Ounting Nstructions: F.L.A.S.H. F - C

MOUNTING INSTRUCTIONS
F.L.A.S.H.
FRONT-END CYLINDER
www.hyva.com
F.L.A.S.H. FRONT-END CYLINDER
Table of contents
1. Introduction ........................................................................................................................................ 2
1.1. Scope of use ................................................................................................................................... 2
1.2. General remarks .............................................................................................................................. 2
1.3. Contact Hyva ................................................................................................................................... 2
1.4. Precautions ..................................................................................................................................... 3
2. Mounting Instructions ........................................................................................................................ 4
2.1. General ............................................................................................................................................ 4
2.1.1. Components .................................................................................................................................. 4
2.1.2. Mounting position and clearances ................................................................................................. 5
2.2. Cross member mounting of the cylinder .......................................................................................... 6
2.2.1. Cross members ............................................................................................................................. 6
2.2.2. Mounting the chassis brackets into the cross members ................................................................ 6
2.3. Cradle mounting of the cylinder ....................................................................................................... 7
2.3.1. Mounting the cradle on a sub frame .............................................................................................. 7
2.3.2. Mounting the cradle when no sub frame is used ........................................................................... 7
2.3.3. Mounting the chassis brackets into the cradle ............................................................................... 9
2.4. Mounting FEE cylinder at bottom .................................................................................................. 10
2.5. Fixing the cylinder into the chassis brackets ................................................................................. 11
2.6. Attaching the cylinder to the tipper body ....................................................................................... 12
2.6.1. FC cylinder ................................................................................................................................... 12
2.6.2. FE/FEE cylinder ........................................................................................................................... 14
2.7. Connecting and testing the cylinder .............................................................................................. 15
2.7.1. Connection of the hydraulic system ............................................................................................. 15
2.7.2. Final Checks ................................................................................................................................ 16
2.8. Painting the cylinder ...................................................................................................................... 16
3. Tables.............................................................................................................................................. 17
3.1. Table 1: Bolt and nut specifications ............................................................................................... 17
3.2. Table 2: Recommended Cross Member Profiles and Dimensions ................................................ 17
Page 1
Subject to change without notice
OH-E CYL-0017 / 13-09-09 / RV AF
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 is
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.
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.
For information and recommendations on hydraulic oils see Hyva document OIL-0002.
1.3. Contact Hyva

If you have any questions concerning the application, installation, operation or repair of any Hyva product
- please contact your nearest Hyva Service Partner and check the Hyva website (both for documentation
as for service partner coordinates):
www.hyva.com
Page 2
OH-E CYL-0017 / 13-09-09 / RV AF
1.4. 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 can cause serious injury and
death.
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 oil inlet). Extend the cylinder until the sling is locked and
transport the cylinder using a suitable lifting device (see chapter 2.5).
Warning
Not using the appropriate equipment when lifting parts (such as the
proper sling for a cylinder) body can cause serious injury and death.
Ensure any oil, spilt during installation and testing, is disposed of in an environmental friendly way.
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OH-E CYL-0017 / 13-09-09 / RV AF
2. Mounting Instructions
2.1. General
2.1.1. Components
The basic components of the Hyva front end cylinders are as shown in Figure 1:
Cylinder FEE type

Cylinder FE type
2 2
1
1
Cylinder FC type
3
3
1
4
5
4
3 24
5
6
7
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 4
OH-E CYL-0017 / 13-09-09 / RV AF
2.1.2. Mounting position and clearances

Select the correct tipping gear with help of the Hyva Tipper Program.
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.
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.
Cylinder must be mounted in the exact centre line of the body. Cylinder must be mounted exactly vertical,
looking to the body front.
max. 20° max. 10°
centred and level
The maximum build in angle for FC cylinders, looking to
the body side, depends on the cover length. As a rule
of thumb:
 cylinders with long cover length (small closed
length) can be build in up to 10°
 cylinders with short cover length (big closed
et)
length) can be build in up to 20°
icatio covers
n she
For more detailed information see cylinder specification
r
der s hort oute
sheet.
pecif
The maximum built in angle for FE/FEE cylinders is 30°

(see 20° for s
from the vertical plane.

cylin
max
(standard)
When mounted under an angle, the FC cylinder swings
343
back towards the body front during the tipping cycle.
Care should be taken that the cylinder stays free from
it.
When cylinder angle is zero degrees, a welding rubber (part no. 092.12.016) is advised to reduce
rattling/movement of the cover. See also RUB-0001. When cylinder is under an angle, it may not be used.
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 50 mm 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 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).
Where a ‘knock-off’ or other end of stroke device is to be used remember to
allow 150mm of stroke for front-end cylinders to activate the device.
Page 5
OH-E CYL-0017 / 13-09-09 / RV AF
2.2. Cross member mounting of the cylinder

Outside
2.2.1. Cross members Cylinder
See the bracket specification sheet, 015BRA01, for the minimum side
distance between the support cross members. Allow free distance for
rotation of the cylinder during tipping (cylinder rotation is approximately
half the tipping angle).
Cross members for the chassis brackets, must be of sufficient cross

section to withstand the cylinder load. See truck manufacturer
bodybuilders guide and table 2 for recommended cross member profiles Outside
and dimensions. FIGURE 2
Make sure the brackets are not mounted inside out, see Figure 2 for
correct position. The brackets must have a sliding fit between the cross members.
2.2.2. Mounting the chassis brackets into the cross members

See the bracket specification sheet, 015BRA01, for the correct position of bracket bolt holes. Drill these
holes in the cross members.
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 BRACKETS 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 cylinder specification sheet for details.
For next steps see section 2.5.
Notes:
- Standard brackets are equipped with maintenance free bearings
- Bracket lips are mounting guides only and not designed as structural members
Page 6
OH-E CYL-0017 / 13-09-09 / RV AF
2.3. Cradle mounting of the cylinder
2.3.1. Mounting the cradle on a sub frame
Fabricate and mount the sub frame according to the truck manufacturer body builder guidelines. Weld or
bolt the cradle rigid to the sub frame. Use welds with a6 minimum.
Welds a6
FIGURE 4
2.3.2. Mounting the cradle when no sub frame is used
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 5
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.
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OH-E CYL-0017 / 13-09-09 / RV AF
Bolt the attachment plates to the chassis (see Figure 6). 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 7)

Fully weld the cradle, attachment plates and cradle.
Ensure the attachment plate is welded the full width of the underside of
the cradle.
Warning FIGURE 6
Disconnect the battery leads before welding.

If the cradle is to be removable, we recommend the cradle be fixed as
shown in Figure 8.
FIGURE 7
FIGURE 8
Page 8
OH-E CYL-0017 / 13-09-09 / RV AF
2.3.3. Mounting the chassis brackets into the cradle

Use the pre-drilled holes in the cradle when mounting the chassis brackets. Use the bracket specification
sheet to determine the correct holes (see 015BRA01).
Position one of the chassis brackets, hand-tighten the required bolts, self-locking nuts and washers, see
Figure 9 for position and orientation of chassis brackets.
FIGURE 9: MOUNTING THE BRACKETS INTO THE CRADLE
For next steps see section 2.5.
Notes:
- Standard brackets are equipped with maintenance free bearings
- Bracket lips are mounting guides only and not designed as structural members
Page 9
OH-E CYL-0017 / 13-09-09 / RV AF
2.4. Mounting FEE cylinder at bottom

In general mount the pin through the trunnion hole, see Figure 10.
- Pin diameter should be equal to N [-0/-2], where N is the trunnion bush internal diameter as indicated
on the cylinder specification sheet
- Pin material: S355JR (St.52-3), C45K, C60K or equivalent material with a minimal yield
stress of 330 N/mm2.
- Pin must be secured in the mountings to prevent axial movement and rotation of the pin. Cylinder must
rotate and not pin itself.
- Clearance between base trunnion and mountings is maximum 1 mm per side.
- Referring to the FEE specification sheet for your cylinder model, the required clearance beneath the
cylinder is indicated by dimension S
FIGURE 10
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OH-E CYL-0017 / 13-09-09 / RV AF
2.5. Fixing the cylinder into the chassis brackets

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 11.
(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.
Figure 12 shows how a sling can be used for FC cylinder: first

wrap the sling around the base below oil inlet, then wrap the sling
around the cover.
Warning
FIGURE 11
Not using proper slings body can cause
serious injury and death.
Remove the protective caps from the cover. Lightly grease the pins to protect
against corrosion. Following grease types can be used:
 Hyva packset grease
 Molykote G-4500
 Molykote EM-30L
 Dinitrol Paste
Position one of the cylinder pins into the pre-placed chassis bracket (see
Figure 3 or Figure 9 ). Make sure the oil inlet is facing the right direction for
FIGURE 12
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 9.). Be aware of the 1 mm maximum clearance between cylinder and bracket per side. 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 serious injuries to persons and / 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 11). Remove the sling.
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.
Page 11
OH-E CYL-0017 / 13-09-09 / RV AF
2.6. Attaching the cylinder to the tipper body

It is advised to stay as close as possible to the build-in dimension on cylinder specification sheet to have a
pull-out of 20 mm.
2.6.1. FC cylinder
Always apply a rigid lifting plate or (reinforced) profile for mounting the lifting brackets. A too flexible plate
or profile may result in the cylinder coming out of the lifting brackets, see Figure 13.
FIGURE 13
Use all bolt holes of the brackets for mounting. Use quality 8.8 bolts with self locking nuts and flat washers
over the slotted hole in the bracket.
In case tipping weight exceeds 50 ton, bolts should be positioned in the corners of the slotted holes and
stoppers should be positioned above the lifting bracket, see Figure 14, Figure , Figure 15.
bolts in one side of slotted holes

when tipping weight is above 50 tons
FIGURE 14 FIGURE 15
Do not mount lifting brackets upside down in case

tipping weight exceeds 50 ton.
FIGURE 15
Page 12
OH-E CYL-0017 / 13-09-09 / RV AF
Remove the protective caps from the cover. Lightly grease the pins to
protect against corrosion. Following grease types can be used: Outside
 Hyva packset grease
 Molykote G-4500
Cylinder
side
 Molykote EM-30L
 Dinitrol Paste
Place the lifting brackets on the cover pins and attach them to the
tipping body. Make sure the brackets are not mounted inside out, see
Figure 16 for correct position.
Outside
Ensure the lifting brackets are in the correct position and orientation FIGURE 16
with a maximum of 1 mm clearance between the cover and brackets
per side.
The nuts and washers should be on the bracket flanges, if there is not enough space they may be
reversed, see Figure 17.
Tighten all bolts securely (see Table 1 for required torque).
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 piston or cover.
For sequence see section 0.
When cylinder angle is zero degrees, a welding rubber (part no.

092.12.016) is advised to reduce rattling/movement of the cover. See
also RUB-0001. When cylinder is under an angle, it may not be used.
FIGURE 17
Page 13
OH-E CYL-0017 / 13-09-09 / RV AF
2.6.2. FE/FEE cylinder

Attach the piston eye to the tipping body (see Figure 18). In general fit the pivot pin and secure it.
FE cylinders with spherical top-eye must be

mounted with filler rings (spacers) on both sides of
the eye to allow 6° of rotation to both sides. 30° max
Make sure that the eye rotates free from the
bracket. Some critical dimensions are:
 Preferred spacer width is 14,5 mm; minimum
spacer width is 12 mm
 Internal bracket width should be minimal 68 spacer ring
mm
 Internal bracket height from centreline pin to 14.5 mm wide
top flange should be minimal 65 (or 75 for
piston 129 and bigger)
 See drawing D072013 for more details.
Make sure pin cannot rotate in top bracket.

FIGURE 18
Separate top brackets are available, see bracket specification sheet 015BRA01 for more details.
Top bracket must be mounted under the canopy. Mounting angle with horizontal must be between 0 and
30 degrees maximum.
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.
For sequence see section 0.
Page 14
OH-E CYL-0017 / 13-09-09 / RV AF
Connecting and testing the cylinder
2.6.3. 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 19). Ensure the hose lengths are sufficient so they do not obstruct the movement of the cylinder
while tipping
FIGURE 19: EXAMPLE OF A HYDRAULIC SYSTEM
Tip
Test oil may leak from the cylinder when the plug is removed.
Page 15
OH-E CYL-0017 / 13-09-09 / RV AF
2.6.4. 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.
Cylinder stages should extend in right sequence: largest (first stage) extends first, then second stage etc.
With a new cylinder, a light empty body and high pump flow however, stages can extend in wrong
sequence (mismatching). But this will disappear in normal operation (loaded body).
2.7. Painting the cylinder

When painting the body, do not repaint the blank parts of cylinder e.g. trunnion pins, piston, stages,
wipers, bearings.
Page 16
OH-E CYL-0017 / 13-09-09 / RV AF
3. Tables
3.1. Table 1: Bolt and nut specifications
Size DIN Minimum Torque
Bolt Nut Quality
M12 960 / 961 985 8.8 80 Nm
M16 960 / 961 985 8.8 210 Nm
M48 - 985 8.8 600-800 Nm

TABLE 1: BOLT AND NUT SPECIFICATIONS
3.2. Table 2: Recommended Cross Member Profiles and Dimensions
Tipping Weight (ton) Minimum Wxx Hot Rolled UNP Cold Rolled U Box Profile
3
(cm ) (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 17
OH-E CYL-0017 / 13-09-09 / RV AF

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MOUNTING INSTRUCTIONS

1.2. General remarks

Applying side-load to any cylinder is dangerous.

1.3. Contact Hyva

Cylinder FEE type

2.1.2. Mounting position and clearances

The maximum built in angle for FE/FEE cylinders is 30°

from the vertical plane.

Additional factors that may affect the mounting position:

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

2.2. Cross member mounting of the cylinder

Cross members for the chassis brackets, must be of sufficient cross

2.2.2. Mounting the chassis brackets into the cross members

FIGURE 3: MOUNTING THE BRACKETS INTO THE SUB-FRAME

For next steps see section 2.5.

2.3. Cradle mounting of the cylinder

2.3.1. Mounting the cradle on a sub frame

2.3.2. Mounting the cradle when no sub frame is used

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 7)

Disconnect the battery leads before welding.

2.3.3. Mounting the chassis brackets into the cradle

FIGURE 9: MOUNTING THE BRACKETS INTO THE CRADLE

For next steps see section 2.5.

2.4. Mounting FEE cylinder at bottom

- Clearance between base trunnion and mountings is maximum 1 mm per side.

2.5. Fixing the cylinder into the chassis brackets

Figure 12 shows how a sling can be used for FC cylinder: first

2.6. Attaching the cylinder to the tipper body

bolts in one side of slotted holes

Do not mount lifting brackets upside down in case

Tighten all bolts securely (see Table 1 for required torque).

When cylinder angle is zero degrees, a welding rubber (part no.

2.6.2. FE/FEE cylinder

FE cylinders with spherical top-eye must be

Make sure pin cannot rotate in top bracket.

For sequence see section 0.

Connecting and testing the cylinder

2.6.3. Connection of the hydraulic system

FIGURE 19: EXAMPLE OF A HYDRAULIC SYSTEM

2.6.4. Final Checks

2.7. Painting the cylinder

Size DIN Minimum Torque

Bolt Nut Quality

M12 960 / 961 985 8.8 80 Nm

M16 960 / 961 985 8.8 210 Nm

M48 - 985 8.8 600-800 Nm

3.2. Table 2: Recommended Cross Member Profiles and Dimensions

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

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