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Simpro MegaDumper Series 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 | v47.0 | December 2019

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Summary of Contents for Simpro MegaDumper Series

  • 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 | v47.0 | December 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 Simpro Handling Equipment Ltd. For the purposes of standards compliance and international conformity, this document uses Système International (SI) units.
  • Page 3 User Manual | Simpro MegaDumper® Original Instructions | English | v47.0 | December 2019 | Page 2...

  • Page 4: Table Of Contents

    1 . C ont ent s Contents ........................3 Product Overview ......................5 Key features ........................... 5 Construction .......................... 6 Mechanism ..........................6 Safe Lifting Capacity ......................6 Duty cycle ..........................6 Intended operational life ..................... 7 Noise emissions ........................7 Environmental restrictions ....................
  • Page 5 Monthly inspection ......................49 Annual inspection ....................... 51 Spare Parts ......................... 53 Warranty ........................55 EC Declaration of Conformity ................57 Notes ........................58 User Manual | Simpro MegaDumper® Original Instructions | English | v47.0 | December 2019 | Page 4...

  • Page 6: Product Overview

    2 . P ro duct O ve rvie w Congratulations on your purchase of a Simpro MegaDumper® bin-tipping machine. Since its introduction in 1998, the MegaDumper has established a reputation as the safest and most reliable high-throughput bin lifter available.

  • Page 7: Construction

    The standard model MegaDumper uses a 3-phase mains power supply. Check the rating plate of your machine if you are unsure of what type of power supply it uses. User Manual | Simpro MegaDumper® Original Instructions | English | v47.0 | December 2019 | Page 6...

  • Page 8: Intended Operational Life

    2.6 Intended operational life The intended operational life of the MegaDumper is as follows: Average Gross Bin Weight Intended operational life < 200kg 100,000 cycles 200kg – 300kg 75,000 cycles 300kg – 500kg 50,000 cycles 500kg – 600kg 25,000 cycles >...

  • Page 9: Notes

    4. If the machine is to be leased, sold or otherwise transferred, then this manual shall accompany the machine. 5. This is a generic manual. Simpro reserves the right to change the design of our products at any time without notification. In cases where the manual does not correspond with the actual product, use the manual as a reference guide only, and contact your authorized Simpro agent for assistance if required.

  • Page 10: Safety Assessment

    3 . S af ety A sse ssme nt The MegaDumper has been designed to be as safe as possible without restricting the ease- of-use and versatility of the machine. A Hazard and Risk Assessment should be undertaken before the MegaDumper is used for the first time, as described in Section 3.4.
  • Page 11 Serious injury or Scarcely possible death Possible under specific PL(d) (irreversible) Frequent to continuous conditions and/or long exposure time Scarcely possible PL(e) User Manual | Simpro MegaDumper® Original Instructions | English | v47.0 | December 2019 | Page 10...

  • 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 | v47.0 | December 2019 | Page 12...
  • Page 14 3.4.2 Identified Hazards The following hazards have been identified that are intrinsic to the MegaDumper design. For each hazard a full Risk Evaluation has been completed and 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 Operators must wear appropriate Personal Protective Equipment (PPE) when measures operating machinery in extreme weather conditions. Comments Section 2.8 for MegaDumper environmental restrictions. User Manual | Simpro MegaDumper® Original Instructions | English | v47.0 | December 2019 | Page 14...
  • Page 16 Site-specific hazard: Operator DPH: Risk Factor: Other DPH: Risk persons Factor: Control measures Comments Site-specific hazard: Operator DPH: Risk Factor: Other DPH: Risk persons Factor: Control measures Comments Site-specific hazard: Operator DPH: Risk Factor: Other DPH: Risk persons Factor: Control measures Comments Site-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 staff. User Manual | Simpro MegaDumper® Original Instructions | English | v47.0 | December 2019 | Page 16...

  • Page 18: Safety Norms

    3.5 Safety Norms The following safety norms must be observed for the safe use of a MegaDumper bin lifter. Only trained and authorised personnel are permitted to use the machine. Operators must read and obey the instructions displayed on the machine. Never operate the machine on soft ground, or ground with a slope ratio greater than 1:12.
  • Page 19 The manufacturer cannot be held liable for the consequences of an inadequate earthing system. User Manual | Simpro MegaDumper® Original Instructions | English | v47.0 | December 2019 | Page 18...

  • Page 20: Operating Instructions

    4 . O pe rat in g Instru ct io n s 4.1 Before operation Before operating a MegaDumper of any type, check the following points to ensure that the machine is stable and safe to use. 1. The machine is on level hard ground, with a slope of 1:12 or less. 2.
  • Page 21 Type MB2 smaller - Max 4.2.4 780L Box dims Base-lift 1200W x 1200L x 1200H Custom Custom Custom bins 4.2.5 applications Example Only User Manual | Simpro MegaDumper® Original Instructions | English | v47.0 | December 2019 | Page 20...

  • Page 22: Type B/E Cradle

    4.2.2 Type B/E Cradle Type B and Type E cradles must be correctly configured before being used for the first time. Section 6.1.1 for cradle configuration instructions. 4.2.2.1 Emplacing bins Open the door and place the wheelie bin onto the cradle.

  • Page 23: Type Mb1/Mb2 Cradle

    Removing bins Open the door and gently remove the bin from the cradle. 4.2.5 Custom Cradle The exact procedure for emplacing bins into a custom cradle may vary. Contact your Simpro agent for advice or training if required. 4.2.5.1 Emplacing bins Open the door and place the bin, drum or container onto the cradle, positioned centrally against the backplate.

  • Page 24: Operation Of Controls

    4.3 Operation of controls All personnel using the machine must know how to correctly operate the controls. Incorrect operation may result in a safety hazard or damage to the machine. The MegaDumper controls are designed to allow simple, safe and fast operation of the electro-hydraulic systems.

  • Page 25: Standard Control Panel

    Wait for the contents of the bin to empty. 5. Press and hold the LOWER button until the cradle returns to the ground. User Manual | Simpro MegaDumper® Original Instructions | English | v47.0 | December 2019 | Page 24...

  • Page 26: Vsd Control Panel

    6. Open the door and remove the empty bin as per Section 4.2. 7. Repeat from step 1) as required. Release the RAISE or LOWER button, or press the EMERGENCY STOP button at any time to stop the cradle. 4.3.4 VSD Control Panel How to operate the controls of a VSD machine, with a joystick to allow progressive control of the cradle lifting speed.
  • Page 27 LOWER button to unlock it at any time. Release the RAISE or LOWER button, or press the EMERGENCY STOP button at any time to stop the cradle. User Manual | Simpro MegaDumper® Original Instructions | English | v47.0 | December 2019 | Page 26...

  • Page 28: Care And Maintenance

    Contact your agent if repair or service work is required. All repair and service work must be carried out by qualified personnel. Replacement parts must be supplied by Simpro or an authorized Simpro agent, and must be of the same design and specification as the original parts.

  • Page 29: Cleaning

    Lack of lubrication on the follower roller, or the main cradle axle. e. The cradle may be sitting out of level, due to poor adjustment of the lifting chains or to a breakage. A technical guide on adjusting the MegaDumper lifting chains is available from Simpro. Th ‘ ( )’...
  • Page 30 3. With the cradle lowered, rectify the problem by lubricating, straightening and/or realigning the mechanical components as required. If the mast is bent, you may need to contact your agent for support. 4. Close the door and run the machine through several complete lift/lower cycles with no bin in the cradle, to check that the problem has been properly resolved.
  • Page 31 Lack of lubrication on the follower roller, or the main cradle axle e. The cradle may be sitting out of level, due to poor adjustment of the lifting chains or to a breakage. A technical guide on adjusting the MegaDumper lifting chains is available from Simpro. Th ‘ ( )’...

  • Page 32: Electrical System (Battery)

    5.4 Electrical System (battery) If you do not operate a battery-powered machine, please disregard this section. Standard battery-powered machines are fitted with four deep-cycle sealed gel batteries in an external enclosure, a digital smart charger, and a series-wound 24VDC motor. The control voltage is 24VDC.

  • Page 33: Smart Charger

    175A Anderson-type plug. By disconnecting the Anderson plug, the batteries can be easily removed for offsite charging without moving the entire machine. Standalone battery chargers are available from Simpro. The enc...

  • Page 34: Solar Panel

    5.4.2 Solar panel If you do not operate a machine with a solar panel kit, please disregard this section. Battery machines may be fitted with a solar panel kit to allow operation in locations without mains power. The two 80W/24V monocrystalline solar panels (dimensions 930x673x35mm) are mounted on adjustable steel brackets at the top of the mast, and deliver power to the battery via a digital regulator.

  • Page 35: Electrical System (3-Phase Mains)

    The transformer input voltage and frequency depend on the standard 3-phase mains power in the country for which the machine was designed. User Manual | Simpro MegaDumper® Original Instructions | English | v47.0 | December 2019 | Page 34...

  • Page 36: Electrical System (1-Phase Mains)

    5.6 Electrical System (1-phase mains) If you do not operate a 1-phase mains machine, please disregard this section. Machines powered by 1-phase mains electricity are generally the same as other models, but are fitted with an electronic Variable Speed Drive (VSD), which operates a 3-phase 2-pole electric motor driving the hydraulic pump.
  • Page 37 User Manual | Simpro MegaDumper® Original Instructions | English | v47.0 | December 2019 | Page 36...

  • Page 38: Hydraulic System

    5.7 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: 5.7.2.1 Check valve This is a one-way valve which prevents oil from flowing back through the pump when the...

  • Page 39: Safety Door And Interlock

    Over time, the gas in the struts can leak out, resulting in reduced lifting force. If the struts do not hold the door open, they may need to be replaced. User Manual | Simpro MegaDumper® Original Instructions | English | v47.0 | December 2019 | Page 38...
  • Page 40 5.8.2 Safety door interlock The standard MegaDumper safety door is fitted with two solenoid-operated safety interlocks. The interlocks are Idec model HS5E-D4403-G or HS5E-F4403-G, ‘ w -to- ck’ , w h four internal contacts which are used to determine whether the door is closed and locked. 5.8.2.1 Interlock manual override This work should only be carried out by a qualified technician.
  • Page 41 Interlock specifications A summary of the interlock specifications is included below. The complete Idec user manual can be downloaded from the following link: https://goo.gl/iafPoI. User Manual | Simpro MegaDumper® Original Instructions | English | v47.0 | December 2019 | Page 40...

  • Page 42: Safety-Monitoring System (Pl(D)/Pl(E) Only)

    5.9 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 43 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 | v47.0 | December 2019 | Page 42...

  • Page 44: Assembly, Handling, Transport & Storage

    6. A ssem bly, H an d l in g , Tra n sp o rt & Sto rag e 6.1 Assembly The MegaDumper is usually delivered fully assembled. 6.1.1 Type B/E Cradle configuration As standard, MegaDumpers designed to empty EN840 wheelie bins are fitted with a Type B or Type E cradle.
  • Page 45 25mm proud. c. Conduct a complete lifting/lowering cycle and check that the bin is held securely throughout, and can then be easily removed. User Manual | Simpro MegaDumper® Original Instructions | English | v47.0 | December 2019 | Page 44...
  • Page 46 6.1.1.3 Adjusting the Secondary Swing Arms Type E cradles have an additional pair of pivoting arms called Secondary Swing Arms (yellow in the diagram above) ‘ ’ out of the cradle when inverted. Although the secondary arms have the same functionality as the primary arms (see Section 6.1.1.2) they are loosely sleeve-mounted on the axle, and moved by separate arm-guide collars (red in the diagram above).
  • Page 47 4. Charge the batteries (if fitted) and apply a suitable lubricant to the electrical contacts. 5. Turn the lockout switch to the OFF position. 6. Remove the key and store in a safe location. User Manual | Simpro MegaDumper® Original Instructions | English | v47.0 | December 2019 | Page 46...

  • Page 48: Safety Inspections

    The inspection procedures are described in the following pages, along with logs for recording the results. Simpro strongly recommends that safety inspections are carried out according to the schedule described in this section. Operators should immediately stop using the machine and request an inspection if any fault or abnormal operation is observed.
  • Page 49 Service Checks Notes on repairs or Parts and Date Location Person complete maintenance required materials used User Manual | Simpro MegaDumper® Original Instructions | English | v47.0 | December 2019 | Page 48...

  • Page 50: Monthly Inspection

    7.3 Monthly inspection The following inspection should be carried out every month, and the results recorded in the log on the following page. Monthly Inspection Checklist Category Item Check Conduct a complete tipping cycle and check for General Entire machine any faults or abnormal behaviour.
  • Page 51 Service Checks Notes on repairs or Parts and Date Location Person complete maintenance required materials used User Manual | Simpro MegaDumper® Original Instructions | English | v47.0 | December 2019 | Page 50...

  • Page 52: Annual Inspection

    7.4 Annual inspection The following inspection should be carried out every 12 months, and the results recorded in the log on the following page. Annual Inspection Checklist Category Item Check Conduct a complete tipping cycle and check for General Entire machine any faults or abnormal behaviour.
  • Page 53 Service Checks Notes on repairs or Parts and Date Location Person complete maintenance required materials used User Manual | Simpro MegaDumper® Original Instructions | English | v47.0 | December 2019 | Page 52...

  • Page 54: Spare Parts

    8 . S pare 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 website here: https://simpro.world/bin-lifters/megadumper/spare-parts. Diagram Ref.
  • Page 55 User Manual | Simpro MegaDumper® Original Instructions | English | v47.0 | December 2019 | Page 54...

  • Page 56: 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 57 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 58: Ec Declaration Of Conformity

    1 0 . E C D ec l arat io n of C onf o rm it y 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...

  • Page 59: Notes

    1 1 . N ote s User Manual | Simpro MegaDumper® Original Instructions | English | v47.0 | December 2019 | Page 58...
  • Page 60 +64 9 634 7445 Takanini 2105 sales@simpro.world Auckland, New Zealand shop.simpro.world PO Box 202236 @simpro.world Southgate, Takanini 2246 Auckland, New Zealand @SimproWorld_Lifters User Manual | Simpro MegaDumper® Original Version | English | v47.0 | December 2019 | © 2019 Simpro Handling Equipment Ltd...

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