06-14 I RV AB
FL .A. S. H. series
3.3. Cradle mounting the cylinder
3.3.1. Mounting the cradle

Set the height of the cradle (see Figure 4) to allow clearance for the
gearbox etc., using standard rectangular or U- profile channels.
Use manufacturer's recommended subframe profiles for channel

dimensions
Channel must be angled with rounded edges to minimise stress on the

chassis
FIGURE 4
Fabricate the attachment plates to run down to the chassis from the
underside of the cradle.
The brackets must run the full width of the cradle and about 2/3 of the depth of the chassis (minimum 100mm).
Where the attachment plate coincides with parts on the chassis (such as a suspension bracket), the plate may
be cut to fit. Follow the shape of the bracket as closely as possible using rounded corners.
Refer to the truck manufacturer's guide before moving any vehicle components. It may be possible to
reposition the parts on the chassis or fit the plate behind.
If the chassis is formed at the fixing points, the attachment plates may be formed to suit. If necessary the
plates can be cut and welded at the required angle with the stiffener rib over the weld.
Bolt the attachment plates to the chassis (see Figure 5). Use a minimum
of four M16x1.25 quality 8.8 bolts per plate and existing holes wherever
possible.
Weld the cradle to the attachment plates (see Figure 6)

Fully weld the cradle, attachment plates and cradle.
Ensure the attachment plate is welded the full width of the underside of 011
the cradle.
Warning FIGURE 5
Disconnect the battery leads before welding.

If the cradle is to be removable, we recommend the cradle be fixed as
shown in Figure 7.
FIGURE 6
page 11 of 20
OH-E CYL-0017 / 06-06 -141 RV AB
r .
F.L.A.S.H. series
3.3.2. Mounting the chassis brackets into the cradle

Position one of the chassis brackets, hand -tighten the required bolts, self -locking nuts and washers, See
Figure 8 for position and orientation of chassis brackets.
Use the pre -drilled holes in the cradle when mounting the chassis brackets. Use the bracket specification
sheet to determine the correct holes.
r FIGURE 7
FIGURE 8: MOUNTING THE CYLINDER INTO THE CRADLE
For sequence see section 3.4
Note:
All brackets are equipped with maintenance free bearings
page 12 of 20
CYL-00I7 106-06-14 I RV AB
01-1-0
3.4. Fixing the cylinder into the chassis brackets
Warning
dir Not using proper slings is danger to life.
Be careful that while lifting the cylinder the stages may extend. For easy lifting of FC cylinders, a lifting eye bolt
is available, which can be mounted in top of piston head, see Figure 10 (Part no. 71875105).
Wrap the sling around the outer cover and base (for FE types use the base), and transport it using an
overhead crane, or other suitable lifting device.
Before mounting the cylinder, remove the protective caps.
Position one of the cylinder pins into the pre -placed chassis bracket (see Figure 3 or Figure 8 ). Make sure the
oil inlet is facing the right direction for connection of the hydraulic system.
Fix the second chassis bracket and align the cylinder with the centre of
the truck chassis (see Figure 3 or Figure 8.). Be aware of the 2 mm
maximum clearance between cylinder and brackets. Tighten all bolts
securely (see Table 1 for required torque).
Warning
After removing the sling, the cylinder may fall towards the cab, this
can result in injuries to persons or damage of components.
To hold the cylinder in the correct position, place wooden wedges or
blocks between the cylinder and the chassis (see Figure 10). Remove the
sling. As mentioned above, the lifting eye bolt can be mounted in the
piston head.
Tip
if only the tipping gear is to be fitted

(i.e. the body is to be fit elsewhere)
secure the cylinder and brackets to prevent damage during transport. Lean
the cylinder (and rear brackets) back and secure to chassis with ropes.
FIGURE 10
/Th
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011.E CYL- 0017106 06-14 f RV AB
F.L.A.S.H. series
t 3.5. Attaching the cylinder to the tipper body
3.5.1. FC cylinder
Remove the protective caps from the cover and lightly grease the pins
with SAE 140 grease or equivalent. Place the lifting brackets (Figure 11)
on the cover pins and attach them to the tipping body. See Figure 12.
The brackets are equipped with maintenance free bearings.
\
Ensure the lifting brackets are in the correct position and orientation
with a maximum of 2mm clearance between the cover and brackets.
The nuts and washers should be on the bracket flanges, if there is not
enough space they may be reversed.
Tighten all bolts securely (see Table 1 for required torque). FIGURE 11
Tip
The lifting bracket holes may not be in -line with the tipping body holes.
The cylinder can be carefully extended hydraulically or by physically
pulling out the small inner (piston), the tipping body can also be lowered.
L
If the cover is likely to make contact with the body and rattle use rubber
block (092.12.016) to reduce noise and damage, but only if cylinder is
vertical mounted (angle 0 °).
3.5.2. FE cylinder
Attach the piston eye to the tipping body (see Figure 13). Actual
attachment method will depend on eye and top bracket type (see
bracket specification sheet for details). In general fit the pivot pin and
secure with split pin.
Ensure the bearing has sufficient free working space (2 x 6 °) and where
necessary use filler rings to close the gap between bearing and bracket. FIGURE 12
FIGURE 13
page 14 of 20
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OH -E CYL-0017 10696-14 I RV AB
F F.L.A.S.H. series
3.6. Connecting and testing the cylinder
3.6.1. Connection of the hydraulic system

Connect the hydraulic system as specified by the hydraulic kit. Remove the plug from the oil -inlet and connect
the cylinder to the hydraulic system (Figure 14). Ensure there is sufficient hose so does not obstruct the
movement of the cylinder while tipping.
FIGURE 14: EXAMPLE OF A HYDRAULIC SYSTEM
WO Tip
Test oil may leak from the cylinder when the plug is removed.
page 15 of 20
OH.E CYL-0017106-06.141 RV AB
3.7. Final Checks

The first tip should be slow and all movements are to be closely observed to check:
cylinder movement is smooth.
hoses do not interfere with any parts.
cylinder extends in a straight line.
while tipping, there is no contact between the rear end of the body and other parts of the truck (such
as towing- hooks, tail lamps etc.).
Tip the body 4 or 5 times and check there is no side -load on the cylinder and the clearances are correct
If you find the cylinder movement is stiff, loosen the bolts and realign the cylinder. Protect hoses where they
move against metal parts (if they can not be repositioned). It is not necessary to bleed air from the cylinder.
Tip
During the first few tips some packset grease may appear on the stages of the
cylinder, this is normal and does not mean the cylinder is leaking.
Where the installation does not operate as expected, see "Operating & Maintenance Instructions - Complete
Tipper" for full details of use including trouble- shooting guide (Hyva document: TIP -0005).
3.8. Painting the cylinder

Hyva cylinders are painted with 40 microns of black primer (RAL 9005). When painting the body, do not
repaint the blank parts of cylinder e.g. trunnion pins, piston, stages, wipers, balls /eyes.
For small FE cylinders it is possible that the first outgoing stage sticks out instead of the piston. In this case
use preservation grease on the tube that is sticking out. The grease must be oil based (not wax based). Use
Hyva packset grease, Shell Ensys or equivalent.
It is also advised to keep as close as possible to the build -in dimension on cylinder specification sheet to have
a pull -out of 20 mm.
page 16 of 20
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OH -E CYL-0017106.06-14/RYAS
F.L.A.S.H. series
Ir
Tables Table 1:
4
Bolt and nut specifications
Specifications and helpful advice for use during fitting.
Table 2: Recommended Cross Member
Profiles and Dimensions
tj
page 17 of 20
OH-E CYL -0017 1 06 -06 -14 /RV AB
i
4. Tables
4.1. Table 1: Bolt and nut specifications
Size DIN Quality Torque

Bolt Nut
M12 931 985 8 8 80 Nm
M16 931 985 8 8 210 Nm
TABLE 1: BOLT AND NUT SPECIFICATIONS
4.2. Table 2: Recommended Cross Member Profiles and Dimensions
Tipping Weight (ton) Minimum W. Hot Rolled UNP Cold Rolled U Box Profile
{
(cm3) (yield 235 MPa) (yield 235 MPa) (yield 235 MPa)
Upto 7.5 30 - 100x50x6 100x50x5
Upto 10 40 100 120x60x6 100x60x6

Upto 15 60 120 140x65x6 120x60x6
Upto 20 80 140 - 140x60x8
Upto 25 100 160 - 140x70x8
Upto 35 140 180 - 160x80x8
35 and over 140+ 200 - 180x80x8
Note: All strength calculations based on St.37 -2 and cross -member length of 1m.
TABLE 2: RECOMMENDED CROSS MEMBER PROFILES AND DIMENSIONS
page 18 of 20
OH -E CYL-0017 106-06 -141I2V AB
Service points
5
An overview of main (or national) service agents to contact in the
event your Hyva equipment does not perform as you expect..
Even if you are considerable distance from the agents listed, you
should still contact your nearest agent. Most agents maintain their
own networks and can advise you of the most convenient for your
work.
page 19 of 20
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OHE CYL-0017106-06 -141 RV AB
F.L.A.S.H. series
5. Service points
Hyva International B.V. Hyva Transporttechnik GmbH Hyva Rusland
Ondernemingsweg 1 Bahnhofstrasse 60 4th floor, Laboratory bldg.
2404 HM Alphen aan den Rijn 4810 Gmunden VNIIMETMASH
The Netherlands Österreich 8a, Ryazanskiy prospect
Telephone (31) 172 - 42 35 55 Telefon (43) 7612 630 03 109428 Moscow
Telefax (31) 172 - 43 31 96 Telefax (43) 7612 630 03 - 33 Telephone +7 4 95 739 35 18
info(p2hvva corn hvva @aon.at office @hyva.ru
Hyva Nederland B.V. Hyva do Brasil Hidráulica Ltda. Hyva Baltic SIA
Ondernemingsweg 1 Rua Evaristo De Antoni 780 Perles 1, Sigulda
2404 HM Alphen aan den Rijn 95041 - 000 Sao José Rigas Rajons LV 2150
Nederland Caxias do Sul - RS Latvia
Telefoon (31) 172 - 42 35 55 Brazil Telephone +317 770 34 81
Telefax (31) 172 - 41 38 97 Telephone (55) 54 - 224 34 33 Telefax +317 770 34 81
¡lederlandi hvva corn Telefax (55) 54 - 224 34 33 ranis hvvaballic biv Iv
hwa @malbanet corn
Hyva France S.A. Hyva -CS s.r.o.
Rue de la Grande Prée Hyva (Malaysia) SDN. BHD. Sudomerska 9
Z.I. du Meux - B.P. 50317 Lot no.3, Jalan 3/37A CZ -130 00 Praha 3
60618 La Croix Saint Ouen Cedex Taman Bukit Maluri Industrial Area Czech Republic
France Kepong 52100, Kuala Lumpur Telephone +420 222 711 427
Téléphone (33) (0) 3 44 41 50 00 West Malaysia Telefax +420 222 711 427
Télécopieur (33) (0) 3 44 41 72 00 Telephone (60) 3 - 62 74 73 19 hwa *Often, CZ
jllfo @hvva fr Telefax (60) 3 - 62 74 74 75
hyva(a the net my Hyva Corporation (U.S.A.)
Hyva Belgium N.V. - S.A. 1395 East Irving Park Road
I Industriepark / Z.I. Blauwe Steen Hyva Thailand Co. Ltd. Itasca, Illinois 60143
Blauwe Steenstraat 85 18/8 Bangna -trad Rd M007 United States of America
2550 Kontich Tambol Babgchalong Amphuur Telephone +1 630 773 9020
Belgium Bangplee, Samutprakarn Telefax +1 630 773 9029
Telefoon (32) 3 - 450 70 20 Thailand hvva usaldaboolobal net
Telefax (32) 3 - 458 13 85 Telephone (66) 2 - 75 08 547
[email protected] Telefax (66) 2 - 75 08 548 Kennis' Machinefabriek B.V.
[email protected] Geuzendijk 74
Hyva GmbH 6021 PV Budel
Marie -Bernays -Ring 25A Hyva India Transportation Sys. Pvt. The Netherlands
41199 Monchengladbach-Gúdderath Ltd. Telephone (31) 495 - 43 18 88
Industriegebiet West C112, MIDC, Telefax (31) 495 - 43 02 90
Deutschland Pawane, sales(@kennis corn
Telefon (49) 2166 - 959 70 Navi Mumbai - 400 -705,
Telefax (49) 2166 - 959 749 India Technamics B.V.
info @hvva.de Telephone (91) 22 - 5616 54 40/45 Zeppelinstraat 21
Telefax (91) 22 - 2767 28 46 7903 BR Hoogeveen
Hyva (U.K.) Limited. hvvaind(dbom3 vsnl net ¡n The Netherlands
10, Huntsman Drive Telephone (31) 528 - 22 98 50
Northbank Industrial Estate, Irlam Hyva Maroc S.A.R.L. Telefax (31) 528 - 26 62 11
Manchester M44 5EG 386 Boulevard Chefchouni inf. technamics M
United Kingdom Quartier Industriel Ain Sebaa
Telephone (44) 161 - 77 66 600 20250 Casablanca Hydraulic Floor Systems B.V.
Telefax (44) 161 - 77 66 619 Maroc Ondernemingsweg 1
info @hvva.co.uk Telephone +212 (0) 22 66 26 46 2404 HM Alphen aan den Rijn
Telefax +212 (0) 22 66 26 46 The Netherlands
Hyva Ibérica S.A. hwamaroc@menara. ma Telephone (31) 172 - 42 35 55
Poligono Clot de Moja Telefax (31) 172 - 43 31 96
C /UIl de Liebre No. 7 Hyva Mechanics Co. Ltd. [email protected]
08734 Olérdola, (Moja, Barcelona) 18 Sha Wan Road
España Guangling Industrial Park
Teléfono (34) 93 - 89 02 044 Yangzhou
Fax (34) 93 - 89 02 867 People's Republic of China
[email protected] Telephone +86 (0) 514 78 29 969
Telefax +86 (0) 514 78 17 938
Hyva Polska Sp.z o.o. sales(oïhyva corn cn
UI. Mysliwska 68
30 - 718 Krakow
Poland
Telephone (48) 12 658 65 05
Telefax (48) 12 658 44 39
®hwa
page 20 of 20
Subject to change without malice
Oli-E CYL -0017 / 06 -06 -14 / RV AB
Repair instructions
front -end cylinders
F.L.A.S.H. series
q1° HYDRAULICS
Repair Instructions
Front-End FC, FE and FEE type F.L.A.S.H.
Table of contents
1. Introduction 3
1.1. Scope of use 3
1.2. General remarks ............................................................................................................ ............................... 3
1.3. Safety .............................................................................................................................. 4
1.3.1. Explanation of guidance 4
1.3.2. Precautions 4
1.4. Spare parts ............................................................................................................. 4
1.4.1. General . 4
1.4.2. Storage 5
1.4.3. Prior to use 5
1.5. Recycling 5
1.5.1. General 5
1.5.2. Reuse of components 5
i 2. Guarantee 8
Hyva International Terms of Warranty 8
3. Repair Instructions 10
3.1. General 10
3.1.1. Components 10
3.1.2. Removing the cylinder from the vehicle 11
3.1.3. Refitting the cylinder to the vehicle 14
3.2. Dismantling the cylinder 14
3.2.1. Removing piston eye /head 15
' 3.2.2. Opening the base 15
3.2.3. Removing the piston 16
3.2.4. Removing the stages 16
4. Assembly 19
4.1. Replacing packset 19
4.2. Replacing Stages . 20
4.3. Fitting piston eye /head 21
4.4. Closing the cylinder (all types) 21
5. Connecting and testing the cylinder ................................................................................. ............................... 24
5.1. Connection of the hydraulic system ............................................................................. ............................... 24
5.2. Final Checks .................................................................................................................. 24
5.3. Painting the cylinder 24
6. Tables 26
6.1. General ............ ....... ............................... 26
6.2. -
FC cylinders Parts and tools 27
7. Service points 29
page lof 30
OH.E CYL-0020I05 -12.08 I RV AA
HYDRAULICS
Repair Instructions
..,-------
fj
1
Introduction Scope of use
This section gives an overview of the use of this manual. General remarks
It also gives some basic advice on safety and precautions to be
taken before and during installation. Explanation of guidance
Intended for experienced fitters that are new to Hyva Hydraulic
equipment and also as a refresher for those already familiar with
Precautions
Hyva products.
Spare parts
The advice given in these pages is by no means complete and
should not be used as an alternative to common sense.
Recycling
Reuse of components
Elfin IfYDRA(ILJCS
page 2 of 30
OH -E CYL-002010512 -081 RV AA
Repair Instructions
1. Introduction
1.1. Scope of use
This manual is for repair workshops and service agents repairing the Hyva front -end cylinders, where it is
necessary to disassemble the cylinder to replace parts that are subject to wear (i.e. seal kit).
The Hyva cylinder range includes Front -end Outer Cover (FC), Eye (FE), Eye -Eye (FEE) and Gimbal (FEG) type
cylinders. Separate instructions are available for other types of cylinder.
The guarantee is invalidated if:

Components other than original Hyva parts are used.
Hyva components are altered in any way.
Repairs to the cylinder are not in accordance with Hyva
instructions.
1.2. General remarks

Where a tipper is to be built -up with no sub -frame on the chassis, we strongly advise that a Hyva cradle be used
to mount the cylinder. Instructions for cradle mounting of the Hyva cylinder are also given in this manual.
If the cylinder is to be fitted above the gearbox, splitter box or any part that needs periodic service, clearance
must be provided between this part and the bottom of the cylinder.
It is important that the gear is fitted in the correct position, to ensure the safe and /or legal axle loading,
Specification sheets are available for all Hyva cylinders; these sheets contain all relevant dimensional and
application information about your cylinder. Specification sheets are available from your nearest Hyva service
point.
The Hyva cylinder has been developed for lifting purposes only and its use for any other purpose is prohibited.
The cylinder is not to be used as a stabiliser and any kind of side -load must be avoided whenever possible.
Dynamic effects, like shunting, should be avoided to prevent pressure peaks and serious cylinder /vehicle failure
caused by overpressure and/or buckling.
Warning
Applying side-load and dynamic forces to any cylinder is dangerous.

If you have any questions concerning the application, installation, operation or repair of any Hyva product - please
contact your nearest Hyva Service Point.
Hyva cylinders are also compatible with biodegradable oils such as the following synthetic ester based oils:
BP - Biohyd SE -S
Castrol - Carelube HES
Texaco - Hydra
Elf - Hydrelf Bio Safety
Biodegradable oils attract water, for this reason it is important to use a Hyva air filter with dehumidifier (part
number: 14810590).
page 3 of 30
1111VA mums
OHE CYL.0020105-12-08 I RV AA
i
Repair Instructions
1
)
1.3. Safety
1.3.1. Explanation of guidance

Tip
Gives the reader advice in order to simplify certain tasks or warns of potential problems.
Warning
Warning of danger to the operator or product. The operator can be seriously hurt
or the equipment severely damaged if the recommended procedure is not
I followed.
Danger
I
There is a serious threat to the life of the operator.
1.3.2. Precautions
Ensure there is enough free working space for mounting the cylinder. If the tipper body is on the truck chassis, lift
the body using an overhead crane so that the cab protector is well clear of the cylinder. If the tipper body is raised
to create working space, support the body using body props before mounting the cylinder.
Danger
Working under an unsupported tipper body is a danger to life.
To avoid damage to the truck cabin, cover the rear of the cab with a tarpaulin. If necessary tilt the vehicles cabin
(see the truck manual for details). Disconnect the vehicle's battery leads before any welding.
While lifting a cylinder the other stages can extend, to avoid this use a sling around the cover or piston and base
tube (between the trunnion and anti -rattle ring). Extend the cylinder until the sling is locked and transport the
cylinder using a suitable lifting device.
Warning
Not using the appropriate equipment when lifting parts (such as the proper sling
for a cylinder) is a danger to life.
Some parts in the cylinder are mounted under tension (i.e. snap rings) they may
spring out when removed. They should be secured when removed to prevent
injury.
Ensure any oil spilt during installation and testing is disposed of in an environmentally friendly way.
1.4. Spare parts
1.4.1. General
We have continuous development programmes to improve our products, which means parts may have been
changed between fitting and repair. To avoid ordering the wrong parts we recommend ordering spare parts listed
on the relevant specification sheet.
[1,,YR HYDRAULICS
page 4of30
OH.E CYL.0020 105- +2.081 RV AA
Repair Instructions
1.4.2. Storage
Unless other wise stated, Hyva spare parts are delivered suitable for storage as described in this section.
I Provided the following basic conditions are met:
Internal - protected from extreme temperatures, rain and
corrosive atmospheres.
Clean - free from excessive dust and dirt
-
Dry minimal humidity and sheltered from water vapour and
steam
r Spare parts must not be stored externally under any conditions.
1. Cylinders (including Tubes, Bases and Covers)
Supplied suitable for 18 months storage under the above conditions. These parts should be stored flat on
pallets, no more than 6 (tubes) high to avoid deformation. Damage to the inside- & outside- diameters and
grooves will make parts unusable and must be avoided
2. Non -metallic parts (Seals, Wipers and Wear- rings)

r Should be kept in packaging (bags or boxes) until required for use. Items suitable for storage for up to 2
1 years.
3. Metallic parts (Sliders, Snap- rings, Spacers, PTO's and Pumps)

1
Supplied with light duty protective layer. Should be kept in packaging (bags or boxes) until required for use.
Items suitable for storage for up to 2 years
i
I.1
1.4.3. Prior to use
Clean all parts to remove any dust, dirt or protective coatings. Check parts for damage during transport or
storage. Do not use any damaged parts
If for any reason the above conditions can not be met contact your nearest Hyva
Service Point for further guidance.
1.5. Recycling
1.5.1. General
Remove and dismantle the components as described in this manual. Clean all parts thoroughly (using degreaser
and compressed air). All oil products must be disposed of in an environmentally friendly manner (usually by a
licensed disposal agent). The components can then be recycled in the normal way. For example; non metal
components such as seals and wipers with plastic materials, clean steel parts with other scrap metals.
1.5.2. Reuse of components

When the Hyva cylinder is stripped (for example after decommissioning a cylinder) some parts may be reused.
Warning
Never use parts from a cylinder that has been subject to over-pressure,
mismatching or side -load.
Using second hand parts in cylinder repairs can change the function or
operating conditions of the cylinder and may affect the terms of warranty.
H1fA
page 5 of 30
Subject to change wilhoul notice
_
#Yûucs OH-E CYL-0020 !ÙS.17.08 1 RV AA
i!
Repair Instructions
Assuming the following parts are in good working order (i.e. no visible damage such as scratches, imprints or
deformation, no corrosion and dimensionally correct) then they may be reused:
Bases, Stages, Pistons and Covers,
Sliders, Locking Plates, Bottom Plate
Eyes, Eye Bushes, Eye Bearings, Lift rings when not deformed during dismantling
Cradle, Chassis Brackets and Body Brackets
The following parts must never be reused:

Packset (seals, wear-rings, wipers)
O -rings
Top -nut & washer
i Inner stop -rings
Locking pin for threaded piston eye /head
"Th
page 6 of 30
IIIVA HYDRAULICS
11114/A
OHE CYL-0020 105.12-08 RV AA
1
Repair Instructions
2
Guarantee
This section contains an overview or guide to Hyva terms of
warranty.
It is not complete or contractual, so in the event that you do have a

problem with a Hyva product you should contact your nearest Hyva
service point.
page 7 of 30
H1vi HYDRAUlICS
Subject fo change without notice
OH-E CYL-002010512-08 /RV M
Repair Instructions
Front -End FC, FE and FEE type F.L.A.S.H.
2. Guarantee
li'
I 1
Hyva International only issues warranty to products under agreed conditions.

The following products are covered by warranty:
1. Hydraulic Cylinder
2. PTO & Pump
3. Tipping valve & Air Control
4. Oil Tank
5. Body
The warranty is only valid under the following conditions:
01) All Hyva products must be installed, operated, maintained and repaired in accordance with the
relevant Hyva guidelines.
02) For the parts listed above, the warranty period covering is valid 12 months from date of delivery or up to a
maximum, whichever comes first, of:
I 20.000 tipping cycles for the cylinder, tipping valve, control and body.
l
11
300 running hours for the PTO and pump.
100.000 km for the oil tank.
03) The warranty period does not cover:
1 Wear of parts during normal operation (e.g. sealing set), parts
made of rubber or with limited lifetime.
Paint coatings.
Damage caused by forces beyond our control.
Damage caused by incomplete or erroneous installation.
Damage caused by abusive or inappropriate operation.
Damage as a result of service not carried out in accordance
with the Hyva Operating & Maintenance Instructions.
04) This warranty is valid only in accordance with the Hyva General Terms unless otherwise specified
(document FO- E00000130/21- 07 -05 /Rv AB).
05) A completed Claim Report shall be delivered with every claim.
06) All broken parts shall be kept for inspection, these parts will be returned to Hyva International for
inspection on request (transportation costs to be met by end user).
07) Where warranty is granted, Hyva International will meet the cost of the following:
All necessary spare parts.
A replacement part where the original cannot be repaired.
08) Hyva International does not accept any liability for transport costs or travel expenses.
09) During the warranty period the equipment must be serviced at the appropriate periods (costs to be met by
the end user). Checks listed in the Hyva Operating & Maintenance instructions must be completed.
10) Drivers must be trained to operate the Hyva equipment with the appropriate operating instructions made
available.
11) Drivers should include the Hyva equipment in their daily vehicle inspection and arrange service for the
vehicle /equipment as described in the Maintenance Instructions.
...""\ Any variation from the conditions listed above must be agreed with Hyva prior to
the operation of the equipment.
H*A HYDRAULICS
page 8 of 30
Subject to changewithout notice
OH.E CYL.00201051248IRV AA
Repair Instructions
r
r
r
Repair Instructions
3
General
This section makes up the main body of the repair instructions.
Components
It is separated into sections to enable you to go directly to areas you
are unsure about or work through in sequence as a 'repair course'.
Removing the cylinder from the vehicle
The first part gives information about the nature and appearance of
each type of cylinder. How to prepare the cylinder for disassembly Refitting the cylinder to the vehicle
by disconnecting from the body and then removal from the chassis.
The remainder of the section covers opening of the base, removal Dismantling the cylinder
of piston and then stages.
Removing piston eye/head
Removing the stages
Ilia HYDRAULICS
page 9 of 30
OH-E CYL -002010512-08 t RV M
Repair Instructions
i
3. ? Repair Instructions
3.1. General
3.1.1. Components
Cross -section of the FC, FE & FEE cylinders
,.. 4\ \I
FIGURE 9: CROSS -SECTION OF THE FC, FE & FEE CYLINDERS
FE cylinder with gimbal
FIGURE 2 FE CYLINDER WITH GIMBAL
-AIVI
page 10 of 30
HYDRAULICS OH -E CYL- 002010512 -081 RV M
Repair Instructions
f
Position of pack-set, sliders, stop ring and lift rings
FIGURE 3: POSITION OF PACK SET, SLIDE RINGS, STOP RING AND LIFT RINGS.
Pack set consisting of:

1 = wiper 5* = outer stop ring
2 = wear rings 6* = sliders
3 = seal 7 * *= lift ring (round for small, square for larger diameters
4 = stop ring
` Tubes with diameters 072, 091 & 129 have double sliders
Tubes with diameters 149, 169, 191 & 214 have one slider and one outer stop ring
**
Tubes with diameters 091, 129 & 149 have square lift rings
Tubes with diameters 169, 191 & 214 have round lift rings
3.1.2. Removing the cylinder from the vehicle
i Disconnection from the body

Where an FC cylinder is to be repaired, the main body of the cylinder can be removed from the truck, leaving the
outer cover attached to the body. With the Gimbal type cylinder, it is possible to leave the gimbal attached to the
body.
Danger
Working under an unsupported tipper body is a danger to life.
page 11 of 30
lIlvrAHYoRaUucs Subject to change without notice
OH-E CYL-0020 05-12-08 1 RV AA
1
Repair Instructions
Support the tipper body with a body prop using a rope or sling and a suitable lifting device, to prevent the cylinder
from falling over. (Figure 34)
FIGURE 4: BODY SUPPORT AND LIFTING DEVICE
1. FC cylinder
Remove the top nut from the cylinder (Figure 5). Slowly raise the tipping
body (using hydraulic system) until the first moving stage is visible.
i--
Support the body and cylinder (Figure 4) and allow the cylinder to settle
away from the cover.
2. FE cylinder
Secure the cylinder, using a
rope or sling and a suitable
lifting device, to prevent the
cylinder from falling over.
FIGURE 5
Remove the pivot pin from the
piston eye, the actual method
will depend on eye and top bracket. In general remove the split -pin and
tap out the pivot pin. (Figure 6)
3. FE cylinder with gimbal

Raise the body (using hydraulic system) until the second moving stage
is visible. Secure the gimbal to the tipper body using a rope or sling to
prevent the gimbal from falling. FIGURE 6
i-
IrÑA HYDRAULICS
page 12 of 30
OWE CYL-0020 /05-12-08! RV AA
Repair Instructions
Al
/
Remove the securing bolt and top pin. (Figure 7)
Tip
Never lift the body using the gimbal construction, as this will damage the
cylinder
Support the body and allow the cylinder to settle away from the gimbal.
It Removing the cylinder from the chassis

Put the air control valve in the 'lower' position and allow the stages to
settle to their rest position.
1. FC and FE cylinder FIGURE 7

Remove one of the trunnion brackets from the cradle or sub frame
(Figure 8) and ease the cylinder from the other bracket.
FIGURE 8: REMOVAL OF THE FC & FE CYLINDER
HÑA HYDRAULICS
page 130130
OWE CYL-0020105.12-08 IRV M
i Repair Instructions
2. Gimbal cylinder
FIGURE 9 REMOVING THE CYLINDER FROM THE BRACKET CRADLE
Remove both of the trunnion brackets from the cradle.
From this point the gimbal cylinder can be treated as a normal FE cylinder
3.1.3. Refitting the cylinder to the vehicle

After the cylinder has been reassembled, it can be re- fitted to the chassis. Refitting the cylinder to the vehicle is
the same as removal but in reverse. Apply a thin layer of preservation grease (for example packset grease) on
the trunnion pins prior to fitting the brackets.
For further information see mounting instructions for FC /FE cylinder.
3.2. Dismantling the cylinder

Lay the cylinder flat on a clean bench with the oil inlet facing downward. Clamp securely to avoid damage and
injuries (a "V" block arrangement is usually the best) and collect any waste oil.
rN
HIM HYDRAULICS
OH -E
page 14 of 30
Subject to change wlhout notice
mono /05-1246 /RV M
weene-
Repair Instructions
3.2.1. Removing piston eye/head

The F.L.A.S.H. series is standard equipped with a threaded
piston eye /head. To lock the threading an oval pin with round
head is hammered in a 6 mm round hole. This pin must be
removed by drilling it out with a 5 or 6 mm drill. Then remove
the eye as shown in Figure 10. Remove the piston through the
bottom of the cylinder. After drilling make sure that burrs from
the drilling operation are removed properly to prevent damage
of the packset.
Remove the seal ring CO" ring) from the threaded eye /head.
3.2.2. Opening the base

Use a ring spanner to remove the bolts from the bottom plate
(3 or 6 depending on cylinder type) and remove the locking
plates (Figure 11 & Figure 12.). FIGURE 10
FIGURE 11 FIGURE 12
The bottom plate can now be removed by either:

Using two bolts in the bottom plate to lever it out of the base tube. (Figure 14)
Or:
Strike the head of the piston with a soft- headed mallet or similar. If the piston eye /head is unscrewed, be carefull
not to damage the tube. This will push the bottom plate from the base tube. (Figure 13)
FIGURE 14 FIGURE 13
page 15 of 30
Irw;,A NYDMLIUCS
OH -E CYI.- 0020105.12081 RV AA
Repair Instructions
Remove the seal from the bottom plate. (Figure 15)
3.2.3. Removing the piston

Pistons of diameter 129 mm or less have two part sliders, these should
be removed to avoid loss or damage. 149 mm pistons (or larger) have
one piece sliders, these don't need to be removed.
Push the piston forward until the lift ring is visible at the inside diameter
of the next stage (Figure 17). FIGURE 15
Warning
The lift ring is mounted under tension, it may spring out and hit you in the face.
Remove the lift ring by pushing the tip of a screwdriver under the ring at one end and levering the ring out.
(Figure 18)
The piston can now be removed through the bottom of the cylinder (Figure 16).
FIGURE 17 FIGURE 16 FIGURE 18
3.2.4. Removing the stages
Warning
The stages must be placed on a clean surface to prevent scratches and other
damage.
Never remove a stop ring, if it shows signs of damage the whole stage must be
replaced.
The seals and wipers must not be re-used.
Before a stage can be removed through the bottom of the cylinder, the lift ring of the next stage must be removed.
Remove the lift ring in the same way as for the piston. The stage can then be removed through the bottom of the
cylinder.
Subsequent stages can be removed in the same way.
page 16 o130
1110A HYDRAULICS
DI-E CYL-0020! 0512-08I RV AA
Repair Instructions
Remove the seal, wiper and wear rings from the internal grooves at the
top of each stage (Figure 19).
Tip
Do not remove the seals and wipers with a screwdriver or other sharp
instrument as this may irreparably damage the grooves and cause leaks.
Only the wear rings can be removed with a screwdriver.
Clean each stage carefully and check each groove and the tube FIGURE 19
surface for any irregularities. Check also the sliders on each tube; if
these are damaged, they should be replaced.
If the slider is damaged, check the stop ring in the subsequent tube for signs of damage or twisting.
page 17 of 30
1114/A HYDRAULICS
Soiled to change without rotas
OH -E CYL-0020 /054248/ RV AA
Repair Instructions
I :.
i
I
r'
Assembly
4
Replacing packset
Step by step guide on how to replace the packset in each stage,
replace the stages and piston, refitting of the piston eye (where
applicable). Replacing Stages
Finally refitting the bottom plate to close the cylinder, ready for
Fitting piston eye /head
reuse.
Closing the cylinder (all types)
Ida HYDRAULICS
page 18 at 30
0N,E CYL-002010512 -081 RV M
Repair Instructions
1
4. ",' Assembly
4.1. Replacing packset
Clean each stage thoroughly and apply sufficient grease to the packset and the grooves (Figure 21). Put a new
packset into each stage (Figure 20),
FIGURE 21 FIGURE 20
Starting with the seal (Figure 23), followed by the wear rings (Figure 22) and the wiper (Figure 24).
See also Figure 3 page 11.
FIGURE 23 FIGURE 22
Caution
Ensure that each of the rings are seated correctly in
the grooves; incorrect fitting can cause seizure, leaks
or damage.
FIGURE 24
IfifA
page 19 of 30
HYDRALILICS 0 H -E CYL- 0120105 -12 -06 /RV AA
Repair Instructions
4.2. I Replacing Stages

Slide the first stage almost fully into the base tube, ensuring that the tube is not scratched when passing the stop
ring (Figure 25 & Figure 26). Some resistance will occur when the tube enters the packset.
To prevent damage and ease assembly, special cones are available. See Table 1 page 26.
-1!'Ili1
FIGURE 25 FIGURE 26
Place the sliders and /or outer stop rings at the end of the stage (Figure 27); use enough grease at bottom inside
of the tube to prevent scratches. Slide the tube further in to the base until the sliders are in the base tube.
Subsequent stages can be mounted in the same way.
After mounting a stage, fit the lift ring (Figure 28) in the previous inner (except cylinder base). See Figure 3 on
page 11.
The piston is mounted in the reverse sequence to dismantling. Make sure that no sharp edges are at the top side
that can damage the packset. For further assembly see point 3.2.4 page 16 for dismantling the cylinder.
Tip
Make sure that the surface of the top end of the piston is smooth, especially around the
old locking pin hole.
The sliders must be mounted with the flat side of the top slider facing upwards (not
relevant for sliders 072 -129). See Figure 3 on page 11.
FIGURE 28 FIGURE 27
/1
ullvrA HYDRAULICS
page 20 al 30
OH-E CYL-002010512-05/RV AA
Repair Instructions
t a
4.3. Fitting piston eye/head

I
Fit a new "O" ring to the piston eye. Apply plenty of grease and screw the eye onto the piston. (Figure 29)
t Warning
Not fitting the locking pin is danger to life.
Fitting the eye onto the piston can be eased by applying copper
grease to the screw thread.
I Make sure that the piston eye /head is firmly screwed into the
piston tube. Use a hammer to be sure and check if there is
absolutely no gap between piston eye /head and top end of the
piston tube. Drill a new hole, 5,9 -6,0 mm diameter, 16 mm deep,
at least 60 degree rotated from the previous hole for the grooved
locking pin.
Firmly hammer the locking pin in the new hole, apply locking
FIGURE 29
agent (i.e. Loctite 242 or equivalent) before mounting. If during
hammering the grooved pin is not causing substantial resistance,
the diameter of the drilled hole is too big.
Warning
Make sure eye/head is fully threaded into the piston
Make sure that diameter of the hole for the locking pin is not bigger then 6,0 mm
Do not reuse the old hole for locking pin
. 4.4. Closing the cylinder (all types)

Fit a new seal to the bottom plate and slide the bottom plate into the base (Figure 30) use plenty of grease
(Figure 31) to avoid damage to the seal.
FIGURE 30 FIGURE 31
page 21 of 30
uIivAHYoRauucs OISE CYL-0020 105 -12-08 I RV AA
Repair Instructions
Secure the bottom plate with the 3 locking plate (Figure 32 & Figure 33) using 2 new bolts and spring washers for
each. See table 6.1.11 page 26 for bolt torques.
FIGURE 32 FIGURE 33
Warning
The top nut on the outer cover must not be re-used.
uI1A NYDAUL1C$
page 22 of 30
OH-E CYL-0020 ¡05-12-08! RV AA
Repair Instructions
5
Connecting and testing the Connection of the hydraulic system
cylinder Final Checks
Once the repairs to the cylinder are complete it is ready to be
replaced on the vehicle. Painting the cylinder
The hydraulics can then be reconnected and tested with a series of
simple checks.
There is also details of the Hyva standard paint at the end of the
chapter should the cylinder need repainting.
page 23 of 30
II1W1 HYDRAULICS
Subject to change without police
OH-E CYL-0020 / 05-12-08/RV AA
i
Repair Instructions
5. Connecting and testing the cylinder

5.1. Connection of the hydraulic system
Connect the hydraulic system as specified by the hydraulic kit. Remove the plug from the oil -inlet and connect the
cylinder to the hydraulic system (Figure 34).
FIGURE 34: EXAMPLE OF A HYDRAULIC SYSTEM
Ensure there is sufficient hose so it does not obstruct the movement of the cylinder while tipping.
It is not necessary to bleed air from the cylinder after assembly (air is
automatically discharged during the first few tips).
5.2. Final Checks

The first tip should be slow and all movements are to be closely observed to check:
Cylinder movement is smooth and hoses do not interfere with any parts.
Cylinder extends in a straight line, while tipping there is no contact between the rear end of the body and other
parts of the truck (such as towing- hooks, tail lamps etc.).
Tip the body 4 or 5 times and check there is no side -load on the cylinder and the clearances are correct.lf you find
the cylinder movement is stiff, loosen the bolts and realign the cylinder. Protect hoses where they move against
metal parts (if they can not be repositioned). It is not necessary to bleed air from the cylinder.
Tip
During the first few tips some packset grease may appear on the stages of the cylinder,
this is normal and does not mean the cylinder is leaking.
Where the installation does not operate as expected, see "Operating & Maintenance Instructions - Complete
Tipper" for full details of use including trouble- shooting guide (Hyva document: TIP -0005).
5.3. Painting the cylinder

Hyva cylinders are painted with 40 microns of black primer (RAL 9005). When repainting, do not repaint the blank
parts of the cylinder e.g. trunnion pins, piston, stages, wipers, balls /eyes.
IrfA HYDRAULICS
page 24 of 30
OH-E CYL-0020 105-12-08 I RV M
Repair Instructions
6
Tables General
Specifications and helpful advice for use during fitting.
Cones for assembly
Packsets, bottom plate nut sizes, torques and
o -rings
FC cylinders - Parts and tools.
rs,
page 25 of 30
IIIVAxroRauucs 01-1-ECYL-0020 !05.12-08! RV M
Repair Instructions
6. Tables
6.1. General
Use nylon rod (100 00 080) to ease the dismantling of the cylinder
Consult the appropriate specification sheet for each special cylinder version
I Cones for assembly
Stage Part Number Piston Part Number

Diameter Cone Diameter Cone
- - Piston 72 719 11 310
Stage 91 719 11 130 Piston 91 719 11 320
Stage 110 719 11 140 Piston 110 719 11 330

Stage 129 719 11 150 Piston 129 719 11 340
Stage 149 719 11 160
Stage 169 719 11 170 - -
Stage 191 719 11 180 - -
Stage 214 719 11 190 - -
TABLE 1: CONES FOR CYLINDER ASSEMBLY
f! Packsets, bottom plate nut sizes, torques and o -rings
Tube /Base FC /FE Packset* Bottom Plate Bottom Plate Bottom Plate
Diameter (mm) Nut Size (mm) Nut Torque (Nm) Seal
091 718 02 091 K - - -
110 718 02 110 K 13 (M8x1,25) 20 718 70 020 K

129 718 02 129 K 718 70 025 K
149 718 02 149 K " 718 70 030 K
169 718 02 169 K 718 70 035 K
191 718 02 191 K 718 70 040 K
214 718 02 214 K 19 (M12x1,25) 60 718 70 045 K
1 238 718 02 238 K 718 70 050 K
Use Hyva 'Packset Grease' part number: 100 01 030

TABLE 2: PACKSETS, BOTTOM PLATE NUT SIZES, TORQUES AND 0-RINGS
Fria HYDRAULICS
page 26 of 30
Subject to change Without notice
OH-E CYL-0020 105-12-08 I RV AA
T 1.

Hydraulic Cylinder PT 1 CV01

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HYVA CYLINDER

D ca- --- G'

stroke [inch] 44 9 45.7 45.7 136.0

Information for reference only no other conditions are expressed or implied

g O-- 122 123

Spare part list Spare part list

0 71802149 K PACKSET 149 01 100 71831091 PISTON HEAD 091 MACHINED 01

Seal kit complete: i 1

71901430 K Seal kit complete:

Subject to change without notice DO-U 715 04 195 /07-1106 /RVAE

The advice given in these pages is by no means complete and

1.2. General remarks

1.3.1. Explanation of guidance

It is not complete or contractual, so in the event that you do have a

Hyva International only issues warranty to products under agreed conditions.

Cradle mounting the cylinder

Mounting the cradle

Mounting the chassis brackets into the cradle

Fixing the cylinder into the chassis brackets

Attaching the cylinder to the tipper body

Connecting and testing the cylinder

Connection of the hydraulic system

Painting the cylinder

Cylinder FEE type

3.1.2. Mounting position and clearances

For minimum body weight use:

Additional factors that may affect the mounting position:

The cylinder should be mounted with a minimum pull out of 15 mm and a

I 3.2. Sub -frame mounting the cylinder

FIGURE 3: MOUNTING THE CYLINDER INTO THE SUB FRAME

For sequence see section 3.4.

3.3. Cradle mounting the cylinder

3.3.1. Mounting the cradle

Use manufacturer's recommended subframe profiles for channel

Channel must be angled with rounded edges to minimise stress on the

Weld the cradle to the attachment plates (see Figure 6)

Disconnect the battery leads before welding.

3.3.2. Mounting the chassis brackets into the cradle

FIGURE 8: MOUNTING THE CYLINDER INTO THE CRADLE

For sequence see section 3.4

3.4. Fixing the cylinder into the chassis brackets

Before mounting the cylinder, remove the protective caps.

if only the tipping gear is to be fitted

t 3.5. Attaching the cylinder to the tipper body

For sequence see section 3.6.

3.6. Connecting and testing the cylinder

3.6.1. Connection of the hydraulic system

FIGURE 14: EXAMPLE OF A HYDRAULIC SYSTEM

3.7. Final Checks

3.8. Painting the cylinder

Profiles and Dimensions

Size DIN Quality Torque

TABLE 1: BOLT AND NUT SPECIFICATIONS

4.2. Table 2: Recommended Cross Member Profiles and Dimensions

Upto 10 40 100 120x60x6 100x60x6

35 and over 140+ 200 - 180x80x8

The guarantee is invalidated if:

1.2. General remarks