operation & maintenance manual
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OPERATIONAND
MAINTENANCE MANUAL
HYVA INDIA PVT. LTD.Plot No. EL-215, MIDC, MAHAPE,
Navi Mumbai - 400 701
(The contents given in this manual are not binding and are subject tochange without notice. The details given are guidlines and are for
illustration purpose only.)
60
Dear Customer,
This manual outlines the maintenance and operating prac-tices of Hyva Tipping System fitted on your vehicle. Thepurpose of this manual is to assist you in maintaining thesystem and get maximum life out of components. This isalso to educate you in good operating practices and safetyof equipment at all times. Overall it helps you to obtain bet-ter performance at optimum operating costs.
All service and maintenance tasks are to be carried out atthe specified intervals.
This manual briefs about the system and components foryour understanding and knowledge. Fault diagnosis at theend helps you in diagnosing the problem in a systematicmanner.
Some of the items/accessories/features given in this bookmay not be fitted on your vehicle, but they are applicable toother versions.
Hyva India Pvt. LimitedMumbai
FOREWORD
61
INDEX
l Safety 1
l Periodic Check List 5
l Recommended Replacement Period for Consumables 6
l Recommended Hydraulic Oil Specification 6
l Tipper Operation Instruction 7
l Major Operating Parts
l HYVA P.T.O 11
l HYVA Gear Pump 17
l HYVA Tipping Valve 22
l Air Control for P.T.O / Valve 23
l Tank Return Line Filter 24
l Air Breather Filter 25
l Cylinder Nomenclature 26
l Tipper Model and Cylinder 27
l Cylinder Repair Instructions 30
l Hyfix Body Clamp 40
l Hydraulic Hose Orientation 42
l Fault Diagnosis 43
l Greasing Layout 45
l Specific Densities 48
blank page
1
IMPORTANT SAFETY NOTICE
Proper service and repair isextremely important for the safeoperation of your machine. Theservice and repair techniquerecommended by HYVA anddescribed in this manual are botheffective and safe methods ofoperation. Some of theseoperations require the use of toolsspecially designed by HYVA forthe purpose.
SAFETY
GENERAL PRECAUTIONS
Mistakes in operation areextremely dangerous. Read theOperation and MaintenanceManual carefully BEFOREoperating the machine.
1 Before carrying out anygreasing or repairs, read allthe precautions given on thedecals which are fixed to themachine.
2 When carrying out anyoperation, always wearsafety shoes and helmet.Do not wear loose workclothes, or clothes withbuttons missing.
l Always wear safetyglasses when hittingparts with a hammer.
l Always wear safetyglasses when grindingparts with a grinder, etc.
3 If welding repairs areneeded, always have a
trained, experienced weldercarry out the work. Whencarrying out welding work,always wear weldinggloves, apron, glasses, capand other clothes suited forwelding work.
4 When carrying out anyoperation with two or moreworkers, always agree onthe operating procedurebefore starting. Alwaysinform your fellow workersbefore starting any step ofthe operation. Beforestarting work, hang“UNDER REPAIR” signs onthe controls in the operator’scompartment.
5 Keep all tools in goodcondition and learn thecorrect way to use them.
6 Decide a place in the repairworkshop to keep tools andremoved parts. Alwayskeep the tools and parts intheir correct places. Alwayskeep the work area cleanand make sure that there isno dirt or oil on the floor.Smoke only in the areasprovided for smoking. Neversmoke while working.
PREPARATIONS FOR WORK7 Before adding oil or making
any repairs, park themachine on hard, level
SAFETY
2
ground, and block thewheels or tracks to preventthe machine from moving.
8 Before starting work, restdump body on prop andhang “UNDER REPAIR”board on them.
9 When disassembling orassembling, support themachine with blocks, jacksor stands before startingwork.
10 Remove all mud and oilfrom the steps or otherplaces used to get on andoff the machine. Always usethe handrails, ladders orsteps when getting on or offthe machine. Never jump onor off the machine. If it isimpossible to use thehandrails, ladders or steps,use a stand to provide safefooting.
PRECAUTIONS DURING WORK
11 When removing the oil fillercap, drain plug or hydraulicpressure measuring plugs,loosen them slowly toprevent the oil from spurtingout.
Before disconnecting orremoving components ofthe oil and air circuits, firstremove the pressurecompletely from the circuit.
12 The oil in the circuits is hotwhen the engine is stopped,so be careful not to getburnt.
Wait for the oil to cool beforecarrying out any work on theoil circuits.
13 Before starting work,remove the leads from thebattery. Always remove thelead from the negative (-)terminal first.
14 When raising heavycomponents, use a hoist orcrane.
Check that the wire rope,chains and hooks are freefrom damage.
Always use liftingequipment which has amplecapacity.
Install the lifting equipmentat the correct places. Use ahoist or crane and operateslowly to prevent thecomponent from hitting anyother part. Do not work withany part still raised by thehoist or crane.
15 When removing coverswhich are under internalpressure or under pressurefrom a spring, always leavetwo bolts in position onopposite sides. Slowlyrelease the pressure, thenslowly loosen the bolts toremove.
SAFETY
3
16 When removingcomponents, be careful notto break or damage thewiring. Damaged wiringmay cause electrical fires.
17 When removing piping, stopthe oil from spilling out. Ifany oil drips on the floor,wipe it up immediately. Fuelor oil on the floor can causeyou to slip, or can even startfires.
18 As a general rule, do not usegasoline to wash parts. Inparticular, use only theminimum of gasoline whenwashing electrical parts.
19 Be sure to assemble allparts again in their originalplaces.
Replace any damaged partswith new parts.
l When installing hosesand wires, be sure thatthey will not be damagedby contact with otherparts when the machineis being operated.
20 When installing highpressure hoses, make surethat they are not twisted.Damaged tubes aredangerous, so be extremelycareful when installingtubes for high pressurecircuits. Also, check thatconnecting parts arecorrectly installed.
SAFETY
21 When assembling orinstalling parts, always usethe specified tighteningtorques. When installingprotective parts such asguards, or parts whichvibrate violently or rotate athigh speed, be particularlycareful to check that theyare installed correctly.
22 When aligning two holes,never insert your fingers orhand. Be careful not to getyour fingers caught in ahole.
23 When measuring hydraulicpressure, check that themeasuring tool is correctlyassembled before takingany measurements.
24 While carrying out weldingon tipper, earthing should bedone nearer to the weldingspot. Earthing should not bedone through cylinder andother hydrauliccomponents, to avoiddamage due to sparking.
25 While carrying out weldingon head board / load body,the tipping cylinder andother hydraulic componentsshould be covered with fire-resistant cover so thatwelding spatters will notdamage stages and seals.
4
SAFE PRACTICES
Do’s Don’ts
OVER LOAD
LOAD UNEVEN
TIP ON UNEVEN GROUND
STAY UNDER AN UNSUPPORTED BODY
STAY IN THE WORKINGAREA OF THE TIPPER
DRIVE WITH RAISED BODY
TIP WITH TRAILER IN ANANGLE TO THE TRUCK
5
PERIODIC CHECKLIST
DAILY CHECK LIST (BEFORE STARTING THE TRUCK)
l Check the Oil level in the Oil Tank. Oil level has to be in the middle ofthe sight glass or level Indicator, while the body in resting on the sub-frame.
l Make visual inspection of Hydraulic System i.e. P.T.O., Pump, Tank,Valve, Hoses and Couplings for leakages.
l Check all Pneumatic and Hydraulic connections for slackness.
l Care should be taken while tightening Pivot Mounting Bolt, so thatPivot Spring doe’S not get compressed completely and there isminimum gap equivalent to thickness of a Hacksaw Blade so that thisSpring can offer required compression under load.
PERIODIC CHECKLIST - WEEKLY
l Breather Element must be cleaned once in a week with compressedair only.
l Lubricate all greasing points on the tipper. (Cylinder Eye End,Stabilizer, Body Prop, Rear Hinge Shaft - Refer Greasing Layout)
l Check Gearbox Oil level.
l Check Pivot bracket bolts, Attachment bolts (80 NM) and CylinderCradle Mounting Brackets Bolts, Pump Mounting Bolts and tighten ifnecessary. Tightening Torque for Cylinder Mounting Bracket Bolts is200NM.
6
RECOMMENDED REPLACEMENT
Sl. No. Description of Items Replacement Periods
1 Air Breather Filter Element Once in every 4 months innormal working condition.(Non Mining application)
Once in every 2 months industy working condition.(Mining application)
2 Return Line Filter Element Once in every 4 months innormal working condition.(Non-Mining application)
Once in every 2 months industy working condition.(Mining application)
3 Hydraulic Oil First change after 6 monthsand later once in every year.
We recommend Super-clean anti-wear, oxidation stable and rustpreventive Hydraulic oil conforming the characteristics according to BIS-11656-86 and DIN 51524/2 (Viscosity grade - 68)
RECOMMENDED HYDRAULIC OIL
Make Brand & Type Working TemperatureFrom To
B.P. Hydrol 68 - 5OC 50OC
H.P Enklo 68 - 5OC 50OC
Castrol Castrol WH 15 - 5OC 50OC
ELF Elforia DS 68 - 5OC 50OC
IOC SERVO System HLP 68 - 5OC 50OC
Note :Please note, over and above the schedule, Filter and Breather elementsneed to be replaced whenever the hydraulic oil is replaced.
7
OPERATION INSTRUCTIONS
Before putting your vehicle into operation, it is necessary to familiarizeyourself thoroughly with the mode of the operation and function ofthe tipper.
LOADINGl Body must be uniformly loaded.
l Please load as per the specification chart provided in order to ensurelonger life and safer operation.
l Ensure proper loading or hopping process in order to avoid undueimpact load on vehicle.
TIPPINGl Before tipping, make sure the tipper is standing on level & stable ground.
l Make sure that front wheels are in line with rear wheels.
l Ensure that hand brake of the vehicle is in “ON” position.
l In neutral gear, start the engine, build up the air pressure upto7 kg/cm2, then press the clutch pedal and engage the PTO slowlyusing air control valve lever inside the cabin
l In case of vehicle with tail gate system, ensure that the safety lock pin isremoved & stowed in open position from the tail door locking mechanism.
l Do not attempt to tip the body without ensuring that mechanical lockpin is removed from the tail door locking mechanism. Otherwise thiswill damage the locking mechanism.
l Start tipping by using the air control inside the cabin.
LOWERINGl Using the air control inside the Cabin, lower the tipper body. Lowering
operation automatically disengages PTO.
l Do not put the engine in high R.P.M, while lowering the body.
GENERAL TIPS
l Please ensure the raising of body prop while doing any work on chassisor sub-frames underneath the body.
l Please remember, incorrect operational practice may be fatal to thevehicle and cause even casualty of human life.
WARNING :
l Applying side load and dynamic forces to any cylinder is dangerous.
l Working under an unsupported body is a danger to life.
8
HYDRAULIC TIPPING SYSTEM
Hyva Tipping System comprises of following hydraulic components toprovide highest level of tipping efficiency.
l HYDRAULIC TANK
l TIPPING VALVE
l AIR CONTROL VALVE
l GEAR PUMP
l POWER TAKE-OFF (PTO)
l HYDRAULIC CYLINDER - TIPPING CYLINDER
HYVA – Tipping Diagram
Return Line Filter Assly.
3DHMP Valve
Breather Assly.
Cylinder Assly.
PTO & Pump
Air ControlValve
9
HYDRAULIC & PNEUMATIC CIRCUIT DIAGRAMH
YD
RA
UL
IC &
PN
EU
MA
TIC
CIR
CU
IT D
IAG
RA
M W
ITH
3D
HM
P V
AL
VE
10
HYDRAULIC & PNEUMATIC CIRCUIT DIAGRAMH
YD
RA
UL
IC &
PN
EU
MA
TIC
CIR
CU
IT D
IAG
RA
M W
ITH
PT
VA
LV
E
11
P.T.O
P.T.O : A P.T.O (Power Take Off) is an auxillary gear box mounted onthe transmission. Its function is to transmit the power from rotationof the engine.
Hyva Supplies the following P.T.Os :I. Side mounted P.T.O : 1. G600 V1 Type (Remote Drive)
2. G600 V2 Type (Direct mounting)
II. Rear mounted P.T.O : 1. Dual Block P.T.O.
2. Mono Block P.T.O.
III. Use of the P.T.O
IMPORTANT : When engaging and disengaging the PTO, alwayspress the clutch pedal!
WORKING TEMPERATURE AND LOAD CONDITIONS
The temperature depends on the way the PTO is used and it isrecommended to keep it between the following values.
Short duration (less than 15 minutes) max. 120OC, long duration(more than 15 minutes) max. 100OC.
The PTO temperature is affected by various factors; it is possible toreduce overheating by:
l Changing the oil more often in case of heavy duty system.
l When the PTO is side mounted, ensuring that the gear backlash isaccurately checked.
l When the PTO is rear mounted, considering to provide the PTO witha supplementary lubrication kit.
IV. PTO Installation
a. Side mounted PTO installation :
l Empty or reduce the gearboxoil level, check cleanliness. Ifoil is dirty or contaminated itshould be replaced. (Pict. 1)
Notice : In some applications(for example automatic AllisonGearbox) it is not necessary toempty gearbox. Always checkgearbox service manual.
Picture. 1
12
P.T.O
l Remove gearbox aperturecover and accurately clean thegearbox aperture surface(Pict. 2)
l Check gearbox gear teeth andthe gear backlash (Pict. 3)
l Open the PTO package. UsePTO specific mounting kit andif necessary spacers.
l Studs for mounting onto thegearbox :
- Accurately check that the holesin the gearbox are threaded. Becareful that studs do notinterfere with gears.
- Fit the studs. (Pict. 4) shows atypical mounting example.
Backlash check between geartooth and spacer insertion:
To get backlash of 0.15 + 0.4 mm,fit spacers between PTO andgearbox as necessary.
Backlash checking can be carriedout in two ways.
Picture. 2
Picture. 3
Picture. 4
13
- In case of PTOs equipped withinspection plug, check by hand,(rocking the gear to get the“feel” for gear backlash) or bymeans of a dial gauge (Pict. 5).The use of a dial gauge isrecommended as it is muchmore accurate.
- In case of PTOs withoutinspection plug, adjustment iscarried out in stages. The PTOhas to be checked against thetransmission flange by addingspacers until there is nobacklash. After that, another0.5 mm spacer should beadded and the nuts tightened.
Recommendations on seal andspacer use.- Remember that once the nuts
have been tightened, the sealthickness reduces, resulting in asimilar backlash reduction. Thebacklash therefore has to bechecked even after tightening.
- Available seals (Pict. 6) have athickness of 0.5 and 0.25 mm(special series).
- When a spacer is fitted, use agasket to ensure tightness (atleast one on both sides).
- In order to avoid the sealssticking to each other, usegrease. NEVER use adhesivefluid when the PTO mountingkit requires special gasket.USE adhesive fluid onlywhen the PTO mounting kitDOESN’T involve any gasket.
0.5 mm 0.25 mm
P.T.O
Picture. 5
Picture. 6
Picture. 7
14
Once the suitable thickness hasbeen determined, tighten the nutswith a torque wrench (seetightening torque table)
Notice : Once the nuts havebeen tightened, the backlashhas to be rechecked and ifnecessary the shimingoperation may be repeated.When the installation operationhas been completed, fill thegearbox with oil (Pict.7)
Notice : In case of applicationswith separate lubrication (forexample on Allisontransmission) an external tubekit is needed to be fitted.
After installing operations, proceedwith the checks.
b. Rear mounted PTOinstallation :
l Empty or reduce the gearboxoil level, check cleanliness. Ifoil is dirty or contaminated itshould be replaced.
Notice : In some applications(for example automatic Allisongearbox) it is not necessary toempty gearbox.
l Remove gearbox aperture coverand accurately clean the gearboxaperture surface (Pict. 8)
l If a shaft kit is provided for theapplication, carefully read therelevant mounting instructions.
l PTO mounting (see pict.9)
P.T.O
Picture. 8
Picture. 9
15
The typical way of mounting isshown in the picture. It isrecommended to lock studs orbolts with locking fluid. (seetightening torque table)
Notice : In case of a connectionto an ISO flange pump: if theoil seal is fitted to the pump,then the pump must be fitted tothe gearbox before filling withoil.
l When the fitting operation iscomplete, refill gearbox with oil(Pict.10)
Notice : In case of applicationwith separate lubrication, asupplementary lubrication kitshould be fitted.
l When installation is completed,proceed with the checks (see‘After Installation checks’ onnext page)
c. Mounting bolt torques :
Thread Studs (tightening on Gearbox) Screw & Nuts
M8 10 NM 25 NM
M10 20 NM 50 NM
M12 30 NM 80 NM
3/8” 10 NM 25 NM
7/16” 20 NM 50 NM
P.T.O
Picture. 10
16
P.T.O
V. AFTER INSTALLATION CHECKS. :
Once the installation phase is complete, the following checks arerecommended.
Engagement / Performance soon after engine start. If adisengagement check clash is heard, this may be due to one of the
following:
- Clutch not working properly
- There’s no or insufficient air pressure.
Oil level check Carry out an oil check when the engine isstill cold and top up if necessary.
Oil Leak Check to be carrier out under all the workingconditions, with PTO engaged, gearbox inneutral position.
In case of a side mounted PTO, an excessivenoise may mean a wrong backlash accordingthe following:
- High pitched noise; backlash is too tight -Rattle noise; excessive backlash.
Tightening bolts check Normally bolts tend to loosen because of theseal setting. It is recommended that all boltsand nuts are checked after a few hours ofwork checking the tightening by means of atorque wrench. With side mounted PTO’s,recheck the backlash after tightening.
17
GEAR PUMP
Gear Pump specifications 52 cc 87 cc 82 cc
Displacement per revolution 51.88 86.39 81.29 cm3
Maximum peak pressure 230 Bar 230 Bar 230 Bar
Maximum intermittent pressure 230 Bar 230 Bar 220 Bar
Maximum Continuous pressure 230 Bar 230 Bar 190 Bar
Oil temperature range: -25OC to -25OC to -25OC to110OC 110OC 110OC
Inlet pressure range: 230 Bar 230 Bar 0.7-3 Bar (abs)
Hyva Gear Pump (if fitted)
Hyva Gear pumps. Gear pump is a model with two gearwheels havingexternal teeth. Normally we use Gear Pumps with one direction of rotationfor following reasons.
l Higher maximum working pressure and efficiency compared to bi-directional pumps.
l As the required pressure range for the tippers application is not morethan 170 bar.
The direction of rotation can be changed in case if required. (Theprocedure for changing the direction is given on the next page).
We are using, 52.cc/82.cc/87.cc & 109.cc pumps with Hyva tippingsystem.
Note:
82/ 87 denotes the displacement of oil in cc per rev i.e. 82.cc pump runsat 1000 rpm capacity will be 82 lts/min
We recommend operating tipper application with correct Engine RPMas per PTO ratio of that particular housing and gears. Raving up theengine can lead to Pump failure or excessive wear and tear on the Pump.
Mode. Usually it roughed from 1000 to 1200 engine rpm.
18
One of the two gearwheels is driven from outside (Drive Gear) and drivesthe other gearwheel (Driven Gear). With the right hand rotation of the topgearwheel (consider fig.) oil is sucked from the LHS port (Pump suction).Oil trapped in between the gear teeth and the pump body travels alongthe periphery of the Pump body towards the RHS port (Pump delivery).As the teeth and the side of the gears are closely sealed against thePump body and the Thrust Plates, pressure builds up against theresistance to the oil flow at the delivery port.
Basic principle of Gear Pump
GEAR PUMP
19
GEAR PUMP
Hyva Gear Pump (82 cc Black)
SL. Description Qty.
1 Pump body 1
2 Front Cover 1
3 Trust plate 2
4 Drive Gear 1
5 Driven gear 1
6 Roller Bearing 2
7 Screw 8
8 Grub screw 1
9 Washer 8
10 Lock washer 1
11 ‘O’ Ring 1
12 Seal 2
13 Shaft Seal (42x55x7) 1
14 Circlip 1
SL. Description Qty.
15 Circlip S1372 1
16 Back Up Ring 2
17 Mounting Ring 1
18 Sleeve Bearing 4
19 Spacer Ring 1
20 Threaded Locking Ring 1
22 ‘O’ Ring 1
23 Support Shaft 1
24 Steel Brush 4
25 protection Ring 1
26 Circlip 1
27 Support Ring 1
28 Shaft Seal (24 x 40 9) 1
29 Roller Bearing 32007 1
20
GEAR PUMP
HYVA GEAR PUMP OVERHAULING PROCEDURE :
Please follow the steps mentioned below:
l Remove the pump from vehicle and place it on a clean table
l Loosen all allen bolts by using suitable allen key
l Tap the flange area and remove the cover of the pump
l Slowly remove the O-ring from groove of cover plate. Check andreplace, if necessary
l Remove the oil seal from pump shaft. Check the condition and replace,if necessary
l Remove the top thrust plate. Also, remove the thrust plate seal andanti extrusion ring
l Remove the set of drive and driven gear
l Follow the above instruction for removing the bottom thrust plate
l Check clearance between housing and gear teeth. The clearanceshould not be more than 0.005”.
l Check and replace the seal and backup ring, if necessary
l Clean each part thoroughly and assemble back in reverse sequenceof dismantling pump
l Check the backlash of gears
l Belt tightening torque - 20 NM
TO BLEED THE SYSTEM :
The Hyva Gear pumps, as well as the Hyva cylinders do not have ableeder screw. After installation of tipping system some components canhave some amount of air trapped inside. Therefore it becomes necessaryto bleed the system. To bleed the system, follow some of the instructionsgiven here.
l Loosen the pressure hose of the pump a little so that the air in thesuction hose and the pump can escape and the system will be filledup with oil.
l Loosen the pressure hose and the cylinder hose a little. Run the pumpat a low speed and put the tipping valve in “Tip” position. After a shortwhile once the air escapes from the system, the connections must betightened.
21
l As the piston of the cylinder is closed, only a little air remains betweenthe stages. This will “mix-up” with the oil after a few tips and willescape via the oil tank.
l If air remains in the system after 8-10 tips the position of the suctionhose must be checked and the connections must be tightened. If thetemperature is high or the oil is thick, one must wait longer beforebleeding a second time.
l Top up the oil tank as oil has now entered the cylinder, hoses and oilfilter.
l Check the working pressure and check that the pump is operatingproperly. It is too noisy or if there are shocks in the hoses, air may stillbe there in the system and the pump is facing cavitation. Bleed thesystem.
l Check the working pressure. Check if the complete hydraulic systemworks properly. (Working pressure - 170 bar)
GEAR PUMP
22
HYVA TIPPING VALVE
GENERAL MOUNTING INFORMATION
l The tipping valve is mounted on oil tank through valve mounting block.To prevent the valve housing deformation the mounting plate surfaceor block must be completely flat.
l Before mounting the valve, remove the plug underneath the valveand use the O-ring between valve return line opening and valve block.
l Recommended torque for tipping valve mounting bolts is 15 NM.
DISMANTLING TIPS
l The Valve must be dismantled in a clean area and using the correcttools.
l If a fault has been developed which can be traced to the valve it ispossible to replace the internal seals and a-rings.
l All parts should be thoroughly cleaned before reassembly.
l Hyva recommends that total hydraulic circuits must be tested oncompletion of fitting as per following:
l Make sure that the body is fully lowered and the PTO isdisengaged.
l Connect a 1/18” B.S.P. threaded pressure gauge to the pointshown on the figure.
l Engage the P.T.O. and tip the body fully. Hold the lever at tippingcondition until the oil get relieves to tank.
l Check for leaks in the system and read the pressure gauge.
PRESSURE CHECKING POINTS
pressuregauge
System working pressure is 170 bar
pressure gauge
23
AIR CONTROL FOR P.T.O. / VALVE
GENERAL INFORMATION
l The air control for P.T.O/Valve with automatic P.T.O. disengagementis a three way operated, variable air control (for P.T.O. engagement,tipping and lowering operation).
l When used with a compatible tipping valve with proportional lowering,the proportional movement of the air control lever can regulate thespeed of descent of the body.
l Hyva Air controls are easy to mount to the cabin.
l The functions of Hyva air controls are clearly indicated with symbol.
MOUNTING OF THE AIR CONTROL
l When air control is mounted next to the driver’s seat, a strong supportshould be used.
l Ensure using rubber grommets to protect air tubes and to prevententry of dust and water inside cabin.
l For trouble free operational life of the entire pneumatic system, thecondensed water in the air tank should be regularly drained.
l Also make sure that the air tubes are not too close to sharp objects,moving parts exhaust and compressor lines, should not get tostretched.
l Please take precaution to protect pneumatic lines while doing weldingin nearby area.
24
RETURN LINE FILTER
RETURN LINE FILTER ASSEMBLY
Return line filter assembly is located on top of the hydraulic oil tank &adjacent to tipping valve. Oil from cylinder on it return path, (CylinderTipper Valve) returns to the tank through Return line filter.
The function of RLF assembly is to remove contamination from thehydraulic oil on its way back to the tank. (Rating 25 Microns)
1
It consists the following Parts1 Cover2. Aluminum Body3. Flange Pipe4. Return Line Filter Element
5
5
2
5. Flange Seal6. ‘O’ Ring7. ‘O’ Ring8. Spring
6
5
4
3
Note:
Periodic replacement of fi lterelement is strongly advised toprevent premature wear and failureof tipping system components.
2
CHECKSl Filter element must be replaced as per the recommendation given in
periodic check list.
25
AIR BREATHER FILTER
Breather Assembly
As the name indicates, this helps the Hydraulic oil tank to ‘Breath in’ or‘Breath out’ air, in order to maintain the atmospheric pressure insidetank, even when there is lower level of oil (in tipped condition) or higherlevel of oil (due to lowering down or heat generation in the system), inorder to prevent any kind of deformation of tank. A Breather filter elementof 10-micron filtration capacity ensures entry of dust and foreign particle– free air inside hydraulic tank.
It consists of the following parts1. Cover2. Housing3. Breather Filter Element4. Seal5. Screw6. Sleeve
Note :Breather Element must be replaced periodically as per therecommendations.
26
HYVA Cylinder Nomenclature
To identify the Type and Part number look for the Cylinder name Plate,which is located above the Trunnion & below the oil Port of the Cylinder.Make sure about all the parameters before placing an order for Assemblyor Spare Parts.
In Front End Tipping Systems used generally in India, Hyva is using twotypes of Cylinders, i.e. FE & FC. (Find herewith the Nomenclature forFront End Cylinder with Cover - FC)
l Stroke Length: Distance travelled between close to open length bycylinder eye or cover trunnion.
Eye withtrunnion FE
Cover withTrunnion FC
CYLINDER NOMENCLATURE
HC001-3210 -3 -105 -FC - HC----FC -
Type of cylinder
Diameter of First Stage (mm)
No. of StagesStroke length (mm)
Position of inletHard Chromed
HC001-4620 -4 -169 -FE - HC----FE -
CYLINDER NOMENCLATURE
27
TIPPER MODELS, CYLINDERS & APPLICATIONM
ake
TA
TA
TA
TA
TA
TA
TA
TA
TA
TA
TA
TA
Mo
del
SK
-161
3L
PK
-161
5L
PK
-151
8L
PK
-161
8L
PK
-161
8L
PK
2516
Tip
per
Typ
eS
TD
R.B
ST
DS
TD
ST
D R
LS
TD
RL
ST
DR
B
Wh
eel
3625
4225
3625
3580
3580
3580
3880
3880
Bas
eIN
mm
Vo
lum
e in
UP
TO
10
UP
TO
8.5
8.5
68
1014
12 &
14
CU
.M
An
gle
of
Tip
pin
g Ø
4949
5050
4949
4953
Cyl
ind
erF
C-1
05-
FC
-105
-3-
FC
-105
-3-
FC
-105
-3-
FC
-105
-3-
FC
-105
-3-
FE
-129
-3-
FE
-129
-3-
Mo
del
3-02
635
/03
210
/03
210-
0321
0-00
103
210-
001
0321
0-00
103
700
0388
0F
C-1
10-3
-F
C-1
10-3
-00
1HC
0263
503
210
Ap
plic
atio
nS
and,
San
d,S
and,
San
d,C
oal
Coa
lS
and,
OB
Gra
vel
Gra
vel
Gra
vel
Gra
vel
Gra
vel
& S
mal
lR
ocks
TIP
PE
R M
OD
EL
S, C
YL
IND
ER
S &
AP
PL
ICA
TIO
N
28
TIPPER MODELS, CYLINDERS & APPLICATIONT
IPP
ER
MO
DE
LS
, CY
LIN
DE
RS
& A
PP
LIC
AT
ION
Mak
eT
AT
AT
AT
AT
AT
AT
AT
AT
AT
AT
AT
AT
AT
AT
AT
A
Mo
del
LP
K25
16L
PK
2518
LP
K25
18L
PT
2515
NO
VU
SD
AE
WO
O31
3531
35
Tip
per
RB
ST
D R
LS
TD
RL
RB
RB
RB
ST
DS
TD
RB
Typ
e(H
YD
TD
)
Wh
eel
3880
3880
4880
4880
3930
4030
3930
2940
2940
Bas
eIN
mm
Vo
lum
e12
1420
UP
TO
16
1515
1623
18in
CU
.M
An
gle
of
4949
4645
5255
5051
52Ti
ppin
g Ø
Cyl
ind
erF
C-1
29-
FC
-129
-F
C-1
29-
FE
-129
-F
E-1
41-
FE
-149
-F
E-1
41-
FE
-149
-4F
E-1
69-4
Mo
del
3-03
700
3-03
700-
3-04
270
3-03
880
3-03
830
3-03
880
3-03
640
-046
20-4
620
000A
-000
A-0
01-0
09A
-001
-009
A-0
09A
Ap
plic
a-S
and,
San
d,C
oal
OB
Min
ing
Min
ing
Con
stru
ct-
Con
stru
ct-
Min
ing
tio
nG
rave
lG
rave
l&
Sm
all
(O
B &
(O
B &
ion,
Coa
lio
n, C
oal
(O
B &
Roc
ks M
ediu
m M
ediu
m M
ediu
mR
ocks
)R
ocks
)R
ocks
)
29
TIPPER MODELS, CYLINDERS & APPLICATIONM
ake
AS
HO
K L
EY
LA
ND
FO
RC
EF
OR
CE
FO
RC
EA
MW
AM
WM
ER
CE
DS
CA
NIA
Vo
lvo
VO
LV
OM
OT
OR
SM
OT
OR
SM
OT
OR
SE
S
Mo
del
AL
-251
6M
AN
MA
NM
AN
2523
2523
AC
TRO
SP
380
FM
-9F
M-4
0048
40
Tip
per
ST
DR
BS
TD
RB
RB
RB
ST
DR
BR
BR
BR
BT
ype
(Tun
nel
Tru
ck)
Wh
eel
4597
3831
4525
4525
4525
4300
4300
4380
4053
3400
4088
Bas
e(1
80")
(150
")IN
mm
Ch
assi
s6x
46x
46x
46X
46X
46X
46X
48X
48X
46X
48X
4T
ype
Vo
lum
e14
/16
1416
1416
1416
1818
1418
in C
U.M
An
gle
of
4953
4853
5353
5153
5352
55Ti
ppin
g Ø
Cyl
ind
erF
E-1
29-
FE
-129
-F
E-1
29-
FE
-129
-F
E-1
49-
FE
-129
-F
E-1
29-
FE
-169
-F
E-1
69-4
FC
169-
4F
E-1
69-4
Mo
del
3-03
700
3-03
880
3-03
880
3-03
880
3-03
880
3-03
700
0370
0-4-
0462
0-0
4620
-042
80-0
4620
-001
A-0
09A
-001
A00
1A
Ap
plic
a-Sa
nd,
OB
& Sm
all
Sand
,O
B &
Smal
lM
inin
g (O
BM
inin
g (O
BSa
nd,
Min
ing
(OB
Min
ing
(OB
Min
ing
(OB
Min
ing
(OB
tion
Gra
vel
Rock
sG
rave
lRo
cks
& M
ediu
m&
Med
ium
Gra
vel
& M
ediu
m&
Med
ium
& M
ediu
m&
Med
ium
Rock
s)Ro
cks)
Rock
s)Ro
cks)
Rock
s)Ro
cks)
30
CYLINDER REPAIR INSTRUCTIONS
FC & FE CYLINDERS REPAIRS INSTRUCTIONS
IntroductionHyva cylinders contain a small number of components, which are subjectto wear. Therefore it is sometimes necessary to dismantle the cylinderand replace the worn out parts like seal kit.
Depending on the load requirements, either of the following types ofcylinders are incorporated in system :
1) FE/FC110 2) FE/FC129 3) FE/FC 149
4) FE/FC 169 5) FE/FC191
Repair of Hyva cylinder repairs should be carried out always inaccordance with instructions given as below.
1. Before dismantling any Hyva cylinders always check the name platefor type of Cylinder, which is primary requirement in ordering rightparts.
2. Remove the Cylinder from the chassis prior to dismantling and alwaysplace it horizontally on a clean and dust free place.
Only in case of FC type of cylinder it is possible to leave the outer coverattached to the body.
FC TYPE CYLINDER DISMANTLING
Procedure :l Remove the top nut from the cylinder.
l Raise the tipping body using the Hydraulic System until the first stageis visible.
l Support the tipper body securely by use of a body prop.
l Place the lever of the air control valve in the lowering position andallow the inners to sink to then rest position. Secure the cylinder,using a proper rope or sling to a suitable lifting device to prevent thecylinder from tipping over.
l Disconnect one of the trunion brackets from the cradle or sub frameand ease the cylinder from the other bracket. The cylinder can nowbe laid on a bench ready for dismantling.
l Lay the cylinder flat on a clean bench with the oil inlet facingdownwards and clamp securely to avoid any kind of damage andinjuries. A ‘V’ block arrangement is usually the best. Collect the wasteoil.
31
CYLINDER REPAIR INSTRUCTIONS
l Use a ring Spanner to unscrewthe Bolts of the bottom plateand remove the locking plates(Fig. 1 & 2)
l Place a filter ring in the grooveleft vacant by the locking plates,to ease the removal of theBottom Plate. The Bottom platecan now be removed usingeither of the following methods.
l Using two small bolts insertedinto the bottom plate lever it outof the base tube. (Fig. 3)
Figure. 1
Figure. 2
Figure. 3
32
CYLINDER REPAIR INSTRUCTIONS
l Strike the head of the pistonwith a mallet or mandrel. Thisforces the Bottom Plate out ofthe Base Tube. (Fig 4)
l When the Bottom Plate is freethen remove its O-ring. (Fig. 5)
l Push the piston forward untilthe snap ring or lift rings withspacing ring are visible on theinternal diameter of the nextinner, (Fig. 6).
Figure. 4
Figure. 5
Figure. 6
33
CYLINDER REPAIR INSTRUCTIONS
l The snap ring can be removedusing screw driver, the lift ringscan be removed using a set ofpliers. (Fig. 7).
l The piston can now beremoved through the bottom ofthe cylinder. The sliders on thepiston, which have a diameterless than or equal to 99 mm,consist of two parts and thesemust be collected to preventdamage. Pistons with diametergreater than 99 mm containersliders, consisting of one part,which do not need to beremoved (Fig. 8)
l The snap ring or lift rings of thesubsequent inner must beremoved before removing nextinner stage through the bottomof the cylinder.
l Push the inner stage forwarduntil the snap ring or lift ringswith spacer in the subsequentinner is exposed. Remove thesnap ring or the lift rings asdescribed. The removed innerstage must be placed on isclean surface in order toprevent scratches and otherdamage (Fig. 9).
Figure. 7
Figure. 8
Figure. 9
34
l All the subsequent inner stagescan be removed in this way.The seals and wipers must notbe reused. (Fig. 10 & 11)
Remove the seal, scraper andwear rings from the internalgrooves at the top of each innerstage. Do not remove the sealsand wipers with a screwdriveror other sharp instruments asthis may damage the groovesirreparably and lead inevitablyto leaks. The wear rings can beremoved using a screwdriver.
l Never remove a Stop ring if itshows signs of damage. In thatcase the whole stage must bereplaced.
l Clean each stage carefully andcheck each groove and thesurface of the tube for anyirregularities. Check also theslider on each tube. If these aredamaged, they should bereplaced. In this case, it isnecessary to check the stopring in the subsequent tube forsigns of damage or twisting.
CYLINDER REPAIR INSTRUCTIONS
Figure. 10
Figure. 11
Figure. 12
35
FE TYPE CYLINDERDISMANTLING
Procedure:l Secure the cylinder, using a
proper rope or sling to suitablelifting device to prevent thecylinder from tipping over.
l Remove the split pin out of thepivot pin and tap the pivot pinout of the piston eye.
l Disconnect one of the trunionbrackets from the otherbracket. The cylinder can nowbe laid on a bench ready fordismantling.
l To remove the piston, push itforwards until the snap ring orlift rings with spacer in the nextinner stage are exposed. Thesnap ring can be removedusing a screwdriver; the liftrings can be removed using apair of pliers. (Fig. 12)
l Push the piston downwards andremove the sliders. In case ofpistons and tubes with diameter99 mm or smaller, the slidersconsist of two parts which haveto be collected up to preventdamage. (Fig. 13 & 14)
l Never remove the pistonsthrough the top of the cylinderwithout use of the filler rings inthe slider groove.
l Place a filler ring in the slidergroove of the piston andlubricate it with the grease for
the packing set.
l The piston can now beremoved through the top of thecylinder.
l Piston with a larger diameterthan 99 mm can be removedthrough the bottom of thecylinder. In case of pistons andtubes with a larger diameterthan 99 mm, the slider consistof one part which does not needto be removed.
CYLINDER REPAIR INSTRUCTIONS
Figure. 13
Figure. 14
36
ALL TYPES OF CYLINDERASSEMBLING
General Procedure :l Clean each inner part
thoroughly and apply sufficientgrease to the pack-set and thegrooves. Use new pack-set toeach stage. Mounting shouldstart with the seal, followed bythe wear rings and the wiper.Always ensure that each of thering is seated correctly in thegroove. Incorrect fitting canlead to leakage of oil anddamage to seals. (Fig. 1, 2, 3,4, 5)
CYLINDER REPAIR INSTRUCTIONS
Figure. 2
Figure. 1 Figure. 4
Figure. 3
37
l Slide the first outgoing innerstage almost fully into the basetube ensure that scraping overthe stop ring does not damagethe tube. Some resistance willoccur when passing throughthe pack-set (Fig. 6 & 7)
l To prevent damage andfacilitate assembly, Hyva hasdeveloped special cones.
l Place the sliders at the end ofthe inner stage and usesufficient grease. (Fig. 8)
CYLINDER REPAIR INSTRUCTIONS
Figure. 6
Figure. 5 Figure. 8
Figure. 7
38
l The sliders must be mountedin a particular position with flatside of top slider always facingupwards.
l Slide the tube further home untilthe sliders are in the basic tube.
l Each of the subsequent innerStages can be mountedsimilarly. After mounting aninner stage the snap ring of liftRings with spacer should beplaced. In the previous innerstage with the exception of thecylinder base.
l Mounting the position is carriedout in the reverse sequence ofdismantling.
l Fit a new ‘O’ ring to the bottomplate and slide the bottom plateinto the base. Use sufficientgrease and the fitter ring toprevent damage to the seal.(Fig. 9,10&11)
l Due to the special design of thecylinder, it is not necessary tobleed the air followingassembly; the air isautomatically discharged afterthe first few tipping operations.After testing for correctfunctioning of the cylinder, itcan be re-fitted to the chassis.Follow the mountinginstructions for FC/FE cylinder.
l The top nut on the outer casingmust not be re-used.
CYLINDER REPAIR INSTRUCTIONS
Figure. 9
Figure. 10
Figure. 11
39
FE TYPE CYLINDER (WITH SCREW EYE) ASSEMBLING
Procedure :l Fit a new “Q” ring the piston eye, apply sufficient grease and screw
the eye onto the piston. Applying grease to the screw thread canease fitting the eye onto the Piston.
l The locking rivet should be placed or the same height but not in thesame existing hole.
l Drill a new hole (5.8 mm & 18 mm deep) and hammer the rivet intothe hole.
CYLINDER REPAIR INSTRUCTIONS
40
HYFIX BODY CLAMPS
This is a unique feature of hyvatipping system.
l Hyfix clamp mountedunderneath the body, stopsrattling of the empty tipper bodyon the chassis and thusprevents damage to thechassis, structural part andsub-frame and reduced thenoise nuisance.
l This hyfix clamp is arevolutionary solution forcontinuous tipper problem ofchassis receiving enormoushammering from the tipperbody caused by potholes andbumps on the road.
l Hyfix ensures a fixedconnection between tipperbody chassis. The continuousbolt and nut, depending onwhere hyfix is fitted and thedimensions of the tipper bodycan adjust the compressionload in the power block. Thecompression load can varyfrom 250 to 1600 kgs.
WELDING OF THE HYFIX
l The hyfix to be fully supportedand welded over the entiresurface before the compressonload is set, so that no bendingmoment will arise on the powerblock and locking.
l Also the Hyfix bracket has tobe fully welded.
DISMANTLING THE HYFIXl Open the Hyfix with hollow
steel bar and remover thesetting pin.
l While setting pin is removedand the Hyfix closes, there is apossibility of clamping between
l The power block and the hook.
l Greasing points should beproperly greased at regularintervals.
l Condition of power block andcompression rod must bechecked twice a year.
41
HOSES AND ADAPTERS
SECTION & HIGH PRESSURE HOSES
Make sure the proper hose orientation in order to ensure (a) Same isnot getting rubbed with any object (b) there is no twist (c) Hose is notbent too sharply.
l The mounting torque of the hose clamp must be 6 NM
l Take care the hoses do not come in contact with hot or moving partslike the exhaust or drive shaft.
l Use Nylon Tape to seal the threads of elbows and hose pillars withoutO-ring, do not use Nylon Tape in combination with elbows or hosepillars with O-ring
Please use Hyva hoses only for replacement whenever required inorder to ensure longer and safe life of hydraulic components.
42
HOSE ORIENTATION
43
FAULT DIAGNOSIS
Fault Possible Causes Remedy / Check
lThe cylinder does lThe PTO IS not engaged l Move Cab Control to “innot mend when the mesh” positionair control is intipping position l Pump does not deliver oil l Disconnect hose at ‘P’ and
check if oil circulates
l No oil in tank l Fill the oil tank
l Gate valve closed l Open the gate valve
l Insufficient air pressure l Check air supply
l Cylinder is connected to l Connect cylinder to port ‘A’wrong Valve port
l Air supply correct but l Air Control fault l Remove all air tubes excepttipping valve does feed and exhaust. Check ifnot get actuated. air passes through relevant
port when control move onto correct position. Replacethis Valve if faulty
l Air Tube ‘kinked’ or l Check all Tubes for sharprestricted bends. Disconnect both air
tubes from valve and checkair flow with air control inrelevant position. If no airescapes from air tube ends,replace tubes
l Cylinder raises l Lowering speed adjusting l Turn the screwbut not lower or screw turned in completely anticlockwiselowers too slowly (PT valve only)
l Knock-off valve does not l Check through the separatework properly (if provided)
l instructions for knock-offvalves
l Air Control fails l Check air supply inlowering position
l Return filter is chocked l Replace filter element
l Grade of oil being used l Refill with proper grade oftoo heavy oil (see recommended list)
l Cylinder drops when l Non return valve in port l Replace tipping valveclutch is depressed ‘P’ not fitting
l Air supply is sufficient l Internal leak in tipping l Change tipping valvebut tipping valve willnot work
44
FAULT DIAGNOSIS
Fault Possible Causes Remedy / Check
l Valve works properly l Broken air tube l Replace the O-ring sealbut suddenly fails l Plunged blocked by dirt l Check air tubes and replace
as required
l Cylinder jerks when l Air in the system l Bleed the pump by slightlyextending opening the adapters from
the pressure hose
l Cylinder raises l Pump defective l Replace pumpvery slowly l Too low air pressure l Check air pressure, check
air control, air tubes andtipping valve as describedbefore
l Cylinder does not l Relief valve is opening, l Check the pressure at whichextend fully by returning the oil tank, the relief valve is opening by
caused by too much load connecting a pressure gaugeor all the load too far to the serial port.forward in the body If this pressure is not being
obtained then contact Hyvaauthorised service centre
l Oil level in tank too low l Top up the tank
l Body comes down l The lowering speed l Extended the cylinder fully,too fast adjuster screw is worn out Put cab control in ‘HOLD’
position. Adjust the screwin position as far as possible.Move cab control to ‘LOWER’;unscrew the adjuster untilthe body descends atcorrect speed.
l Valve selector shaft l The selector shaft is l Loose three fixing bolts bydoes not move even sticking or stopped half a turn and try to switchwith sufficient air the valve again. The torquepressure of the bolts should not
exceed 15 NM’.
l Cylinder does not l Air in the system l Bleed the system, check oilextend smoothly level in tank
l Pump is performing l Replace pumpirregularly
l Excessive oil temp. l Check for increase in l Clean the filter cartridge(> 60OC) system pressure
l Check relief valve l Replace the cartridge ifcartridge for dirt or free necessary.
45
GREASING LAYOUT
46
GREASING POINTS
1 Cylinder Mounting BracketGreasing - Weekly
2 Piston Eye Greasing - Weekly
3 Rear Hinge greasing - 2 Points- Weekly (Mining Trucks-Daily)
4 Tail Door Locking Mechanismgreasing - 3 Points. Weekly
47
GREASING POINTS
5 Tail Door Hinge - 2 Points -Weekly
6 Body Prop - Weekly
7 Hyfix Assy. Greasing - 1 point- Weekly
8 Stabiliser Assy. Greasing - 6.Points - Weekly (All RockBodies on Mining Trucks)
48
Material Kg / Cu. M. Material Kg/Cu. M.
Ashes and cinders (wet) 1015-1330 Gravel and sand (dry) 1460-1728
Ashes and cinders (dry) 780-1030 Lime paste 1150-2000
Asphalt (pitch) 2128 Lime Powder 500
Asphalt (massive) 2394 Limestone burnt 775-1000
Asphalt (tar) 1878-2510 Marl 2300-2600
Barley in bulk 1729-1928 Molding sand 1446-1596
Bone meal 700-1100 Oats 415-515
Brick (loose) 1263-1662 Ore 2095-2560
Brick (stacked) 1480-1995 Potatoes 650-700
Brick (general) 630 Pebbles 1350-2000
Cement (loose) 1446 Rubble (broken stone) 1530-1730
Cement (natural) 897 Sand (wet) 1660
Clay (wet) 1760 Sand (dry) 1330
Clay (dy) 1015 Slag and cinders 1263-1660
Coal (anthracite) 897 Snow 80-800
Coke Grit 400-548 Stone (broken, coarse) 1662
Coke 360-615 Stone (broken, fine) 1197-1462
Concrete (wet) 2377 Stone (Grinded) 1600
Concrete (dry) 1240 Sugar in bulk 797-880
Corn and rye 765 Sulpher 1930-2070
Earth (wet) 1600-1800 Super phospate 1000-1200
Earth (dry) 1200 Town refuse 498
Fertilizer 1030 Wheat 765
Flour of corn 400-500 Wood chips 200
Flour 600-731 Wooden logs deal 320
Garbage 680 Wooden logs oak 420
Gravel 1680 Wooden logs beech 400
Gravel and sand (wet) 1928 Woodwool 50
APRROX. SPECIFIC DENSITIES
SPECIFIC DENSITIES
49
Material Kg / Cu. M. Material Kg/Cu. M.
Ashes, dry 33 Earth, loose 28
Ashes, damp 36 Gravel 40
Ashes, wet 30 Ore, fine 37
Asphalt 45 Ore, dry 30
Brick 40 Pebbles 40
Cinders, dry 33 Refuse 30
Cinders, wet 31 Rubbish, broken stone 45
Cinders and clay 30 Sand, dry 35
Coal 30 Sand, damp 40
Coke 23 Stone, grinded 30
Compost 50 Stone, broken 27
Concrete 30
Minimum required angle of tip :
TIPPING ANGLE
WA
RR
AN
TY
GU
IDE
LIN
ES
Sr.
Co
mp
on
ent
Typ
e o
fR
easo
nA
ctio
nR
emar
ks#
Des
crip
tio
nfa
ilure
1T
ippi
ngC
ylin
der
bent
lT
ippi
ng
on u
neve
n gr
ound
.W
arra
nty
N.A
.
Cyl
inde
rl
Run
ning
of v
ehic
le b
y ke
epin
gW
arra
nty
N.A
.bo
dy in
tipp
ing
con
ditio
n
lV
ehic
le
topp
ling
in
an
acci
dent
War
rant
y N
.A.
Cyl
inde
rl
Tip
ping
Val
ve s
et p
ress
ure
War
rant
y N
.A.
Bul
geis
ta
mpe
red
.
lP
ress
ure
relie
f va
lve
isW
arra
nty
appl
icab
leIf
Mai
nten
ance
sc
hedu
les
are
follo
wed
.m
alfu
nctio
ning
.
lS
ticky
sp
ool o
f tip
ping
va
lve.
War
rant
y ap
plic
able
If M
aint
enan
ce
sche
dule
s ar
e fo
llow
ed
lLo
wer
ing
ope
ratio
n
is
too
fast
.W
arra
nty
N.A
.
lC
hoke
d fi
lter
War
rant
y N
.A.
Cyl
inde
rl
Sco
ring
on
sta
ges
due
to
War
rant
y ap
plic
able
If m
aint
enan
ce s
ched
ules
ar
e fo
llow
edS
corin
gsl
ider
chi
p of
f.an
d co
rrec
t gr
ade
of o
il is
use
d.
lS
corin
g in
th
e a
xis
of
War
rant
y N
.A.
trun
ion
due
to
side
lo
ad .
lS
corin
g d
ue
to
stop
rin
gW
arra
nty
appl
icab
leP
rovi
ded
cor
rect
gr
ade
of o
il is
use
ddi
sloc
atio
n an
d gr
oove
def
orm
atio
n.&
Mai
nten
ance
sch
edul
es
are
follo
wed
.
lW
eldi
ng s
patte
r a
nd
spar
k ju
mpi
ngW
arra
nty
N.A
.du
e to
ea
rthi
ng
thro
ugh
cylin
der.
War
rant
y N
.A. =
War
rant
y N
ot a
pplic
able
50
WA
RR
AN
TY
GU
IDE
LIN
ES
(C
on
td..)
Sr.
Co
mp
on
ent
Typ
e o
fR
easo
nA
ctio
nR
emar
ks#
Des
crip
tio
nfa
ilure
Oil
leak
ages
lW
rong
fit
men
t of
se
alW
arra
nty
appl
icab
lefr
om s
tage
sl
Exc
ess
Load
War
rant
y N
.A.
lB
ody
exte
nsio
nW
arra
nty
N.A
.
lO
pera
tiona
l abu
seW
arra
nty
N.A
.U
nau
tho
rize
d b
od
y ex
ten
sio
n w
ill
lH
igh
Oil
Tem
pera
ture
due
to m
ore
War
rant
y N
.A.
wai
ve-o
ff
all t
ypes
of
war
ran
ty
num
ber
of t
ippi
ngs.
clai
ms.
lH
igh
Oil
tem
pera
ture
du
e to
War
rant
y N
.A.
con
tinuo
us P
TO
eng
agem
ent.
lC
onta
min
ated
oi
l.W
arra
nty
N.A
.
lW
eldi
ng
spat
ter
on
seal
War
rant
y N
.A.
runn
ing
are
a.
Oil
leak
age
lP
oor
qual
ity s
eal
War
rant
y ap
plic
able
from
cy
linde
rl
Wro
ng
fitm
ent
of s
eal
War
rant
y ap
plic
able
botto
m
plat
e·
·P
isto
n co
min
g·l
Jerk
y o
pera
tion
by
pus
hing
War
rant
y N
.A.
out
back
war
d af
ter
unlo
adin
g.
Pis
ton
Eye
lP
oor
lock
ing
arr
ange
men
tW
arra
nty
appl
icab
leco
min
g ou
t·
Cyl
inde
r ba
sel
Cra
ck i
s on
tru
nion
sid
e d
ueW
arra
nty
N.A
.tu
be c
rack
·to
sid
e lo
ads.
·l
Cra
ck
is
on a
ll a
roun
d tr
unio
n.W
arra
nty
appl
icab
le
Cyl
inde
r S
tuck
lS
lider
s o
ver
ridin
gW
arra
nty
appl
icab
le
War
rant
y N
.A. =
War
rant
y N
ot a
pplic
able
51
Sr.
Co
mp
on
ent
Typ
e o
fR
easo
nA
ctio
nR
emar
ks#
Des
crip
tio
nfa
ilure
2T
ippi
ng V
alve
Oil
leak
age
lS
eal
failu
re d
ue
to
wro
ng
fitm
ent.
War
rant
y ap
plic
able
Mal
func
tioni
ngl
Stic
ky s
pool
War
rant
y ap
plic
able
Pro
vide
d m
aint
enan
ce s
ched
ules
are
of v
alve
follo
wed
.
Hig
h op
erat
ing
lP
ress
ure
rel
ief
valv
e ta
mpe
red.
War
rant
y N
.A.
pre
ssur
e.
Wor
king
lLo
w s
yste
m p
ress
ure
as
relie
fW
arra
nty
appl
icab
lepr
essu
re is
valv
e m
al fu
nctio
ning
too
low
.·
3H
ydra
ulic
Pum
p fa
ilsl
Rel
ief v
alve
se
t pre
ssur
e is
ta
mpe
red.
War
rant
y N
.A.
pum
pl
No
hydr
aulic
oil
in th
e ta
nkW
arra
nty
N.A
.
lP
ump
ope
rate
d w
ithou
t ope
ning
War
rant
y N
.A.
ball
valv
e.
lE
xter
nal
dam
age
due
to h
it b
yW
arra
nty
N.A
.ex
tern
al
obje
ct.
lC
orre
ct
grad
e of
oi
l is
no
t us
ed .
War
rant
y N
.A.
lT
hrus
t pla
te &
hou
sing
wea
r ou
t du
eW
arra
nty
N.A
.to
ex
cess
rav
ing
of
engi
ne r
pm.
Pum
p le
akag
el
Pum
p r
ever
sing
pro
cedu
re n
ot fo
llow
edW
arra
nty
N.A
.
lO
il c
onta
min
atio
n le
vels
ar
e h
igh
War
rant
y N
.A.
Pum
p d
rive
lM
anuf
actu
ring
def
ect
War
rant
y ap
plic
able
shaf
t br
oken
lS
yste
m
pres
sure
re
lief
is ta
mpe
red.
War
rant
y N
.A.
lE
ntry
of
fore
ign
par
ticle
s.W
arra
nty
N.A
.
War
rant
y N
.A. =
War
rant
y N
ot a
pplic
able
WA
RR
AN
TY
GU
IDE
LIN
ES
52
Sr.
Co
mp
on
ent
Typ
e o
fR
easo
nA
ctio
nR
emar
ks#
Des
crip
tio
nfa
ilure
Thr
ust p
late
&w
ear
out
4T
ippe
rS
ub f
ram
el
Cra
ck d
evel
op
due
to n
ot
tight
enin
gW
arra
nty
N.A
.su
b-fr
ame
crac
km
ount
ing
bol
ts.
lC
rack
due
to im
prop
er lo
adin
g pa
ttern
.W
arra
nty
N.A
.
lC
rack
dev
elop
s ne
ar w
eldi
ng j
oint
sW
arra
nty
N.A
.un
der
nor
mal
w
orki
ng
cond
ition
s.
lC
rack
s d
ue t
o a
ccid
ent
to v
ehic
leW
arra
nty
N.A
.
Sub
fra
me
·l
Tw
ist i
s d
ue
to
acci
dent
War
rant
y N
.A.
tw
iste
d
5H
ydra
ulic
Oil
leak
age
lLe
akag
e fr
om c
rimpi
ngW
arra
nty
appl
icab
le
Hos
esl
Bur
st a
ge o
f ho
se.
War
rant
y ap
plic
able
lT
wis
ting
due
to
wro
ng fi
tmen
tW
arra
nty
N.A
.
l·E
xter
nal d
amag
e d
ue
toW
arra
nty
N.A
.ru
bbin
g /
hitti
ng
No
te:
War
ran
ty
is
no
t a
pp
licab
le
un
der
fo
llow
ing
co
nd
itio
ns.
1.W
ron
g a
pp
licat
ion
/ u
sag
e o
f ti
pp
er.
2. U
nau
tho
rize
d b
od
y ex
ten
sio
n.
3.A
bu
sive
op
erat
ing
pra
ctic
es.
4.N
ot
follo
win
g r
eco
mm
end
ed m
ain
ten
ance
sch
edu
les
.
War
rant
y N
.A. =
War
rant
y N
ot a
pplic
able
WA
RR
AN
TY
GU
IDE
LIN
ES
(C
on
td..)
53
Dat
e P
arti
cula
rs o
f Rep
air
Hyv
a au
tho
rise
dR
epre
sen
tati
ve S
ign
.
Rec
ord
of
Ser
vice
/ R
epai
rs p
erfo
rmed
54
Dat
e P
arti
cula
rs o
f Rep
air
Hyv
a au
tho
rise
dR
epre
sen
tati
ve S
ign
.
Rec
ord
of
Ser
vice
/ R
epai
rs p
erfo
rmed
55
56
Model .......................................................................................................................................
Chassis No. ..............................................................................................................................
Body Type ..............................................................................................................................
Body Sr. No. ............................................................................................................................
Date of sale ............................................................................................................................
Owner’s name .......................................................................................................................
Address ....................................................................................................................................
....................................................................................................................................................
....................................................................................................................................................
VEHICLE PARTICULARS