SUNRISE HTKS Hydraulic Tipper Kit User Manual

SUNRISE HTKS Hydraulic Tipper Kit

Optional Parts

Hydraulic Tipper Wireless Remote Part Number: HTRW

Suits many tipper trucks and trailers Quick and easy to set up Controls tipper up and down Allows for safer operation during loading and unloading Operate the hydraulic system from multiple locations Get the best view for the loading and unloading process

• Tipper Kit Rear Pivot Hinge Part Number: RPHG7T
• Capacity: 7000kg (7T) 2 pivots per kit Weldable design 25mm Greaseable bars Made from quality steel Maximum safety and service life

HYDRAULIC TIPPER KIT

The Sunrise hydraulic tipper kit cylinder is made of high-grade carbon steel tubes, ensuring excellent stability and flexibility during tipping. Its mechanical properties allow it to withstand higher stress levels, making it ideal for heavy-duty applications. Our cylinders have a significantly higher loading capacity than those made with light-duty welded tubes commonly found in other cylinders. Sunrise cylinder utilizes hot rolled tubes which provide superior structural strength and load-bearing capabilities, in contrast to welded tubes which are prone to weak-ness at the welding line.

Specifications

PARTS LIST

OPTIONAL PARTS

Hydraulic Tipper Wireless Remote

Part Number: HTRW

• Suits many tipper trucks and trailers
• Quick and easy to set up
• Controls tipper up and down
• Allows for safer operation during loading and unloading Operate the hydraulic system from multiple locations Get the best view for the loading and unloading process
  More information: https://sunriseint.com.au/product/hydraulic-tip-per- wireless-remote/

Tipper Kit Rear Pivot Hinge
Part Number: RPHG7T

• Capacity: 7000kg (7T)
• 2 pivots per kit
• Weldable design
• 25mm Greaseable bars
• Made from quality steel
• Maximum safety and service life
  More information: https://sunriseint.com.au/product/tipper-kit-rear-piv- ot-hinge-greaseable-7t-l-r-set/

TECH SHEET

| HTK4S825| HTK5S1030| HTK5S1245| HTK6S1000
---|---|---|---|---
STAGE| 4| 5| 5| 6
STOKE (mm)| 825mm| 1030mm| 1245mm| 1000mm
PIVOTS (48° mm)| 1020mm| 1270mm| 1540mm| 1230mm
WEIGHT (kg)| 20kg| 24kg| 28kg| 20kg
CAPACITY (T)| 4.5T| 5T| 5T| 5T
A| 108mm| 123mm| 123mm| 123mm
B| 40mm| 40mm| 40mm| 40mm
C| 40mm| 40mm| 40mm| 40mm
D| 148mm| 148mm| 148mm| 148mm
E| 233mm| 234mm| 276mm| 230mm
F| 160mm| 160mm| 160mm| 148mm
G| 389mm| 377mm| 435mm| 393mm
H| 45mm
I| 88mm
J| 45.5mm
K| 18mm
L| 33mm
M| 105mm
N| 140mm
O| 37mm
P| 15mm

WIRING DIAGRAM

INSTRUCTION

Usage Warnings
Tipping poses inherent risks, making it crucial to adhere to correct procedures to prevent harm to the hydraulic system, the vehicle, and the safety of individuals. Incorrect selection or use of cylinders and their associated accessories can result in severe injuries, fatalities, and damage to the cylinder and cargo. The hydraulic cylinder must never be employed for lifting people. Common factors contributing to tipper overturns include:

• Tipping on unstable or sloped terrain
• Dumping materials like mud, clay, or substances that adhere to the body
• Dumping in windy or gusty weather conditions
  In the event of a tipper overturn, it’s essential to recognize that the damage to the cylinder is an outcome, not the root cause of the overturning incident.

Usage Recommendations

• The telescopic cylinder is specifically designed for lifting purposes and must never be used for any other application.
• Under no circumstances should the telescopic cylinder be utilized as a mechanical limit stop for moving loads.
• The cylinder’s design is intended for lifting loads along the longitudinal axis, and side-load-ing should be avoided whenever possible.
• Always ensure that the load remains within the maximum payload capacity of the vehicle.
• ensure that the load is evenly distributed within the body.
• Operate and tip on a solid, level surface.
• Verify that tire pressures are correct before initiating the tipping operation.
• Before tipping, unlock the tailgate, taking care to stand clear of the area.
• Before tipping, thoroughly inspect the work area, ensuring it is free from people, ground-level obstructions, and overhead hazards such as cables.
• Avoid tipping in windy conditions.
• Activate the cylinder only when the tractor and trailer are aligned in a straight line. Avoid a jack-knife position of the tractor and trailer during dumping.
• Throughout the entire tipping process, the operator must remain in control of the tipper kit at all times. If any issues arise or the body does not tip smoothly, immediately lower the body completely, slowly, and without sudden interruption. Inspect and rectify any potential problems before resuming the tipping operation.
• Ensure that the vehicle is stationary when initiating the tipping process.
• Do not attempt to move the truck or jam the brakes while the cylinder is partially or fully extended in an attempt to dislodge stuck loads in the dump body or trailer.
• If the load becomes stuck or the body does not tip smoothly, lower the body completely, very slowly, and without any sudden interruption before resuming the tipping operation. If the issue persists, manually unload the dump body or trailer or use alternative mechanical means.
• Refrain from driving or distributing materials until the body is fully lowered.
• Exercise particular caution and ensure even load discharge in icy conditions.
• Always disengage the power take-off (PTO) during the lowering process. Return the tip-per-control lever to the neutral position once the tipper body is fully lowered.
• Never work beneath a raised body unless it is properly supported and located in a safe environment.
• Do not tamper with the pressure relief valve or end-of-stroke valve for the cylinder.
• Be aware that pressure spikes, especially exceeding the maximum working pressure of the cylinder, can result in severe injury, fatalities, and damage to the cylinder and cargo.
• Avoid leaving an unchromed cylinder extended for more than two hours.
• For tipping tankers, follow these additional steps:
• Activate the stabilizers before unloading.
• Raise the tank to a maximum angle of 25° and wait until 50% of the load has discharged.
• Then complete the tank-raising process.

Maintenance Warnings

Only fully trained, highly professional, and qualified personnel with technical expertise should be allowed to install, repair, or service this equipment. Failure to do so can result in serious damage and/or injury.
In case of any uncertainties or if assistance is required, please contact your supplier or reach out to the Sunrise Sales & Customer Service nearest to you.

• The hydraulic cylinder is designed exclusively for lifting purposes and should never be utilized as a stabilizer for supporting the body of the equipment.
• Working underneath a raised body is strictly prohibited unless it is correctly propped and in a safe environment.
• Ensure that the body prop is securely positioned between the body underframe and chas-sis for stability and safety.
• Use only hydraulic oil with the recommended density as specified in the manufacturer’s guidelines.
• Employ high-quality hydraulic oil specifically intended for hydraulic circuits to maintain the equipment’s performance.
• Avoid using vegetable cutting oil additives or any oil with different constituents from the original hydraulic oil, and never mix different products together.
• Never leave the vehicle with the body in a raised or tipped position, as this can lead to potential accidents.
• Refrain from cleaning the hydraulic cylinder with a high-pressure water cleaner to prevent damage and maintain the cylinder’s integrity.
• When performing welding tasks, do not attach the ground clamp to the hydraulic cylinder, as this can result in electrical hazards.
• Always take measures to shield the hydraulic cylinder from welding spatter and other foreign materials that could cause damage or impair its functionality.

General Maintenance Suggestions
Regular maintenance is crucial to ensure the safe and extended operation of both the telescopic cylinder and the vehicle. Incorporating a vehicle inspection into the operator’s daily routine is essential as it aids in identifying potential issues before they lead to damage

Weekly

• Verify the oil level in the oil tank (depending on the tank type, the oil level should be visible in the sight glass or level gauge).
• Apply grease to all moving parts of the cylinder and its related accessories.
• Inspect the condition of all hydraulic components in the hydraulic system, including the PTO, pump, tipping valve, oil tank, hydraulic pipes, and tipper level control.

Monthly

• Ensure the proper functioning of the end-of-stroke device (if installed) and pressure relief valve.
• Check and lubricate the stabilizer frame and the tipper hinge (if applicable).
• Examine the hydraulic pipes, secure all flexible pipes to the chassis, tighten any loose pipe connections, and ensuring they are free from knots and kinks.
• Regularly inspect hydraulic connections and hoses, replacing them if they are worn or damaged.
• Verify the tightness of fixing bolts.
• Replace any damaged or worn bolts with new ones of equivalent or higher grade.
• Examine the mounting of the cylinder, the cylinder top nut (located at the top of the outer cover), all brackets, cradle supports, tipper valve, PTO, and pump.
• Check the oil level in the hydraulic tank with the tipping cylinder at rest.
• Inspect the vehicle for any signs of damage.
• Apply lubrication to all greasing points on the tipper.
• If the hydraulic oil is dirty or contaminated, drain and clean the oil tank (and hoses) and refill it with new oil.
• Clean the cylinder and remove dirt and excessive grease.

6 monthly

• Clean the return filter if one is installed.
• Replace the air breather filter.

Yearly

• Refill the tank with clean hydraulic oil by first draining the tank. Then replace the return line filter.
• During oil draining, take care to prevent spills and dispose of the old oil in an environmentally responsible manner.
• Apply grease to non-painted and moving parts if the tipping system is to be stored for an extended period.
  

TROUBLESHOOTING

The cylinder doesn’t extend when the air control is in “tip” position

| PTO not engaged| Engage PTO

Pump doesn’t deliver oil

| Disconnect hose at valve and check if oil circulates

Check there are no kinks or leaks from any oil

or air oioes

No oil in the tank| Fill the oil tank
Air pressure is not enough| Increase pneumatic pressure
Cylinder connected to wrong valve port| Connected cylinder to port “OUT”

The body stops on the

way up

| Material in excess or badly distributed| Remove or better spread the material
Not oil enough in the tank| Fill the oil tank
The cylinder extends when the air control is in “low• position| Pneumatic hoses wrongly connected with

the valve and/or the cab control

| ****

Connected up as instructed

Cylinder jerks when

extending

| ****

Air in the oil supply

| Engage PTO and tip hoist to full stroke on tick over. DO NOT REV ENGINE.

Turn engine off when hoist is at full stroke Drop down the body until resting on chassis correctly

Repeat the procedure until the air will be com- pletely escaped.

Pump Is damaged| Repair or replace pump

The body doesn’t drop

| PTO not disengaged| Check PTO has disengaged and eventual warning light is out

Air in the system

| Rev the engine until the relief (overload) valve blows (i.e. until you hear a high pitched noise coming from the tipper valve)

Keep the engine revs going for 5 seconds Lower the body

If the body still won1 come down, put the tipper lever in “hold”, prop the body, switch the PTO to “out” and turn off the engine.

Contact Sunrise Sales&Service Agent

Air supply correct but the tipping valve doesn’t work

| ****

Air in the system

| Remove all the pneumatic hoses (except the feed and exhaust ones). Check if air passes through the relevant port when the control moves on to the correct position. Replace this valve if faulty.

Check all pipes for sharp bends. Disconnect both air pipes from the valve and check air flow with air control in the relevant position. If no air escapes from air pipe and replace pipes.

Put air control in “low” position, remove pipe from valve “TIP” port; if air leaks from this port then the O·rino of the air cylinder is faulty

Air pipe “kinked” or restricted

Internal leak in the tipping valve

The cylinder doesn’t go up or it goes up very slowly

| Air pressure is not enough| Check air pressure, air control, air pipes, and tipping valve as described before.
Pump fault| Replace pump

The cylinder goes up, but it doesn’t go down or it goes down very slowly

| The return filter is blocked| Replace oil filter
Air control fails| Check air-supply in lowering position
Knock-off valve does not work properly| Check through the separate instructions for

knock-off valves

The oil used is too tick| Refill with the oil recommended
The cylinder drops when

clutch is depressed

| The nonreturn valve in port “IN” does not work or it is not properly fitted.| Replace the valve

The cylinder doesn’t extend smoothly

| Oil level in tank is too low| Check oil level in the tank, and fill the oil tank if necessary
Air in the oil| Bleed the system
The pump does not work properly| Replace the pump

The valve works properly but

suddenly fails

| Broken air pipe| Check air pipes and replace as required
Plunger blocked by dirt| Clean hydraulic system (oil tank included)
Knock-off valve fails| Replace the tipping valve if necessary

Check knock-off valve

Valve selector shaft does not move even when air pressure is enough| ****

The selector shaft is slicking or trapped

| ****

Loosen lhe fixing bolts by half a turn and try to switch the valve again (the torque of the bolts should not exceed 15 Nml

The cylinder doesn’t fully extend

| The oil level in the tank is too low| Fill oil tank
The relief pressure valve is open and the oil goes back to the oil tank| The Knock-off valve fails Remove or redistribute the

material in the body

The body will not stay up with the tipper lever in the “hold” position

| ****

The tipping valve not working properly

| ****

Put the tipper lever back in “raise” and lift the body Rev the engine until the relief (overload) valve blows (i.e. until you hear a high-pitched noise coming from the tipper valve)

Keep the engine revs going for 5 seconds

If the body still will not stay up, lower the body

and contact Sunrise Sales&Service

Excessive noise

| Not enough oil| Refill with the oil recommended
Damaged or kinked pipes| Check air pipes and repair or replace them as required

The cylinder goes down

too fast

| ****

Unloaded material in the lipping body

| Lower the body with special care, completely, very slowly and without any sudden interruption. If necessary, unload the dump body or trailer manually or with an alternative mechanical aid, before resuming tipping operation.

Fuses

| A fuse is generally not required as when the tipper kit first starts the battery draws a lot of power and will typically always blow a small fuse at the 20 or 50-amp range| ****

Replace the fuse or use it without

WARRANTY

Sunrise stands behind the quality of its products and offers the following warranty terms:

1. Defective Materials and Workmanship: Sunrise warrants products manufactured by Sunrise against operational failure resulting from defective materials or workmanship. This warranty is valid during proper and normal use within the warranty period, starting from the date of purchase from Sunrise. Sunrise reserves the right to determine what constitutes proper and normal use.
2. Exclusions from Warranty: The following components are not covered by this warranty:
3. Packing, wipers, bearings, and bushings, may experience wear due to internal or external contamination or normal operating conditions.
4. Failures are caused by forms of oxidation.
5. Excluded Damages: Sunrise does not warranty any damage directly or indirectly caused by accidents, abuse, or defects in hydraulic repair kits.
6. Alterations and Modifications: Products that have been altered, modified, or repaired by non-professional/approved personnel or without written approval from Sunrise are not covered by this warranty.
7. Inadequate Tools and Procedures: Sunrise will not be liable or responsible for damages resulting from inadequate tools, incorrect procedures, or the use of incorrect aftermarket components.
8. Limitation of Liability: Sunrise shall not, under any circumstances, be liable for:
9. Labor expenses related to removal and installation.
10. Loss of time, manufacturing costs, materials, or loss of profits.
11. Incidental, special, or consequential damages, whether direct or indirect.
12. Repair or Replacement: Sunrise’s sole obligation is to repair or replace, at its discretion and free of charge, any part of the product found to be defective upon inspection.
13. Extended Warranty: If a product is repaired under warranty, it will carry the remainder of the original warranty period.
14. Cylinder Warranty: Please note that failure to observe our advice and instructions will auto-matically void any warranty on the cylinders.

Please keep in mind that the above warranty terms are subject to Sunrise’s discretion and should be read in conjunction with any specific warranty documentation provided with the product and other warranty material stated on our website. If you have any questions or require warranty service, please contact Sunrise for further assistance.

REGISTRATION FORM

Please keep the following registration form with the vehicle together with this User Manual.

FAQ

• Q: What is the capacity range of the Sunrise Hydraulic Tipper Kit?
• A: The capacity range of the Sunrise Hydraulic Tipper Kit is from 4.5T to 6T.
• Q: What is the voltage of the pump?
• A: The pump voltage is 12V.
• Q: What type of hydraulic oil should be used?
• A: The recommended fluid type is 46 Grade Hydraulic Oil.
• Q: Can I operate the hydraulic system from multiple locations?
• A: Yes, you can operate the hydraulic system from multiple locations with the optional Hydraulic Tipper Wireless Remote.
• Q: How do I engage the PTO?
• A: To engage the PTO, please refer to the instruction manual for your specific vehicle model.

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VISIT OUR SITE: sunriseint.com.au

MORE INFORMATION

• 03 9794 0415
• sales@sunriseint.com.au

References

• SUNRISE Hydraulic Tipper Kit Complete
• Tipper Kit Rear Pivot Hinge Greasable 10T L & R Set

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