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Related Manuals for HYVA FE
Summary of Contents for HYVA FE
- Page 1 REPAIR INSTRUCTIONS FRONT-END CYLINDERS...
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Page 2: Table Of Contents
Warranty....................................... 6 Removing the cylinder ..................................7 2.1. Removing the cylinder from the chassis ........................7 2.2. FC removal including outer cover ............................8 2.3. FE, FEE, FSE removal – top ............................... 9 2.4. FEE, FCE removal - bottom ..............................9 2.5. -
Page 3: Introduction
1.1. Scope of use This manual is for repair workshops and service partners repairing the Hyva front-end cylinder, manufactured from 2014 onwards (the ALPHA series), where it is necessary to disassemble the cylinder to replace parts that are subject to wear (i.e. seal kit, bearings and pivot pins). -
Page 4: General Remarks
Hyva Service Partner. It should not be used as a structural member and should not be subjected to side loads. Hyva is aware that stabilizing cylinder will be subjected to some side load, however side loads should be avoided. Side loads should be taken by proper stability/rigidity of the full tipper design (suspensions, chassis, frame and body). -
Page 5: Spare Parts
While lifting a cylinder not properly the stages can extend. To avoid this, use a sling around the cover or piston and base tube (between the trunnion and oil inlet, see also Hyva mounting manuals). Lift the cylinder until the sling is locked and transport the cylinder using a suitable lifting device. -
Page 6: Warranty
Inner stop rings (when dismounted) Locking pins for threaded piston eye 1.8. Warranty The Hyva Group B.V. warranty terms are described in the General Sales Terms, Hyva document FO- E000130. subject to change without notice OH-E CYL-0040 / 08-06-20 / RV AD... -
Page 7: Removing The Cylinder
REPAIR INSTRUCTIONS FRONT-END CYLINDER REMOVING THE CYLINDER Danger Working under an unsupported tipper body is a danger to life. When the cylinder needs to be serviced, then it must be removed from the truck secured by a rope or sling and a suitable lifting device. Make sure that there is no pressure in the cylinder. Please follow below procedures to remove each respective cylinder. -
Page 8: Fc Removal Including Outer Cover
REPAIR INSTRUCTIONS FRONT-END CYLINDER 2.2. FC removal including outer cover Secure the cylinder, using a rope or sling and a suitable lifting device, to prevent the cylinder from falling over. Unscrew the bolts and nuts from the chassis and lifting brackets and remove the lifting brackets. Verify that the rope or sling is holding the cylinder and then follow the same procedure as mentioned in the last step in section 2.1: removing the cylinder from the chassis. -
Page 9: Fe, Fee, Fse Removal - Top
REPAIR INSTRUCTIONS FRONT-END CYLINDER 2.3. FE, FEE, FSE removal – top Remove the clevis pin from the piston eye, the actual method will depend on eye and top bracket. In general, remove the split pin(s) and then remove the clevis pin (Figure 3). Verify that the rope or sling is holding the cylinder and then follow the same procedure as mentioned in the last step in section 2.1: removing the cylinder from the chassis. -
Page 10: Fe Cylinder With Gimbal
REPAIR INSTRUCTIONS FRONT-END CYLINDER 2.6. FE cylinder with gimbal It is possible to leave the gimbal attached to the tipper body. Remove the pipe pin from the pin through the yoke. Remove the pin out of the yoke and cylinder. (Figure 6). -
Page 11: Removing The Cylinder From The Chassis
REPAIR INSTRUCTIONS FRONT-END CYLINDER 2.6.1. Removing the cylinder from the chassis IGURE REMOVING THE CYLINDER FROM THE BRACKET CRADLE Verify that the rope or sling is holding the cylinder and then unscrew the bolts and nuts from the chassis brackets in the cradle and lift the cylinder to remove the chassis brackets from the trunnion pins. -
Page 12: Disassembling The Cylinder
This will push the bottom plate out of the base tube (Figure 11). IGURE IGURE Use a nylon rod (Hyva part no. 100 00 080) to ease the dismantling of the cylinder. Consult the appropriate specification sheet for each specific cylinder version. subject to change without notice... -
Page 13: Fee, Fce Cylinder
Remove grease nipples from eye trunnion tube (Figure 13). Remove locking bolt of eye trunnion tube (Figure 13). Remove eye trunnion tube (Figure 13). Then follow the same steps as for FC, FE and EF cylinder (Figure 14). IGURE IGURE... -
Page 14: Fse Cylinder
REPAIR INSTRUCTIONS FRONT-END CYLINDER 3.1.3. FSE cylinder Remove locking screw from threaded bottom (Figure 5). Unscrew the threaded bottom (Figure 16). Remove the O-ring and backup ring inside the threaded bottom as well the O-ring around the base. IGURE IGURE 3.2. -
Page 15: Fc Uhd
3.3.1. FC UHD Remove the dust cover. The FC UHD cover is locked with six M16 bolts and Nord-lock washers. Remove the six bolts and washers so that the cover can be removed from the cylinder. shown in Figure The top nut plate is locked to the piston head with a dowel pin. -
Page 16: Removing The Piston Head
REPAIR INSTRUCTIONS FRONT-END CYLINDER 3.4. Removing the piston head The piston head is threaded and glued in the piston tube. As the diameter of the head is smaller as the tube, it is not necessary to unscrew the head. For some models the piston head is welded to the piston tube, this type also does not require to be removed for repair / disassembly. -
Page 17: Replacing The 1Da Piston
REPAIR INSTRUCTIONS FRONT-END CYLINDER 3.6. Replacing the 1DA piston In case of damage to the piston or 1DA housing remove the locking screw before removing the 1DA housing by using the appropriate tools as shown in below picture. IGURE subject to change without notice OH-E CYL-0040 / 08-06-20 / RV AD... -
Page 18: Removing The Stages
REPAIR INSTRUCTIONS FRONT-END CYLINDER 3.7. Removing the stages Warning The stages must be placed on a clean surface to prevent scratches and other damage. Never remove/replace an inner stop ring, if it shows/feel signs of damage/twist the whole stage must be replaced. This means that there should be no sharp edges or corners on the ring. -
Page 19: Cylinder Assembly
4.1. Replacing the pack set Clean each stage and base thoroughly and apply sufficient grease (Hyva pack set grease) to the pack set and the grooves (Figure 26). Apply grease on the seal and groove before mounting. We recommend the use of the Hyva pack set grease, Dinitrol Paste, Molykote G-4500 or Shell Ensis. - Page 20 REPAIR INSTRUCTIONS FRONT-END CYLINDER Followed by either 4 wear rings for standard stages (Figure 29), IGURE or 2 wear rings, the second seal, and again 2 wear rings for HD stage (Figure 30). IGURE And the wiper (Figure 31). Take care of the direction of the wiper;...
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Page 21: Replacing The Stages
Some resistance will occur when the stage enters the pack set. To prevent damage and make assembly easier, some grease (Hyva pack set grease or general-purpose grease) may be used at the inside of the larger stage (bottom side). -
Page 22: Replacing The Piston
Fit a new O-ring to the piston eye. Apply some grease and screw the eye on the piston (Figure 36). Apply grease on the seal and groove before mounting. We recommend the use of the Hyva pack set grease, Dinitrol Paste, Molykote G-4500 or Shell Ensis. Warning Not fitting the locking pin is danger to life. -
Page 23: Closing The Cylinder
Clean the groove for the bottom plate seal. Fit a new seal to the bottom plate and slide the bottom plate into the base (Figure 37) using plenty of grease, Hyva pack set grease or general-purpose grease, (Figure 38) to avoid damage to the seal. - Page 24 REPAIR INSTRUCTIONS FRONT-END CYLINDER FEE, FCE CYLINDER Assemble the bottom plate as shown in FC, FE, EF . Then re-mount eye trunnion bush, locking bolt and the grease nipples (Figure 41 & Figure 42). IGURE IGURE FSE CYLINDER Clean the grooves for the O-ring in the threaded bottom. Fit a new O-ring + Back-up ring and add plenty of grease, Hyva pack set grease or general-purpose grease, to avoid damage to the O-ring during assembly.
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Page 25: Mounting The Outer Cover
The top nut and washer on the outer cover must not be re-used. 4.6.1. FC UHD To mount the UHD outer cover, first the top nut plate must be screwed (Figure 45) on the piston head. Tighten it according to the torque indicated in table V. -
Page 26: Refitting The Cylinder To The Vehicle
REPAIR INSTRUCTIONS FRONT-END CYLINDER IGURE IGURE IGURE 4.7. Refitting the cylinder to the vehicle Use the mounting instruction for all steps to refit the cylinder to the vehicle. subject to change without notice OH-E CYL-0040 / 08-06-20 / RV AD... -
Page 27: Connecting And Testing The Cylinder
REPAIR INSTRUCTIONS FRONT-END CYLINDER 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(s) from the oil- inlet(s) and connect the cylinder to the hydraulic system (Figure 51). IGURE Ensure there is sufficient hose length, so it does not obstruct the movement of the cylinder while tipping. -
Page 28: Final Checks
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-0009). Cylinder stages should extend in the right sequence: largest (first stage) extends first, then second stage etc. -
Page 29: Tables
REPAIR INSTRUCTIONS FRONT-END CYLINDER TABLES I & II CONES FOR ASSEMBLY Nose cones can be ordered at the Hyva dealers. Note that there are differences between piston-nose cones and stage-nose cones. Stage Piston Diameter Nose Cone Nose Cone FL 072... - Page 30 238 (9.4) 718 02 238K 238 (9.4) 718 08 238K “ “ 718 70 050K *Use Hyva ‘Packset Grease’ part number: 100 01 030 ABLE III ACK SETS OTTOM PLATE BOLT SIZES TORQUES AND SEALS Stage / Base Packset* Stage HD...
- Page 31 REPAIR INSTRUCTIONS FRONT-END CYLINDER BOLT AND NUT SPECIFICATIONS (FASTENERS) Most types of installations require the use of bolts; the table below provides information of the most used types, the recommended class / grade and the torque that must be applied in each case. Hole Available Bolt...
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