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Simpro MegaDumper User Manual

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USER MANUAL
S i m p r o M e g a D u m p e r
®
User Manual
| Simpro MegaDumper®
Original Instructions | English | v44.0 | March 2019

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  • Page 1 USER MANUAL S i m p r o M e g a D u m p e r ® User Manual | Simpro MegaDumper® Original Instructions | English | v44.0 | March 2019...
  • Page 2 Copyright © 2019 Simpro Handling Equipment Ltd. No part of this document may be reproduced or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the written permission of the publisher. For the purpose of standards compliance and international conformity, this document uses Système International (SI) units.
  • Page 3 User Manual | Simpro MegaDumper® Original Instructions | English | v44.0 | March 2019 | Page...

  • Page 4: Table Of Contents

    1 Contents Contents ..........................3 Overview ........................... 5 Key features ..........................5 Construction ..........................6 Mechanism ..........................6 Duty cycle ........................... 6 Intended operational life ......................6 Noise emissions ........................... 7 Environmental restrictions ......................7 Ingress protection ........................7 Notes ............................7 Safety ..........................
  • Page 5 Coverage ..........................47 Exclusions ........................... 47 End User Claim Procedure ..................... 48 Agent Claim Handling Procedure..................48 EC Declaration of Conformity .................. 49 Notes ..........................50 User Manual | Simpro MegaDumper® Original Instructions | English | v44.0 | March 2019 | Page...

  • Page 6: Overview

    2 Overview Congratulations on your purchase of a Simpro MegaDumper bin-tipping machine. Since its introduction in 1998, the MegaDumper has built a reputation as the safest and most reliable high-capacity mobile bin lifter available. With a highly modular design, the MegaDumper is suitable for many different applications –...

  • Page 7: Construction

    Construction The MegaDumper consists of a steel frame with two vertical masts and stabilizing legs, a bin cradle, two hydraulic rams, lifting chains, guarding, powerpack cover, control panel, castor wheels, power lead or batteries, hydraulic powerpack and electronic control systems.

  • Page 8: Noise Emissions

    If the machine is to be leased, sold or otherwise transferred, then this manual shall accompany the machine. Simpro reserves the right to modify the design of the machine. If there is anything in this manual that is not consistent with the actual machine, the actual machine should be considered correct and the manual is only for reference.
  • Page 9 User Manual | Simpro MegaDumper® Original Instructions | English | v44.0 | March 2019 | Page...

  • Page 10: Safety

    3 Safety The MegaDumper has been designed to be as safe as possible without restricting the ease- of-use and versatility of the machine. A comprehensive Hazard and Risk Assessment should be undertaken before the MegaDumper is used for the first time, as described in Section 3.3.
  • Page 11 Serious injury or Scarcely possible death PL(d) Possible under specific (irreversible) Frequent to continuous conditions and/or long exposure time Scarcely possible PL(e) User Manual | Simpro MegaDumper® Original Instructions | English | v44.0 | March 2019 | Page...

  • Page 12: Hazard And Risk Assessment Guide

    In any of these cases, information about the required safety function PLr should be provided to Simpro before placing an order. Simpro will then propose additional or uprated systems to achieve the PLr in compliance with ISO 13849-1:2015. This may include any or all of the...
  • Page 13 Risk Factor 6-10 11-50 101-500 501-1000 1001 + Risk Negli- Very Very Unacce- Significant High Extreme Evaluation gible high ptable User Manual | Simpro MegaDumper® Original Instructions | English | v44.0 | March 2019 | Page...
  • Page 14 3.4.2 Identified Hazards The following common hazards have been identified with the MegaDumper design. For each hazard, a full Risk Evaluation has been completed, and suitable control measures described. Blank template spaces are provided at the end for machinery owners to identify, assess and control additional site-specific hazards.
  • Page 15 Crushing if the machine falls over Risk DPH: 1.25 Factor: Operator Low risk as MegaDumper tippers are very stable and the bin centre of gravity ’ f Risk Other DPH: 1.25 Factor: persons As above. Control Do not operate on uneven ground, or ground with a slope of more than 1:12.
  • Page 16 Application-specific hazard: Risk DPH: Factor: Operator Risk DPH: Other Factor: persons Control measures Comments Application-specific hazard: Risk DPH: Factor: Operator Risk DPH: Other Factor: persons Control measures Comments Application-specific hazard: Risk DPH: Factor: Operator Risk DPH: Other Factor: persons Control measures Comments Application-specific hazard:...
  • Page 17 Posting signage, floor marking, or other warnings as deemed appropriate. Taking steps to develop a culture of safety and open communication among machinery operators. User Manual | Simpro MegaDumper® Original Instructions | English | v44.0 | March 2019 | Page...

  • Page 18: Safety Norms

    Safety Norms The following safety norms must be observed for the safe use of a MegaDumper bin lifter. Only trained and authorised persons should be permitted to use the machine. Operators must read and obey the instructions displayed on the machine.
  • Page 19 The manufacturer cannot be held liable for the consequences of an inadequate earthing system. User Manual | Simpro MegaDumper® Original Instructions | English | v44.0 | March 2019 | Page...

  • Page 20: Operating Instructions

    4 Operating Instructions The operating instructions for the MegaDumper depend on which type of control system is fitted to the machine. There are three principal types of control system, as follows: 1. Standard Control System – Refer to Section 4.1 Description: Standard machine, with no autocycle function or PLC controller.

  • Page 21: Operating Instructions - Autocycle Control System

    Operating instructions - autocycle control system How to operate a machine with autocycle timer, allowing bins to be emptied without continuous operator input. MegaDumper models that are fitted with an autocycle control system may be used in either ‘ ’...

  • Page 22: Operating Instructions - Safety-Monitored Control System

    How to operate a machine with an electronic PLC control unit and a safety monitoring system to comply with safety standards such as ISO13849-1 and AS/NZS4024 up to PL(d)/Cat3 or higher. MegaDumper models that are fitted with a safety-monitored control system may be used in ‘ ’...
  • Page 23 When using a cradle with wheel-catches to empty small EN840-type wheelie bins (80L/120L/240L/360L), only one wheel needs to be placed into a catch. The cradle is designed to hold bins securely using a single wheel. User Manual | Simpro MegaDumper® Original Instructions | English | v44.0 | March 2019 | Page...

  • Page 24: Maintenance

    5 Maintenance The MegaDumper is designed to give many years of service with minimal maintenance. In the event a fault or malfunction does occur, refer to the Quick Trouble Shooting Guide in Section 5.1 before contacting your agent for service. A Service Manual giving specific testing and repair instructions is available on request from Simpro.

  • Page 25: Cleaning

    If the pressure-relief valve is adjusted incorrectly, the cradle may stall even when lifting bins that are within the rated capacity of the machine. Adjustment of the pressure-relief valve should only be carried out by a suitably qualified technician, with prior authorization from Simpro. 5.3.1.2 Mechanical fault 1.
  • Page 26 5.3.2 Cradle jams while lowering If the cradle jams on the way down, or has jammed on the way up but will not come down, it may be due to a hydraulic, electrical, or mechanical fault. 5.3.2.1 Hydraulic or electrical fault When the LOWER button is pressed, the lowering valve sho ‘c ck’...
  • Page 27 5. Close the door and test to see if the cradle lowers correctly. 6. Re-enable the safety door interlock and run the machine through several full cycles to ensure the problem has been properly resolved. User Manual | Simpro MegaDumper® Original Instructions | English | v44.0 | March 2019 | Page...

  • Page 28: Battery Electrical System

    Battery electrical system If you do not operate a battery-powered machine, please disregard this section. Battery-powered MegaDumpers are fitted with deep-cycle sealed gel batteries, a digital smart charger, and a series-wound 24vdc electric motor. The motor only runs when the RAISE button is pressed;...
  • Page 29 Battery-powered machines are fitted with an overload fuse to protect the electrical system from excessive current draw. The fuse is a standard automotive MAXI blade-fuse, purple in colour, with a 60 Amp rating. Replacements are available from Simpro or any automotive parts retailer.

  • Page 30: 3-Phase Mains Electrical System

    3-phase mains electrical system If you do not operate a 3-phase mains machine, please disregard this section. The 3-phase mains specification is recommended for high-intensity applications. Machines powered by 3-phase mains electricity are generally the same as other models, but are fitted with a 3-phase 2-pole electric motor driving the hydraulic pump.

  • Page 31: 1-Phase Mains Electrical System

    Residual voltages may be retained in the VSD inverter after it has been disconnected from the power supply. Use extreme caution when servicing electrical components. User Manual | Simpro MegaDumper® Original Instructions | English | v44.0 | March 2019 | Page...

  • Page 32: Hydraulic System

    Hydraulic system 5.7.1 Powerpack The hydraulic powerpack is supplied as a complete unit. The motor, pump, oil tank, and all control valves are mounted into the centre manifold. 5.7.2 Control valves The hydraulic system has four primary control valves: 1. Check valve: this one-way valve prevents oil from flowing back through the pump when the motor is stopped.

  • Page 33: Hydraulic System Schematic

    Safety door and interlock 5.8.1 Standard safety door (swing-up) The standard MegaDumper is fitted with a single swing-up safety door, consisting of a steel tube frame with 25x25x2mm wire mesh guarding. This type of door is supported by gas struts and takes up a minimum of space.

  • Page 34: Safety Door Interlock

    The interlock Override Key should be stored in a location only accessible to supervisors and technical staff. All routine cleaning and maintenance on the MegaDumper should be conducted with the cradle in the fully-lowered position. If for any reason the interior of the safety cage needs to...
  • Page 35 5.8.2.2 Interlock specifications A summary of the interlock specifications is included below. The complete Idec user manual can be downloaded from this link: https://goo.gl/iafPoI. User Manual | Simpro MegaDumper® Original Instructions | English | v44.0 | March 2019 | Page...

  • Page 36: Safety-Monitoring System (Pl(D)/Pl(E) Only)

    Safety-monitoring system (PL(d)/PL(e) only) If you do not operate a machine with a safety-monitored control system to achieve ISO 13849-1 or AS/NZS 4024 PL(d) or PL(e), please disregard this section. Machines with an ISO 13849-1 safety rating of PL(d) or PL(e) are fitted with a Rockwell CR-30 Safety Relay to monitor the safety systems.

  • Page 37: Troubleshooting

    The CR30 has a USB interface for connection to a personal computer for configuration. Use a standard USB A Male to B Male cable for connecting to the relay. User Manual | Simpro MegaDumper® Original Instructions | English | v44.0 | March 2019 | Page...

  • Page 38: Assembly, Handling, Transport & Storage

    Moving When the MegaDumper is standing upright it may be easily moved on its castor wheels. To ensure stability the bin cradle should always be positioned just off the ground when moving the machine.

  • Page 39: Storage

    4. Fully charge the batteries (if fitted) and apply a suitable contact oil to the electrical contacts. 5. Remove the key and store in a safe location. 6. Turn the lockout switch to the OFF position. User Manual | Simpro MegaDumper® Original Instructions | English | v44.0 | March 2019 | Page...

  • Page 40: Safety Inspections

    7 Safety Inspections It is recommended to conduct regular safety inspections of the MegaDumper. This helps to ensure operator safety and extend the service life of the machine. The inspection schedule is divided into three parts: weekly, monthly and annual inspections.
  • Page 41 Service Checks Notes on repairs or Parts and materials Date Location Person complete maintenance required used User Manual | Simpro MegaDumper® Original Instructions | English | v44.0 | March 2019 | Page...

  • Page 42: Monthly Inspection

    Monthly inspection The following inspection should be carried out monthly, and the results recorded in the log. Monthly Inspection Checklist Category Item Check Entire Conduct a complete tipping cycle and check for General machine any faults or abnormal behaviour. Hydraulic rams Check there are no oil leaks.
  • Page 43 Parts and Service Checks Notes on repairs or Date Location materials Person complete maintenance required used User Manual | Simpro MegaDumper® Original Instructions | English | v44.0 | March 2019 | Page...

  • Page 44: Annual Inspection

    Annual inspection The following inspection should be carried out annually, and the results recorded in the log opposite. Annual Inspection Checklist Category Item Check Entire Conduct a complete tipping cycle and check for General machine any faults or abnormal behaviour. Hydraulic rams Check there are no oil leaks.
  • Page 45 Parts and Service Checks Notes on repairs or maintenance Date Location materials Person complete required used User Manual | Simpro MegaDumper® Original Instructions | English | v44.0 | March 2019 | Page...

  • Page 46: Spare Parts

    The following table includes only the most common MegaDumper spare parts as at the time of publication. A full list of parts is available on request from Simpro, or may be viewed on our support website here: https://simpro.world/bin-lifters/megadumper/spare-parts. Diagram Ref.
  • Page 47 User Manual | Simpro MegaDumper® Original Instructions | English | v44.0 | March 2019 | Page...

  • Page 48: Warranty

    The Agent shall keep accurate records of the date of all machine trials, sales. etc. Simpro will, at its option, repair or replace any items that fail or prove defective within the Warranty period.

  • Page 49: End User Claim Procedure

    Parts requiring replacement will be supplied by Simpro free of charge; in some cases, it may be necessary to source Parts locally if needed urgently, but Simpro must authorize this if the cost of the item exceeds $50.00 and is to be charged to Simpro.

  • Page 50: Ec Declaration Of Conformity

    10 EC Declaration of Conformity DECLARATION OF CONFORMITY ORIGINAL Business Name and Full Address of Manufacturer Simpro Handling Equipment Ltd 66 Rangi Road, Takanini 2105 Auckland, New Zealand Name and Address of Authorised Representative As above Name and Address of the Person in Community Authorised to compile the Technical...

  • Page 51: Notes

    11 Notes User Manual | Simpro MegaDumper® Original Instructions | English | v44.0 | March 2019 | Page...
  • Page 52 Equipment Ltd, company no. 1827916 . machines, crate stackers and goods lifts . The products in this catalogue contain Simpro products play an unobtrusive but intellectual property, including design essential role for thousands of companies elements registered to or licensed by around the world, in industries as diverse Simpro Handling Equipment Ltd.

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