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MOUNTING INSTRUCTIONS
OF HYDRAULIC CYLINDERS

CONTENTS
General Remarks …………………………………………… 2
Explanation of Symbols …………………………………….. 3
Mounting the cylinder …………………………………….... 4

 Preparations ………………………………………….. 4
 Mounting the cylinder into sub frame ……………… 5
 Mounting the cylinder into cradle …………………... 6
 Mounting the cylinder into chassis brackets ……….. 7
 Attachment of the cylinder to the tipper body …….... 8
 Connecting and testing of the cylinder ……………… 9

Painting the cylinder ………………………………………... 11

Mounting the cradle ………………………………………… 12
Bolt and Nut Specifications …………………………………. 14
Service points / Removal of the cylinder …………………… 15
Dimensional details of 32 cbm trailer cylinder...…………… 16-17
Dimensional details of 40 cbm trailer cylinder...…………… 18-19

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1. General remarks

In some countries a sub frame is not used.

Whenever there exists no sub frame on the truck
chassis t is advised that a Hyva cradle is used to
mount the cylinder. The mounting of this cradle
Is also described in this manual.
If the location of the cylinder is above the
gearbox or splitter box or such part which needs
periodic service, than there must be enough
clearance provided between this part and the
bottom of the cylinder.
To ensure correct axle loadings it is important
that the gear is
fitted in the correct position.
For all H cylinders a specification sheet is
available. This
Sheet contains all necessary information about
your cylinder.
The Hyva cylinder is only developed for ii1tih
purposes. It is prohibited to use the cylinder in an
other way. The cylinder is not to be used as a
stabilizer, or to be exposed to any kind of side
load.

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1. Explanation of symbols

 Tips
Gives suggestions and advice to the operator in order to
simplify certain tasks or carry them out easier.
 Attention
Warns the operator of potential problems.
 Caution
There is possible danger to the product The operator should
follow the recommended procedure to avoid damage to the
equipment
 Warning
Warning for danger. The operator can get hurt or seriously
damage the product. Severe damage can be caused to the
operator or the equipment if recommended procedure is not
followed.
 Danger
There is a serious threat to the life of the operator.

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2. Mounting the cylinder

We foresee following cylinder mounting possibilities.

A: Mounting the cylinder on a brand new truck and tipper body.

B: Mounting the cylinder on a used truck but new tipper body.

C : Mounthg the cylinder on an existing used tipper truck as a

Replacement.

3.1. Preparations

I Be sure to have enough free working space to mount the

cylinder. If the tipper body is oh the truck chassis, lift the
body by use of an overhead crane so that the cab protector is
well clear to mount the cylinder.
II If necessary turn over the vehicles cabin. For this see the
manual of the vehicle.
 Never reach under or work on a raised body unless it is
adequately propped.

If to create working space the tipping body is raised, it is necessary

to support the body by use of a body prop before continuing the
mounting of the cylinder.

III To avoid any damage to the truck cabin cover the rear of the
cabin by tarpaulin.

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3.2. Mounting the cylinder Into the sub frame

 While tipping the cylinder pivots on its trunnion-axle.
Cross members
Therefore in cats
take which chassis
of the brackets
required (see Figure
dimension between1)the
shalltopfit,of should
the cressbe member
of sufficient cross
and the section
bottom so cylinder
of the as to
withstand
(when the pittingis moment
cylinder exerted by
fully extended) as the cylinder.onAtthe
mentioned
leastcylinder
2 mm. clearance sheet.
specification is advisable to assemble and
dismantle the chassis brackets.
For sequence see paragraph 3.4
Mount one of the chassis brackets hand tight with the Figure 1.
required amount and size of bolts, self-locking nuts and
washers, as specified on the specification sheet. For placing
the chassis
3.2. Mounting brackets see Figure
the cylinder into2 the cradle

Mount one of the truunion brackets hand tight with the

required amount and size of bolts, self-locking nuts and
washers as specified on the specification sheet. For placing
the chassis brackets into the pre-drilled holes in the cradle.
Use the Hyva cylinder specification sheet to determine the
correct holes. (Figure 3)

FIGURE 2: MOUNTING THE CYLINDER INTO SUB FRAME

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FIGURE 3: MOUNTING THE CYLINDER INTO THE CRADLE

For sequence see paragraph 3.4.

3.3. Mounting the cylinder into the chassis brackets

While tilting the cylinder by the cover the rest of the stages shall
extend which should be avoided.

 Not using proper slings is danger to life.

I To avoid this extension we advice to prepare the plug with

a hook to which a proper sling can be fitted. (See Figure 4)

 Do not weld when the plug is inside the inlet. After FIGURE 4
removing the plug out of the oil inlet it is possible that

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some oil will leak out. This oil remained in the cylinder
after testing during fabrication. This oil must be
exposed iin environmental way.

11 Wrap the sling around the outer cover (for FE cylinder the
base) and the modified plug (see Figure 5) to avoid
extension, and transport it by use of an overhead crane, or
other suitable lifting device.

III Remove the protection caps from the cylinder logs and
grease the logs lightly, use grease SAE 140. FIGURE 5

IV Mount the cylinder with one log into the already placed
chassis bracket (see Figure 2 or Figure 3.). Make sure that
the oil inlet is headed into the right direction, to be
connected with the tipping valve.

V Mount the second chassis bracket into the frame, and align
the cylinder upon the middle of the truck chassis (see
Figure 2 or Figure 3.). Beware of the maximum clearance
of 2 mm between the cylinder and brackets. Tighten all the
bolts securely. For required torque see Table I.
`
FIGURE 6
After removing the sling, the cylinder may fall into the
direction of the cabin, this may result in damage of
components or personal injuries
VI To keep the cylinder in right place, place a wooden wedge
between the cylinder and the chassis (see Figure 6).
Remove the sling.

3.5. Attachment or the cylinder to the tipper body

FC Cylinder

I Remove the protection caps from the outer cover logs and
grease the logs lightly, use grease SAE 140. Mount the
lifting brackets (Figure 7) on the outer cover logs and fit
them to the tipping body. See Figure 8.
FIGURE 7

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Be sure that the lifting brackets are mounted in the proper way
and direction with a maximum clearance of 2 mm. between the
cover and brackets, Nuts and washer should placed on the
brackets. Though It is possible that there is not enough available
space then it is allowed to place bolts and nuts in the reversed
way.

II Tighten all the bolts securely. For torque see Table 1.

FIGURE 8
If the tipping body is raised and the holes of the lifting brackets
are not in line with the holes of the tipping body, it is possible to
connect the cylinder to the hydraulic system and extend It
carefully. Other options are to extend the cylinder by pulling out
the small inner or to lower the tipping body.

For sequence see paragraph 3.6.

FE Cylinder

I Mount the piston eye to the tipping body (Figure 9).Make sure
that the bearing has sufficient free working space (2 x 6°). If
necessary fill up the distance between beating and bracket by use
of filler rings
FIGURE 9
For sequence see paragraph 3.6.

3.4. ConnectIng and testing or the cylinder

Remove the plug from the oil-inlet and connect the

cylinder to the hydraulic system (Figure 10). Connect the
hose to the inlet with sufficient loop so that it is not
obstructing the movement of the cylinder while tipping.

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FIGURE 10: EXAMPLES OF A HYDRAULIC SYSTEM

 After removing the plug out of the oil inlet it is

possible that some oil will leak out. This oil remained
in the cylinder after testing during fabrication. This oil
must exposed in an environmental way.

II Place the grease nipples into the brackets (Figure 11)

and grease all the moving parts before using the tipper.
Use grease SAE 140.

FIGURE 11

Ill First tipping should be slow and all the movements

are to be closely observed.

- cylinder movement is smooth.

- hoses are not interfering with any parts.
- cylinder extension is in straight line.
- while tipping, the rear end of the body will not

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come in collision with parts of the truck such as

towing-hooks, tail lamps etc.

IV Tip the body 4 to 5 times and check afterwards if

the cylinder is functioning without tension and with
the right clearances.

V If you find the cylinder movement is stiff, loosen the

bolts and realign the cylinder.

Due to the special design of the cylinder it is not

necessary to bleed out the air in the cylinder. This will
come out itself after some strokes.

 During the first few strokes some packset grease

can come out of the cylinder. This does not mean
the cylinder is leaking.

4. Painting the cylinder

The Hyva cylinders are delivered with a black alkyd primer (AKZO-63.3225). While
spray painting the body and the cylinder make sure that the exposed machined surfaces of the
cylinder is properly protected and shall not be over sprayed. You can paint over the black painted

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parts.

5. Mounting the cradle

I Set the height of the cradle above the chassis

(Figure 12), to the minimum dimension that will
allow clearance of the gearbox etc.

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II Fabricate the attachment plates (Figure 13), which

will fit under the cradle, down the side of the
channel and chassis. In some cases this plate will
coincide with spring hangers etc.

Refer to the tuck manufacturers guide for permission to

alter the location of other components. If an attachment FIGURE 12
plate comes on a suspension damp then it is
permissible to profile the attachment plate around it, In
these cases follow the contour of the bracket as closely
as possible. Do not square corners. (see Figure 14).

Ill lf the chassis is formed at the fixing points; it is

allowed to form the attachment plate to suit. If this is
not possible, cut the plate completely, set the angle, FIGURE 13

reweld and position the stiffener rib over the weld. (see
Figure 15)

FIGURE 14

FIGURE 15

IV Bolt the attachment to the chassis using a minimum of four

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M 16x1.25 (5/8”) bolts per attachment plate (Figure 16).

Try to utilize existing holes in the chassis.

 Disconnect the battery leads before welding.

V Place the cradle across the attachment plates (Figure 17),

fully weld the attachment plates and channels. It is very FIGURE 16
important that the top of the attachment plate matches with
the underside of the cradle.

When a demountable cradle is required we strongly suggest to

mount the cradle as shown in Figure 18.

FIGURE 17

FIGURE 18

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Bolt and nut specifications

DIN Quality Torque

Bolt M12 931 8.8 60 Nm

Nut M12 985 8.8 60 Nm

Bolt M16 931 8.8 210 Nm

Nut M16 985 8.8 210 Nm

TABLE 1: BOLT AND NUT SPECIFICATIONS

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REMOVAL OF THE
FE CYLINDER
Hyva Operation and Maintenance Instructions
removal of the cylinder
.

Removal of the FE Cylinder . Remountaion .

A separate repair instruction book for the Hyva When remounting the cylinder de the above
cylinders is available. If demounting a cylinder Mentionedhandling in the opposite way.
it is necessary to follow the instructions.

Demountaion . NEVER USE THE SELF L.0CKING NUTS A

SECOND TIME.
The FE cylinder can be demounted complete
with eye: in that case it is necessary to loosen
first the eye end from its bracket.

O Disconnect the hose and drain the cylinder

O Support the cylinder below the base ram,

so that it cannot fall for- or backwards
when removing the pin from the eye.

O Loosen the chassis brackets.

O Use a strong strap around the base and

Carefully take out the cylinder.

0 Follow afterwards the separate repair

instructions.

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WORK INSTRUCTIONS FOR CYLINDER MOUNTING TO TRAILER

1. Ensure the cylinder and brackets are free from air and dirt and grease it properly.
2. Fix brackets on either side of the cylinder bottom mounting pin.
3. Lift cylinder with help of Cylinder Holding Fixture by using forklift.
4. Meanwhile, raise tipper box from the chassis about 800 mm to access bracket mounting channels.
5. Insert cylinder along with brackets to the mounting holes provided in the channel.A
6. Adjust the brackets with respect to corresponding channels by slightly hammering the brackets.
(Heavy duty hammer to be used.)
7. After adjusting the cylinder brackets to mounting channels, use M16 x 60 long, 10.9 grade with flat
washer and locknut.
8. Fix the cylinder top mounting eye to the trailer body top mounting bracket. Insert the shaft to the
mounting bracket & cylinder eye. Arrest the pin movement by providing bolt, nut, flat washer&
locknut or 8mm split.
9. Tighten the bottom mounting bracket bolt (M16) to a torque of 210 NM.
10. Connect the electric power pack to the cylinder and test the function of the cylinder.

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