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OPERATION AND 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 to change without notice. The details given are guidlines and are for illustration purpose only.)

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OPERATION AND MAINTENANCE MANUAL(The contents given in this manual are not binding and are subject to change without notice. The details given are guidlines and are for illustration purpose only.)

HYVA INDIA PVT. LTD. Plot No. EL-215, MIDC, MAHAPE, Navi Mumbai - 400 701

FOREWORD

Dear Customer, This manual outlines the maintenance and operating practices of Hyva Tipping System fitted on your vehicle. The purpose of this manual is to assist you in maintaining the system and get maximum life out of components. This is also to educate you in good operating practices and safety of equipment at all times. Overall it helps you to obtain better performance at optimum operating costs. All service and maintenance tasks are to be carried out at the specified intervals. This manual briefs about the system and components for your understanding and knowledge. Fault diagnosis at the end helps you in diagnosing the problem in a systematic manner. Some of the items/accessories/features given in this book may not be fitted on your vehicle, but they are applicable to other versions.

Hyva India Pvt. Limited Mumbai

60

INDEX

l l l l l l

Safety Periodic Check List Recommended Replacement Period for Consumables Recommended Hydraulic Oil Specification Tipper Operation Instruction Major Operating Partsl l l l l l l l l l l

1 5 6 6 7

HYVA P.T.O HYVA Gear Pump HYVA Tipping Valve Air Control for P.T.O / Valve Tank Return Line Filter Air Breather Filter Cylinder Nomenclature Tipper Model and Cylinder Cylinder Repair Instructions Hyfix Body Clamp Hydraulic Hose Orientation

11 17 22 23 24 25 26 27 30 40 42 43 45 48

l l l

Fault Diagnosis Greasing Layout Specific Densities

61

blank page

SAFETYIMPORTANT SAFETY NOTICE Proper service and repair is extremely important for the safe operation of your machine. The service and repair technique recommended by HYVA and described in this manual are both effective and safe methods of operation. Some of these operations require the use of tools specially designed by HYVA for the purpose. SAFETY GENERAL PRECAUTIONS Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine. 1 Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine. 2 When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. l Always wear safety glasses when hitting parts with a hammer. l Always wear safety glasses when grinding parts with a grinder, etc. 3 If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operators compartment. Keep all tools in good condition and learn the correct way to use them. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

4

5

6

PREPARATIONS FOR WORK 7 Before adding oil or making any repairs, park the machine on hard, level 1

SAFETYground, and block the wheels or tracks to prevent the machine from moving. 8 Before starting work, rest dump body on prop and hang UNDER REPAIR board on them. 9 When disassembling or assembling, support the machine with blocks, jacks or stands before starting work. 10 Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. PRECAUTIONS DURING WORK 11 When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil and air circuits, first remove the pressure completely from the circuit. 12 The oil in the circuits is hot when the engine is stopped, so be careful not to get burnt. Wait for the oil to cool before carrying out any work on the oil circuits. Before starting work, remove the leads from the battery. Always remove the lead from the negative (-) terminal first. When raising heavy components, use a hoist or crane. Check that the wire rope, chains and hooks are free from damage. Always use lifting equipment which has ample capacity. Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.

13

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15

2

SAFETY16 When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires. When removing piping, stop the oil from spilling out. If any oil drips on the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires. As a general rule, do not use gasoline to wash parts. In particular, use only the minimum of gasoline when washing electrical parts. Be sure to assemble all parts again in their original places. Replace any damaged parts with new parts. l When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is being operated. When installing high pressure hoses, make sure that they are not twisted. Damaged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. Also, check that connecting parts are correctly installed. 21 When assembling or installing parts, always use the specified tightening torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speed, be particularly careful to check that they are installed correctly. When aligning two holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. When measuring hydraulic pressure, check that the measuring tool is correctly assembled before taking any measurements. While carrying out welding on tipper, earthing should be done nearer to the welding spot. Earthing should not be done through cylinder and other hydraulic components, to avoid damage due to sparking. While carrying out welding on head board / load body, the tipping cylinder and other hydraulic components should be covered with fireresistant cover so that welding spatters will not damage stages and seals.

17

22

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23

19

24

20

25

3

SAFE PRACTICESDos Donts

OVER LOAD

LOAD UNEVEN

TIP ON UNEVEN GROUND

STAY UNDER AN UNSUPPORTED BODY

STAY IN THE WORKING AREA OF THE TIPPER

DRIVE WITH RAISED BODY

TIP WITH TRAILER IN AN ANGLE TO THE TRUCK

4

PERIODIC CHECKLISTDAILY CHECK LIST (BEFORE STARTING THE TRUCK)l

Check the Oil level in the Oil Tank. Oil level has to be in the middle of the sight glass or level Indicator, while the body in resting on the subframe. Make visual inspection of Hydraulic System i.e. P.T.O., Pump, Tank, Valve, Hoses and Couplings for leakages. Check all Pneumatic and Hydraulic connections for slackness. Care should be taken while tightening Pivot Mounting Bolt, so that Pivot Spring doeS not get compressed completely and there is minimum gap equivalent to thickness of a Hacksaw Blade so that this Spring can offer required compression under load.

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PERIODIC CHECKLIST - WEEKLYl

Breather Element must be cleaned once in a week with compressed air only. Lubricate all greasing points on the tipper. (Cylinder Eye End, Stabilizer, Body Prop, Rear Hinge Shaft - Refer Greasing Layout) Check Gearbox Oil level. Check Pivot bracket bolts, Attachment bolts (80 NM) and Cylinder Cradle Mounting Brackets Bolts, Pump Mounting Bolts and tighten if necessary. Tightening Torque for Cylinder Mounting Bracket Bolts is 200NM.

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5

RECOMMENDED REPLACEMENT

Sl. No. 1

Description of Items Air Breather Filter Element

Replacement Periods Once in every 4 months in normal working condition. (Non Mining application) Once in every 2 months in dusty working condition. (Mining application)

2

Return Line Filter Element

Once in every 4 months in normal working condition. (Non-Mining application) Once in every 2 months in dusty working condition. (Mining application)

3

Hydraulic Oil

First change after 6 months and later once in every year.

Note : Please note, over and above the schedule, Filter and Breather elements need to be replaced whenever the hydraulic oil is replaced. RECOMMENDED HYDRAULIC OIL We recommend Super-clean anti-wear, oxidation stable and rust preventive Hydraulic oil conforming the characteristics according to BIS11656-86 and DIN 51524/2 (Viscosity grade - 68) Make B.P. H.P Castrol ELF IOC Brand & Type Hydrol 68 Enklo 68 Castrol WH 15 Elforia DS 68 SERVO System HLP 68 Working Temperature From To - 5OC - 5OC - 5OC - 5OC - 5OC 50OC 50OC 50OC 50OC 50OC

6

OPERATION INSTRUCTIONSBefore putting your vehicle into operation, it is necessary to familiarize yourself thoroughly with the mode of the operation and function of the tipper. LOADING l Body must be uniformly loaded. l Please load as per the specification chart provided in order to ensure longer life and safer operation. l Ensure proper loading or hopping process in order to avoid undue impact load on vehicle. TIPPING l 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 upto 7 kg/cm2, then press the clutch pedal and engage the PTO slowly using air control valve lever inside the cabin l In case of vehicle with tail gate system, ensure that the safety lock pin is removed & stowed in open position from the tail door locking mechanism. l Do not attempt to tip the body without ensuring that mechanical lock pin is removed from the tail door locking mechanism. Otherwise this will damage the locking mechanism. l Start tipping by using the air control inside the cabin. LOWERING l 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 chassis or sub-frames underneath the body. l Please remember, incorrect operational practice may be fatal to the vehicle 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. 7

HYDRAULIC TIPPING SYSTEMHyva Tipping System comprises of following hydraulic components to provide highest level of tipping efficiency.l l l l l l

HYDRAULIC TANK TIPPING VALVE AIR CONTROL VALVE GEAR PUMP POWER TAKE-OFF (PTO) HYDRAULIC CYLINDER - TIPPING CYLINDER

Return Line Filter Assly. Breather Assly. Cylinder Assly.

3DHMP Valve

Air Control Valve

PTO & Pump

HYVA Tipping Diagram

8

HYDRAULIC & PNEUMATIC CIRCUIT DIAGRAM WITH 3DHMP VALVE

HYDRAULIC & PNEUMATIC CIRCUIT DIAGRAM

9

10

HYDRAULIC & PNEUMATIC CIRCUIT DIAGRAM WITH PT VALVE

HYDRAULIC & PNEUMATIC CIRCUIT DIAGRAM

P.T.OP.T.O : A P.T.O (Power Take Off) is an auxillary gear box mounted on the transmission. Its function is to transmit the power from rotation of 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, always press the clutch pedal! WORKING TEMPERATURE AND LOAD CONDITIONS The temperature depends on the way the PTO is used and it is recommended 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 to reduce 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 is accurately checked. l When the PTO is rear mounted, considering to provide the PTO with a supplementary lubrication kit. IV. PTO Installation a. Side mounted PTO installation : l Empty or reduce the gearbox oil level, check cleanliness. If oil is dirty or contaminated it should be replaced. (Pict. 1) Notice : In some applications (for example automatic Allison Gearbox) it is not necessary to empty gearbox. Always check gearbox service manual. Picture. 1 11

P.T.Ol

Remove gearbox aperture cover and accurately clean the gearbox aperture surface (Pict. 2)

Picture. 2

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Check gearbox gear teeth and the gear backlash (Pict. 3) Open the PTO package. Use PTO specific mounting kit and if necessary spacers. Studs for mounting onto the gearbox : Accurately check that the holes in the gearbox are threaded. Be careful that studs do not interfere with gears.

Picture. 3

-

Fit the studs. (Pict. 4) shows a typical mounting example. Backlash check between gear tooth and spacer insertion: To get backlash of 0.15 + 0.4 mm, fit spacers between PTO and gearbox as necessary. Backlash checking can be carried out in two ways. Picture. 4 12

P.T.OIn case of PTOs equipped with inspection plug, check by hand, (rocking the gear to get the feel for gear backlash) or by means of a dial gauge (Pict. 5). The use of a dial gauge is recommended as it is much more accurate. - In case of PTOs without inspection plug, adjustment is carried out in stages. The PTO has to be checked against the transmission flange by adding spacers until there is no backlash. After that, another 0.5 mm spacer should be added and the nuts tightened. Recommendations on seal and spacer use. - Remember that once the nuts have been tightened, the seal thickness reduces, resulting in a similar backlash reduction. The backlash therefore has to be checked even after tightening. - Available seals (Pict. 6) have a thickness of 0.5 and 0.25 mm (special series). - When a spacer is fitted, use a gasket to ensure tightness (at least one on both sides). - In order to avoid the seals sticking to each other, use grease. NEVER use adhesive fluid when the PTO mounting kit requires special gasket. USE adhesive fluid only when the PTO mounting kit DOESNT involve any gasket.

Picture. 5 0.5 mm 0.25 mm

Picture. 6

Picture. 7 13

P.T.OOnce the suitable thickness has been determined, tighten the nuts with a torque wrench (see tightening torque table) Notice : Once the nuts have been tightened, the backlash has to be rechecked and if necessary the shiming operation may be repeated. When the installation operation has been completed, fill the gearbox with oil (Pict.7) Notice : In case of applications with separate lubrication (for example on Allison transmission) an external tube kit is needed to be fitted. After installing operations, proceed with the checks. b. Rear mounted PTO installation : l Empty or reduce the gearbox oil level, check cleanliness. If oil is dirty or contaminated it should be replaced. Notice : In some applications (for example automatic Allison gearbox) it is not necessary to empty gearbox. l Remove gearbox aperture cover and accurately clean the gearbox aperture surface (Pict. 8) l If a shaft kit is provided for the application, carefully read the relevant mounting instructions. l PTO mounting (see pict.9)

Picture. 8

Picture. 9

14

P.T.OThe typical way of mounting is shown in the picture. It is recommended to lock studs or bolts with locking fluid. (see tightening torque table) Notice : In case of a connection to an ISO flange pump: if the oil seal is fitted to the pump, then the pump must be fitted to the gearbox before filling with oil. When the fitting operation is complete, refill gearbox with oil (Pict.10) Notice : In case of application with separate lubrication, a supplementary lubrication kit should be fitted. When installation is completed, proceed with the checks (see After Installation checks on next page)

l

Picture. 10

l

c.

Mounting bolt torques : Thread M8 M10 M12 3/8 7/16 Studs (tightening on Gearbox) 10 NM 20 NM 30 NM 10 NM 20 NM Screw & Nuts 25 NM 50 NM 80 NM 25 NM 50 NM

15

P.T.OV. AFTER INSTALLATION CHECKS. : Once the installation phase is complete, the following checks are recommended. Engagement / disengagement check Performance soon after engine start. If a clash is heard, this may be due to one of the following: - Clutch not working properly - Theres no or insufficient air pressure. Carry out an oil check when the engine is still cold and top up if necessary. Check to be carrier out under all the working conditions, with PTO engaged, gearbox in neutral position. In case of a side mounted PTO, an excessive noise may mean a wrong backlash according the following: - High pitched noise; backlash is too tight Rattle noise; excessive backlash. Normally bolts tend to loosen because of the seal setting. It is recommended that all bolts and nuts are checked after a few hours of work checking the tightening by means of a torque wrench. With side mounted PTOs, recheck the backlash after tightening.

Oil level check

Oil Leak

Tightening bolts check

16

GEAR PUMPGear Pump specifications Displacement per revolution Maximum peak pressure Maximum intermittent pressure Maximum Continuous pressure Oil temperature range: Inlet pressure range: Hyva Gear Pump (if fitted) Hyva Gear pumps. Gear pump is a model with two gearwheels having external teeth. Normally we use Gear Pumps with one direction of rotation for following reasons.l

52 cc 51.88

87 cc 86.39

82 cc 81.29 cm3

230 Bar 230 Bar 230 Bar 230 Bar 230 Bar 220 Bar 230 Bar 230 Bar 190 Bar -25OC to -25OC to 110OC 110OC -25OC to 110OC

230 Bar 230 Bar 0.7-3 Bar (abs)

Higher maximum working pressure and efficiency compared to bidirectional pumps. As the required pressure range for the tippers application is not more than 170 bar. The direction of rotation can be changed in case if required. (The procedure for changing the direction is given on the next page).

l

We are using, 52.cc/82.cc/87.cc & 109.cc pumps with Hyva tipping system. Note: 82/ 87 denotes the displacement of oil in cc per rev i.e. 82.cc pump runs at 1000 rpm capacity will be 82 lts/min We recommend operating tipper application with correct Engine RPM as per PTO ratio of that particular housing and gears. Raving up the engine can lead to Pump failure or excessive wear and tear on the Pump. Mode. Usually it roughed from 1000 to 1200 engine rpm.

17

GEAR PUMPBasic principle of Gear Pump

One of the two gearwheels is driven from outside (Drive Gear) and drives the other gearwheel (Driven Gear). With the right hand rotation of the top gearwheel (consider fig.) oil is sucked from the LHS port (Pump suction). Oil trapped in between the gear teeth and the pump body travels along the periphery of the Pump body towards the RHS port (Pump delivery). As the teeth and the side of the gears are closely sealed against the Pump body and the Thrust Plates, pressure builds up against the resistance to the oil flow at the delivery port.

18

GEAR PUMPHyva Gear Pump (82 cc Black)

SL. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Pump body Front Cover Trust plate Drive Gear Driven gear Roller Bearing Screw Grub screw Washer Lock washer O Ring Seal Shaft Seal (42x55x7) Circlip

Qty. 1 1 2 1 1 2 8 1 8 1 1 2 1 1

SL. Description 15 16 17 18 19 20 22 23 24 25 26 27 28 29 Circlip S1372 Back Up Ring Mounting Ring Sleeve Bearing Spacer Ring

Qty. 1 2 1 4 1 1 1 1 4 1 1 1 1 1 19

Threaded Locking Ring O Ring Support Shaft Steel Brush protection Ring Circlip Support Ring Shaft Seal (24 x 40 9) Roller Bearing 32007

GEAR PUMPHYVA 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 and replace, 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 and anti 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 clearance should 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 sequence of 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 a bleeder screw. After installation of tipping system some components can have some amount of air trapped inside. Therefore it becomes necessary to bleed the system. To bleed the system, follow some of the instructions given here.l

Loosen the pressure hose of the pump a little so that the air in the suction hose and the pump can escape and the system will be filled up with oil. Loosen the pressure hose and the cylinder hose a little. Run the pump at a low speed and put the tipping valve in Tip position. After a short while once the air escapes from the system, the connections must be tightened.

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GEAR PUMPl

As the piston of the cylinder is closed, only a little air remains between the stages. This will mix-up with the oil after a few tips and will escape via the oil tank. If air remains in the system after 8-10 tips the position of the suction hose must be checked and the connections must be tightened. If the temperature is high or the oil is thick, one must wait longer before bleeding a second time. Top up the oil tank as oil has now entered the cylinder, hoses and oil filter. Check the working pressure and check that the pump is operating properly. It is too noisy or if there are shocks in the hoses, air may still be there in the system and the pump is facing cavitation. Bleed the system. Check the working pressure. Check if the complete hydraulic system works properly. (Working pressure - 170 bar)

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HYVA TIPPING VALVEGENERAL MOUNTING INFORMATION l The tipping valve is mounted on oil tank through valve mounting block. To prevent the valve housing deformation the mounting plate surface or block must be completely flat. l Before mounting the valve, remove the plug underneath the valve and 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 correct tools. l If a fault has been developed which can be traced to the valve it is possible 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 on completion of fitting as per following: l Make sure that the body is fully lowered and the PTO is disengaged.l

Connect a 1/18 B.S.P. threaded pressure gauge to the point shown on the figure. Engage the P.T.O. and tip the body fully. Hold the lever at tipping condition until the oil get relieves to tank. Check for leaks in the system and read the pressure gauge.

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PRESSURE CHECKING POINTS

pressure gauge

pressure gauge

System working pressure is 170 bar 22

AIR CONTROL FOR P.T.O. / VALVEGENERAL INFORMATIONl

The air control for P.T.O/Valve with automatic P.T.O. disengagement is a three way operated, variable air control (for P.T.O. engagement, tipping and lowering operation). When used with a compatible tipping valve with proportional lowering, the proportional movement of the air control lever can regulate the speed of descent of the body. Hyva Air controls are easy to mount to the cabin. The functions of Hyva air controls are clearly indicated with symbol.

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MOUNTING OF THE AIR CONTROLl

When air control is mounted next to the drivers seat, a strong support should be used. Ensure using rubber grommets to protect air tubes and to prevent entry of dust and water inside cabin. For trouble free operational life of the entire pneumatic system, the condensed water in the air tank should be regularly drained. Also make sure that the air tubes are not too close to sharp objects, moving parts exhaust and compressor lines, should not get to stretched. Please take precaution to protect pneumatic lines while doing welding in nearby area.

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RETURN LINE FILTERRETURN 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, (Cylinder Tipper Valve) returns to the tank through Return line filter. The function of RLF assembly is to remove contamination from the hydraulic oil on its way back to the tank. (Rating 25 Microns) It consists the following Parts 1 Cover 5. Flange Seal 2. Aluminum Body 6. O Ring 3. Flange Pipe 7. O Ring 4. Return Line Filter Element 8. Spring1 2 3

4

5

6 5 2 5

Note: Periodic replacement of filter element is strongly advised to prevent premature wear and failure of tipping system components.

CHECKS l Filter element must be replaced as per the recommendation given in periodic check list. 24

AIR BREATHER FILTERBreather 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 inside tank, even when there is lower level of oil (in tipped condition) or higher level of oil (due to lowering down or heat generation in the system), in order to prevent any kind of deformation of tank. A Breather filter element of 10-micron filtration capacity ensures entry of dust and foreign particle free air inside hydraulic tank. It consists of the following parts 1. Cover 2. Housing 3. Breather Filter Element 4. Seal 5. Screw 6. Sleeve

Note : Breather Element must be replaced periodically as per the recommendations. 25

CYLINDER NOMENCLATUREHYVA 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 Assembly or Spare Parts. In Front End Tipping Systems used generally in India, Hyva is using two types of Cylinders, i.e. FE & FC. (Find herewith the Nomenclature for Front End Cylinder with Cover - FC) CYLINDER NOMENCLATURE

FE - 169 - 4 - 4620 - 001- HC FC - 105 - 3 - 3210 - 001- HC Type of cylinder Diameter of First Stage (mm) No. of Stages Stroke length (mm) Position of inlet Hard Chromed

Eye with trunnion FE

Cover with Trunnion FC

l

Stroke Length: Distance travelled between close to open length by cylinder eye or cover trunnion.

26

TIPPER MODELS, CYLINDERS & APPLICATIONTATA LPK-1615 LPK-1518 LPK-1618 LPK-1618 LPK2516 TATA TATA TATA TATA

Make

TATA

Model

SK-1613

Tipper Type STD 3625 3580 3580 3580 3880 STD STD RL STD RL STD

STD

R.B

RB 3880

Wheel Base IN mm 8.5 6 8 10 14

3625

4225

Volume in CU.M

UPTO 10

UPTO 8.5

12 & 14

Angle of Tipping 50 50 49

49

49

49

49 FE-129-303700

53 FE-129-303880

Cylinder Model

FC-105- FC-105-33-02635 / 03210 / FC-110-3- FC-110-302635 03210 Sand, Gravel Sand, Gravel Coal

FC-105-3- FC-105-3- FC-105-3- FC-105-30321003210-001 03210-001 03210-001 001HC Coal

TIPPER MODELS, CYLINDERS & APPLICATION

Application

Sand, Gravel

Sand, Gravel

Sand, Gravel

OB & Small Rocks

27

28TATALPT2515 RB RB RB STD STD NOVUS DAEWOO 3135 3135 RB

TIPPER MODELS, CYLINDERS & APPLICATION

Make

TATA

TATA

TATA

TATA

TATA

TATA

TATA

Model

LPK2516

LPK2518

LPK2518

Tipper Type 4880 4880 3930 4030 3930 2940

RB (HYDTD)

STD RL

STD RL

Wheel Base IN mm 20 UPTO 16 15 15 16

3880

3880

2940

Volume in CU.M 46 45 52 55

12

14

23

18

Angle of Tipping FE-1293-03880 FE-1413-03830 -001 FE-1493-03880 -009A

49

49

50

51

52

Cylinder Model

FC-1293-03700

FC-1293-03700000A

FC-1293-04270 -000A

FE-1413-03640 -001

FE-149-4 -04620 -009A

FE-169-4 -4620 -009A

TIPPER MODELS, CYLINDERS & APPLICATION

Application

Sand, Gravel

Sand, Gravel

Coal

OB & Small Rocks

Mining (OB & Medium Rocks)

Mining Construct- Construct(OB & ion, Coal ion, Coal Medium Rocks)

Mining (OB & Medium Rocks)

Make

ASHOK LEYLAND

FORCE FORCE FORCE MOTORS MOTORS MOTORS

AMW

AMW

MERCED SCANIA ES

Volvo

VOLVO

Model

AL-2516

MAN

MAN

MAN

2523

2523

ACTROS 4840 RB RB RB (Tunnel Truck) 3400 RB

P380

FM-9

FM-400

Tipper Type 4525 4525 4300 4300 4380 4053

STD

RB

STD

RB

RB

RB

STD

Wheel Base IN mm 6X4 14 53 53 53 51 16 14 16 18 53 6X4 6X4 6X4 8X4 8X4 18 53

4597 (180")

3831 (150")

4525

4088

Chassis Type

6x4

6x4

6x4

6X4 14 52

8X4 18 55

Volume in CU.M

14/16

14

16

Angle of Tipping

49

53

48

TIPPER MODELS, CYLINDERS & APPLICATION

Cylinder FE-129- FE-129- FE-129- FE-129- FE-149- FE-129- FE-129- FE-169- FE-169-4 FC169-4 FE-169-4 Model 3-03700 3-03880 3-03880 3-03880 3-03880 3-03700 03700- 4-04620 -04620 -04280 -04620 -001A -009A -001A 001A OB & Small Mining (OB Mining (OB Rocks & Medium & Medium Rocks) Rocks) Sand, Gravel Mining (OB Mining (OB Mining (OB Mining (OB & Medium & Medium & Medium & Medium Rocks) Rocks) Rocks) Rocks)

Application

Sand, Gravel

OB & Small Rocks

Sand, Gravel

29

CYLINDER REPAIR INSTRUCTIONSFC & FE CYLINDERS REPAIRS INSTRUCTIONS Introduction Hyva cylinders contain a small number of components, which are subject to wear. Therefore it is sometimes necessary to dismantle the cylinder and replace the worn out parts like seal kit. Depending on the load requirements, either of the following types of cylinders 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 in accordance with instructions given as below. 1. Before dismantling any Hyva cylinders always check the name plate for type of Cylinder, which is primary requirement in ordering right parts. 2. Remove the Cylinder from the chassis prior to dismantling and always place it horizontally on a clean and dust free place. Only in case of FC type of cylinder it is possible to leave the outer cover attached 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 stage is 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 and allow the inners to sink to then rest position. Secure the cylinder, using a proper rope or sling to a suitable lifting device to prevent the cylinder from tipping over. l Disconnect one of the trunion brackets from the cradle or sub frame and ease the cylinder from the other bracket. The cylinder can now be laid on a bench ready for dismantling. l Lay the cylinder flat on a clean bench with the oil inlet facing downwards and clamp securely to avoid any kind of damage and injuries. A V block arrangement is usually the best. Collect the waste oil. 30

CYLINDER REPAIR INSTRUCTIONSl

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Use a ring Spanner to unscrew the Bolts of the bottom plate and remove the locking plates (Fig. 1 & 2) Place a filter ring in the groove left vacant by the locking plates, to ease the removal of the Bottom Plate. The Bottom plate can now be removed using either of the following methods. Figure. 1

Figure. 2

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Using two small bolts inserted into the bottom plate lever it out of the base tube. (Fig. 3)

Figure. 3 31

CYLINDER REPAIR INSTRUCTIONSl

Strike the head of the piston with a mallet or mandrel. This forces the Bottom Plate out of the Base Tube. (Fig 4)

Figure. 4

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When the Bottom Plate is free then remove its O-ring. (Fig. 5)

Figure. 5

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Push the piston forward until the snap ring or lift rings with spacing ring are visible on the internal diameter of the next inner, (Fig. 6).

Figure. 6 32

CYLINDER REPAIR INSTRUCTIONSl

The snap ring can be removed using screw driver, the lift rings can be removed using a set of pliers. (Fig. 7).

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The piston can now be removed through the bottom of the cylinder. The sliders on the piston, which have a diameter less than or equal to 99 mm, consist of two parts and these must be collected to prevent damage. Pistons with diameter greater than 99 mm container sliders, consisting of one part, which do not need to be removed (Fig. 8) The snap ring or lift rings of the subsequent inner must be removed before removing next inner stage through the bottom of the cylinder. Push the inner stage forward until the snap ring or lift rings with spacer in the subsequent inner is exposed. Remove the snap ring or the lift rings as described. The removed inner stage must be placed on is clean surface in order to prevent scratches and other damage (Fig. 9).

Figure. 7

Figure. 8

Figure. 9 33

CYLINDER REPAIR INSTRUCTIONSl

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All the subsequent inner stages can be removed in this way. The seals and wipers must not be reused. (Fig. 10 & 11) Remove the seal, scraper and wear rings from the internal grooves at the top of each inner stage. Do not remove the seals and wipers with a screwdriver or other sharp instruments as this may damage the grooves irreparably and lead inevitably to leaks. The wear rings can be removed using a screwdriver. Never remove a Stop ring if it shows signs of damage. In that case the whole stage must be replaced. Clean each stage carefully and check each groove and the surface of the tube for any irregularities. Check also the slider on each tube. If these are damaged, they should be replaced. In this case, it is necessary to check the stop ring in the subsequent tube for signs of damage or twisting.

Figure. 10

Figure. 11

Figure. 12 34

CYLINDER REPAIR INSTRUCTIONSFE TYPE CYLINDER DISMANTLING Procedure: l Secure the cylinder, using a proper rope or sling to suitable lifting device to prevent the cylinder from tipping over. l Remove the split pin out of the pivot pin and tap the pivot pin out of the piston eye. l Disconnect one of the trunion brackets from the other bracket. The cylinder can now be laid on a bench ready for dismantling. l To remove the piston, push it forwards until the snap ring or lift rings with spacer in the next inner stage are exposed. The snap ring can be removed using a screwdriver; the lift rings can be removed using a pair of pliers. (Fig. 12) l Push the piston downwards and remove the sliders. In case of pistons and tubes with diameter 99 mm or smaller, the sliders consist of two parts which have to be collected up to prevent damage. (Fig. 13 & 14) l Never remove the pistons through the top of the cylinder without use of the filler rings in the slider groove. l Place a filler ring in the slider groove of the piston and lubricate it with the grease for

Figure. 13

Figure. 14 the packing set. The piston can now be removed through the top of the cylinder. Piston with a larger diameter than 99 mm can be removed through the bottom of the cylinder. In case of pistons and tubes with a larger diameter than 99 mm, the slider consist of one part which does not need to be removed.

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CYLINDER REPAIR INSTRUCTIONSALL TYPES OF CYLINDER ASSEMBLING General Procedure : l Clean each inner part thoroughly and apply sufficient grease to the pack-set and the grooves. Use new pack-set to each stage. Mounting should start with the seal, followed by the wear rings and the wiper. Always ensure that each of the ring is seated correctly in the groove. Incorrect fitting can lead to leakage of oil and damage to seals. (Fig. 1, 2, 3, 4, 5)

Figure. 2

Figure. 3

Figure. 1 36

Figure. 4

CYLINDER REPAIR INSTRUCTIONSl

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Slide the first outgoing inner stage almost fully into the base tube ensure that scraping over the stop ring does not damage the tube. Some resistance will occur when passing through the pack-set (Fig. 6 & 7) To prevent damage and facilitate assembly, Hyva has developed special cones. Figure. 6

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Place the sliders at the end of the inner stage and use sufficient grease. (Fig. 8)

Figure. 7

Figure. 5

Figure. 8 37

CYLINDER REPAIR INSTRUCTIONSl

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The sliders must be mounted in a particular position with flat side of top slider always facing upwards. Slide the tube further home until the sliders are in the basic tube. Each of the subsequent inner Stages can be mounted similarly. After mounting an inner stage the snap ring of lift Rings with spacer should be placed. In the previous inner stage with the exception of the cylinder base. Mounting the position is carried out in the reverse sequence of dismantling. Fit a new O ring to the bottom plate and slide the bottom plate into the base. Use sufficient grease and the fitter ring to prevent damage to the seal. (Fig. 9,10&11) Due to the special design of the cylinder, it is not necessary to bleed the air following assembly; the air is automatically discharged after the first few tipping operations. After testing for correct functioning of the cylinder, it can be re-fitted to the chassis. Follow the mounting instructions for FC/FE cylinder. The top nut on the outer casing must not be re-used.

Figure. 9

Figure. 10

Figure. 11 38

CYLINDER REPAIR INSTRUCTIONSFE 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 can ease fitting the eye onto the Piston. l The locking rivet should be placed or the same height but not in the same existing hole. l Drill a new hole (5.8 mm & 18 mm deep) and hammer the rivet into the hole.

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HYFIX BODY CLAMPSThis is a unique feature of hyva tipping system.l

Hyfix clamp mounted underneath the body, stops rattling of the empty tipper body on the chassis and thus prevents damage to the chassis, structural part and sub-frame and reduced the noise nuisance. This hyfix clamp is a revolutionary solution for continuous tipper problem of chassis receiving enormous hammering from the tipper body caused by potholes and bumps on the road. Hyfix ensures a fixed connection between tipper body chassis. The continuous bolt and nut, depending on where hyfix is fitted and the dimensions of the tipper body can adjust the compression load in the power block. The compression load can vary from 250 to 1600 kgs.

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WELDING OF THE HYFIX l The hyfix to be fully supported and welded over the entire surface before the compresson load is set, so that no bending moment will arise on the power block and locking.l

Also the Hyfix bracket has to be fully welded.

DISMANTLING THE HYFIX l Open the Hyfix with hollow steel bar and remover the setting pin. l While setting pin is removed and the Hyfix closes, there is a possibility of clamping between l The power block and the hook. l Greasing points should be properly greased at regular intervals. l Condition of power block and compression rod must be checked twice a year.

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HOSES AND ADAPTERSSECTION & HIGH PRESSURE HOSES Make sure the proper hose orientation in order to ensure (a) Same is not getting rubbed with any object (b) there is no twist (c) Hose is not bent too sharply.l l

The mounting torque of the hose clamp must be 6 NM Take care the hoses do not come in contact with hot or moving parts like the exhaust or drive shaft. Use Nylon Tape to seal the threads of elbows and hose pillars without O-ring, do not use Nylon Tape in combination with elbows or hose pillars with O-ring

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Please use Hyva hoses only for replacement whenever required in order to ensure longer and safe life of hydraulic components.

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HOSE ORIENTATION

42

FAULT DIAGNOSIS

Faultl The cylinder does

Possible Causesl The PTO IS not engaged

Remedy / Checkl

not mend when the air control is in tipping position

Move Cab Control to in mesh position Disconnect hose at P and check if oil circulates Fill the oil tank Open the gate valve Check air supply Connect cylinder to port A Remove all air tubes except feed and exhaust. Check if air passes through relevant port when control move on to correct position. Replace this Valve if faulty Check all Tubes for sharp bends. Disconnect both air tubes from valve and check air flow with air control in relevant position. If no air escapes from air tube ends, replace tubes Turn the screw anticlockwise Check through the separate instructions for knock-off valves Check air supply in lowering position Replace filter element Refill with proper grade of oil (see recommended list) Replace tipping valve Change tipping valve

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Pump does not deliver oil No oil in tank Gate valve closed Insufficient air pressure Cylinder is connected to wrong Valve port Air Control fault

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Air supply correct but tipping valve does not get actuated.

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Air Tube kinked or restricted

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Cylinder raises but not lower or lowers too slowly

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Lowering speed adjusting screw turned in completely (PT valve only) Knock-off valve does not work properly (if provided)

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Air Control fails Return filter is chocked Grade of oil being used too heavy Non return valve in port P not fitting Internal leak in tipping

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Cylinder drops when clutch is depressed Air supply is sufficient but tipping valve will not work

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FAULT DIAGNOSIS

Faultl

Possible Causes Broken air tube l Plunged blocked by dirtl l

Remedy / Checkl l

Valve works properly but suddenly fails Cylinder jerks when extending Cylinder raises very slowly

Replace the O-ring seal Check air tubes and replace as required Bleed the pump by slightly opening the adapters from the pressure hose Replace pump Check air pressure, check air control, air tubes and tipping valve as described before

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Air in the system

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Pump defective Too low air pressure

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Cylinder does not extend fully

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Relief valve is opening, by returning the oil tank, caused by too much load or all the load too far forward in the body

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Oil level in tank too low The lowering speed adjuster screw is worn out

Check the pressure at which the relief valve is opening by connecting a pressure gauge to the serial port. If this pressure is not being obtained then contact Hyva authorised service centre l Top up the tankl l

Body comes down too fast

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Extended the cylinder fully, Put cab control in HOLD position. Adjust the screw in position as far as possible. Move cab control to LOWER; unscrew the adjuster until the body descends at correct speed. Loose three fixing bolts by half a turn and try to switch the valve again. The torque of the bolts should not exceed 15 NM. Bleed the system, check oil level in tank Replace pump Clean the filter cartridge Replace the cartridge if necessary.

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Valve selector shaft does not move even with sufficient air pressure Cylinder does not extend smoothly

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The selector shaft is sticking or stopped

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Air in the system Pump is performing irregularly Check for increase in system pressure Check relief valve cartridge for dirt or free

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Excessive oil temp. (> 60OC)

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GREASING LAYOUT

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GREASING POINTS1 Cylinder Mounting Bracket Greasing - Weekly

2 Piston Eye Greasing - Weekly

3 Rear Hinge greasing - 2 Points - Weekly (Mining Trucks-Daily)

4 Tail Door Locking Mechanism greasing - 3 Points. Weekly

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GREASING POINTS5 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 Rock Bodies on Mining Trucks)

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SPECIFIC DENSITIESAPRROX. SPECIFIC DENSITIESMaterial Ashes and cinders (wet) Ashes and cinders (dry) Asphalt (pitch) Asphalt (massive) Asphalt (tar) Barley in bulk Bone meal Brick (loose) Brick (stacked) Brick (general) Cement (loose) Cement (natural) Clay (wet) Clay (dy) Coal (anthracite) Coke Grit Coke Concrete (wet) Concrete (dry) Corn and rye Earth (wet) Earth (dry) Fertilizer Flour of corn Flour Garbage Gravel Gravel and sand (wet) Kg / Cu. M. 1015-1330 780-1030 2128 2394 1878-2510 1729-1928 700-1100 1263-1662 1480-1995 630 1446 897 1760 1015 897 400-548 360-615 2377 1240 765 1600-1800 1200 1030 400-500 600-731 680 1680 1928 Material Gravel and sand (dry) Lime paste Lime Powder Limestone burnt Marl Molding sand Oats Ore Potatoes Pebbles Rubble (broken stone) Sand (wet) Sand (dry) Slag and cinders Snow Stone (broken, coarse) Stone (broken, fine) Stone (Grinded) Sugar in bulk Sulpher Super phospate Town refuse Wheat Wood chips Wooden logs deal Wooden logs oak Wooden logs beech Woodwool Kg/Cu. M. 1460-1728 1150-2000 500 775-1000 2300-2600 1446-1596 415-515 2095-2560 650-700 1350-2000 1530-1730 1660 1330 1263-1660 80-800 1662 1197-1462 1600 797-880 1930-2070 1000-1200 498 765 200 320 420 400 50

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TIPPING ANGLEMinimum required angle of tip :Material Ashes, dry Ashes, damp Ashes, wet Asphalt Brick Cinders, dry Cinders, wet Cinders and clay Coal Coke Compost Concrete Kg / Cu. M. 33 36 30 45 40 33 31 30 30 23 50 30 Material Earth, loose Gravel Ore, fine Ore, dry Pebbles Refuse Rubbish, broken stone Sand, dry Sand, damp Stone, grinded Stone, broken Kg/Cu. M. 28 40 37 30 40 30 45 35 40 30 27

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WARRANTY GUIDELINESReason Warranty N.A. Warranty N.A. Warranty N.A. Warranty N.A. Warranty applicable Warranty applicable Warranty N.A. Warranty N.A. Warranty applicable Warranty N.A. Warranty applicable Warranty N.A. Provided correct grade of oil is used &Maintenance schedules are followed. If maintenance schedules are followed and correct grade of oil is used. If Maintenance schedules are followed. If Maintenance schedules are followed Action Remarks

Warranty N.A. = Warranty Not applicable

Sr. #

Component Description

Type of failure

1

Tipping

Cylinder bent

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Tipping on uneven ground.

Cylinder

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Running of vehicle by keeping body in tipping condition

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Vehicle toppling in an accident

Cylinder Bulge

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Tipping Valve set pressure is tampered .

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Pressure relief valve is malfunctioning.

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Sticky spool of tipping valve.

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Lowering operation is too fast.

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Choked filter

Cylinder Scoring

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Scoring on stages due to slider chip off.

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Scoring in the axis of trunion due to side load .

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Scoring due to stop ring dislocation and groove deformation.

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Welding spatter and spark jumping due to earthing through cylinder.

WARRANTY GUIDELINES (Contd..)Reason Warranty applicable Warranty N.A. Warranty N.A. Warranty N.A. Warranty N.A. Warranty N.A. Warranty N.A. Warranty N.A. Warranty applicable Warranty applicable Warranty N.A. Warranty applicable Warranty N.A. Warranty applicable Warranty applicable Unauthorized body extension will waive-off all types of warranty claims. Action Remarks

Warranty N.A. = Warranty Not applicable

Sr. #

Component Description

Type of failure

Oil leakages from stages

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Wrong fitment of seal

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Excess Load

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Body extension

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Operational abuse

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High Oil Temperature due to more number of tippings.

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High Oil temperature due to continuous PTO engagement.

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Contaminated oil.

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Welding spatter on seal running area.

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Poor quality seal

Oil leakage from cylinder bottom plate

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Wrong fitment of seal

Piston coming out

l Jerky operation by pushing backward after unloading.

Piston Eye coming out

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Poor locking arrangement

Cylinder base tube crack

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Crack is on trunion side due to side loads.

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Crack is on all around trunion.

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Cylinder Stuck

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Sliders over riding

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WARRANTY GUIDELINESReason Warranty applicable Warranty applicable Warranty N.A. Warranty applicable Provided maintenance schedules are followed. Action Remarks

Warranty N.A. = Warranty Not applicable

Sr. #

Component Description

Type of failure

2

Tipping Valve

Oil leakage

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Seal failure due to wrong fitment.

Malfunctioning of valve

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Sticky spool

High operating pressure.

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Pressure relief valve tampered.

Working pressure is too low.

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Low system pressure as relief valve mal functioning

3 Warranty N.A. Warranty N.A. Warranty N.A. Warranty N.A. Warranty N.A. Warranty N.A. Warranty N.A. Warranty applicable Warranty N.A. Warranty N.A.

Hydraulic pump

Pump fails

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Relief valve set pressure is tampered. Warranty N.A.

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No hydraulic oil in the tank

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Pump operated without opening ball valve.

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External damage due to hit by external object.

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Correct grade of oil is not used .

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Thrust plate & housing wear out due to excess raving of engine rpm.

Pump leakage

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Pump reversing procedure not followed

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Oil contamination levels are high

Pump drive shaft broken

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Manufacturing defect

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System pressure relief is tampered.

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Entry of foreign particles.

WARRANTY GUIDELINES (Contd..)Warranty N.A. = Warranty Not applicable Reason Action Remarks

Sr. #

Component Description

Type of failure

Thrust plate & wear out Warranty N.A. Warranty N.A. Warranty N.A. Warranty N.A. Warranty N.A.

4

Tipper sub-frame

Sub frame crack

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Crack develop due to not tightening mounting bolts.

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Crack due to improper loading pattern.

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Crack develops near welding joints under normal working conditions.

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Cracks due to accident to vehicle

Sub frame twisted

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Twist is due to accident

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Hydraulic

Oil leakage

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Leakage from crimping

Warranty applicable Warranty applicable Warranty N.A. Warranty N.A.

Hoses

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Burst age of hose.

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Twisting due to wrong fitment

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External damage due to rubbing / hitting

Note:

Warranty is not applicable under following conditions. 1. Wrong application / usage of tipper. 2. Unauthorized body extension. 3. Abusive operating practices. 4. Not following recommended maintenance schedules .

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Record of Service / Repairs performed Particulars of Repair Hyva authorised Representative Sign.

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Date

Record of Service / Repairs performed Particulars of Repair Hyva authorised Representative Sign.

Date

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VEHICLE PARTICULARS

Model ....................................................................................................................................... Chassis No. .............................................................................................................................. Body Type .............................................................................................................................. Body Sr. No. ............................................................................................................................ Date of sale ............................................................................................................................ Owners name ....................................................................................................................... Address .................................................................................................................................... .................................................................................................................................................... ....................................................................................................................................................

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