Related Manuals for Simpro Dumpmaster
Summary of Contents for Simpro Dumpmaster
- Page 1 SERVICE MANUAL S i m p r o D u m p m a s t e r © Simpro Handling Equipment Ltd | v25.0 | February 2017...
- Page 2 The following textual conventions are used throughout this document: Text in GREEN indicates a point of particular interest or importance. Text in RED indicates a point of warning, or a safety hazard. Any errors in this document should be reported by email to info@simpro.world.
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Page 3: Table Of Contents
3-Phase Configuration ..................16 4.9.4 3-Phase Direction of Rotation ................16 4.9.5 Removal and Refitting ..................16 4.10 Transformer ..........................17 4.11 Contactor ..........................17 4.12 Variable Speed Drive (VSD) .....................17 Service Manual | Simpro Dumpmaster | v25.0 | February 2017 | Page 2... - Page 4 4.13 Battery Electric Motor ......................18 4.13.1 General Description ..................... 18 4.13.2 Motor Brushes ..................... 18 4.14 Wiring Diagram for Battery Dumpmaster ................19 4.15 Circuit Diagram for Battery Dumpmaster ................20 4.16 Wiring Diagram for 3-Phase Dumpmaster ................21 4.17 Wiring Diagram for 1-Phase Dumpmaster ................22 5 Hydraulic Powerpack ........................
- Page 5 9 General ............................35 9.1 Lifting Chains ...........................35 9.1.1 Removal and Refitting ..................35 9.2 Castor Wheels .........................35 9.3 Dumpmaster Lifting Arrangement ..................36 10 Common Spare Parts ........................37 Service Manual | Simpro Dumpmaster | v25.0 | February 2017 | Page 4...
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Page 6: Dumpmaster Overview
Dumpmasters are fully guarded and have a locking door. Various door styles are used, depending on the application. The most common type on the Dumpmaster is side-hinged with a single door lock. Some machines have a ‘Lift-up’ door which is supported on 4 arms and balanced by gas struts. -
Page 7: Layout Of Parts
2 Layout of Parts Service Manual | Simpro Dumpmaster | v25.0 | February 2017 | Page 6... -
Page 8: Troubleshooting Guide
3 Troubleshooting Guide Faults generally fall into one of three broad categories - Electrical, Hydraulic, or Mechanical. The first step in troubleshooting should be to determine which category the fault comes under. Issue Possible Cause Category Action / Reference Battery Discharged (battery Refer to Section 4.3 or 4.4 machines only) Faulty door lock or wiring... - Page 9 Check tightness of all bolts. If lifting slowly, Pump bolts loose, seal leaking problem persists, seal may or oil foaming need to be replaced. Contact Simpro to request Cracked housing replacement powerpack. Service Manual | Simpro Dumpmaster | v25.0 | February 2017 | Page 8...
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Page 10: Electrical System
4 Electrical System General Description The standard Dumpmaster control circuit is 24v DC (however on certain older 3-phase machines it may be 24v AC). On new machines the control buttons switch the negative side of the motor contactor/relay and lowering coil. The positive side of the circuit is switched off when the door is open. -
Page 11: Care
4. Undo the red cable from the outer battery and slide it out. 5. Undo the black cable and slide the ‘inner’ battery out. 6. Install in reverse order, ensuring all four terminal bolts are tight. Service Manual | Simpro Dumpmaster | v25.0 | February 2017 | Page 10... -
Page 12: Battery Charger
Battery Charger Battery Charger •Fitted into steel bracket in battery compartment •Works with any mains supply between 110-240v •Digital battery management to prevent overcharging 4.4.1 Testing If the battery does not hold its charge, or will not accept a charge, the fault could be either the battery or the charger. -
Page 13: Motor Relay (Battery Machines Only)
1. Disconnect the wires from the relay, noting their position for correct replacement. 2. Remove the screws or band clamp holding the relay on to the motor. 3. Replace the relay, reconnect the wires and test. Service Manual | Simpro Dumpmaster | v25.0 | February 2017 | Page 12... -
Page 14: Lowering Valve Solenoid
Lowering Valve Solenoid Lowering Valve Solenoid •When open, this electromagnetic valve allows oil to flow back into the reservoir, lowering the cradle 4.6.1 Testing 1. Remove the outer powerpack cover as described in Section 4.2. 2. The solenoid should make a faint ‘click’ when the ‘Lower’ switch is pressed, and an LED in the plug should glow. -
Page 15: Testing
6. To refit, first replace the top section in the cover, and then clip the lower section on. Note that these can only be fitted in the correct orientation. Service Manual | Simpro Dumpmaster | v25.0 | February 2017 | Page 14... -
Page 16: Door Safety Interlock
The lock should be re-enabled using this key before use. The door lock can be retrofitted to some older Dumpmaster models. If required by a Hazard and Risk Assessment or the end-user’s site policies, Dumpmasters may be fitted with a system which continuously monitors all electrical equipment including the door lock. -
Page 17: Mains Electric Motor
3. If replacing with another motor, swap the adaptor flange and coupling over to the new motor. 4. When reassembling the powerpack, ensure the motor coupling lines up with the pump shaft. Service Manual | Simpro Dumpmaster | v25.0 | February 2017 | Page 16... -
Page 18: Transformer
There are dozens of parameters that can be set to suit specific applications. A list of settings is available from Simpro if needed. They can be connected to and calibrated by a PC that has the appropriate program and cable drivers loaded. -
Page 19: Battery Electric Motor
The motors have four brushes which wear down over time. As the brushes are difficult and time- consuming to replace, it is usually better to fit a complete new motor. Service Manual | Simpro Dumpmaster | v25.0 | February 2017 | Page 18... -
Page 20: Wiring Diagram For Battery Dumpmaster
4.14 Wiring Diagram for Battery Dumpmaster This is a generic diagram only. Individual machines may differ depending on date of manufacture. Always refer to the ‘as-built’ circuit diagram affixed to the inside of the powerpack cover. -
Page 21: Circuit Diagram For Battery Dumpmaster
This is a generic diagram only. Individual machines may differ depending on date of manufacture. Always refer to the ‘as-built’ circuit diagram affixed to the inside of the powerpack cover. Service Manual | Simpro Dumpmaster | v25.0 | February 2017 | Page 20... -
Page 22: Wiring Diagram For 3-Phase Dumpmaster
4.16 Wiring Diagram for 3-Phase Dumpmaster This is a generic diagram only. Individual machines may differ depending on date of manufacture. Always refer to the ‘as-built’ circuit diagram affixed to the inside of the powerpack cover. -
Page 23: Wiring Diagram For 1-Phase Dumpmaster
This is a generic diagram only. Individual machines may differ depending on date of manufacture. Always refer to the ‘as-built’ circuit diagram affixed to the inside of the powerpack cover. Service Manual | Simpro Dumpmaster | v25.0 | February 2017 | Page 22... -
Page 24: Hydraulic Powerpack
5 Hydraulic Powerpack General Description The hydraulic powerpacks used in Dumpmaster bin-tippers are very reliable and long-lasting, and require little regular maintenance. The motor driving the pump is either 24vdc/0.8kW or 3-phase/ 0.75kW. The motor, pump, oil tank, and all control valves are mounted into an integral unit. The four main control valves are: check valve, pressure-relief valve, solenoid lowering valve, and pressure-compensating lowering speed valve. -
Page 25: Layout Of Powerpack Valve Body
4. New oil may be put into the tank before refitting, or after. If oil is put in before, keep the level at least 30mm below the filler. 5. Remount the powerpack, and test-run the machine. 6. Refit the outer cover. Service Manual | Simpro Dumpmaster | v25.0 | February 2017 | Page 24... -
Page 26: Lowering Valve
Lowering Valve Lowering Valve •When activated, allows hydraulic oil to flow back into the tank, lowering the cradle •Exploded view showing cartridge, coil, retainer nut and DIN plug 5.4.1 Removal and Refitting 1. Unscrew the retainer nut and slide the coil off. 2. -
Page 27: Pressure-Relief Valve
5.7.1 Removal and Refitting 1. Remove the screw cap 2. Using tool supplied by Simpro, carefully unwind the check valve cartridge. 3. Clean thoroughly. 4. Refitting is the reversal of this process. -
Page 28: Hydraulic Ram
5. If there is a pinhole leak in a weld, it is generally best to fit a complete replacement ram body, and return the faulty one to Simpro for repair. If this is not feasible, mark the location of the hole, and grind a groove at least 3mm... -
Page 29: Ram Alignment
The hose-burst valve operates if the flow out of the ram exceeds approximately 10 litres/min. If it does lock, the hose must be repaired, then the ram extended slightly to reopen the valve. The valve cartridge may be unscrewed from the port with a tool available from Simpro. Service Manual... -
Page 30: Ram-End Rollers
2. The ‘base-to-bar’ length of the hydraulic ram, as shown in the diagram below. 3. The ‘base-to-groove’ length of the hydraulic ram, as shown in the diagram below. This information is essential for a correct replacement ram to be supplied. Simpro is not liable for costs caused by incorrect or inaccurate ram measurement. - Page 31 Service Manual | Simpro Dumpmaster | v25.0 | February 2017 | Page 30...
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Page 32: Bin Cradle
7 Bin Cradle General Description The standard bin-cradle consists of a pressed frame designed to hold plastic two-wheeled bins from 80l-240l. The main axle locates into ‘sliding plates’ inside each mast, and the ‘roller arm’ pivots on a bar near the top of the cradle. The roller arm has a ‘follower roller’ that runs on a specially shaped ‘tipping track’. -
Page 33: Cradle Jamming
Cradle Jamming Use the following procedures to identify and solve issues with cradle jamming or sticking. Note that the Dumpmaster cradle is not powered down, it is lowered by gravity alone. 7.3.1 Cradle jams at top of cycle 1. Check that the lowering valve solenoid is operating as per Section 4.6. -
Page 34: Guarding And Door
8 Guarding and Door 8.1 Mesh Guarding and Side-hinge Door Mesh side guards have a square steel tube frame, and are used with side-hinge doors only. A plastic bung with an 11mm hole at the ‘top inner corner’ locates onto a 10mm rod welded to the mast. Another plastic bung with a 10mm steel pin moulded in at the ‘lower inner corner’... -
Page 35: Sheet-Metal Guarding Assembly
To remove, lever out with a screwdriver. To refit, the plate must be bent; clip the ends in then tap the plate flat with a hammer. Service Manual | Simpro Dumpmaster | v25.0 | February 2017 | Page 34... -
Page 36: General
9 General Lifting Chains Dumpmaster bin tippers have two lifting chains; they are attached to the ram mount bracket by means of adjusting (levelling) bolts, and to the ‘sliding plates’ which run inside the masts. The chain is nickel-plated ½” British Standard Simplex (08B-1). The chains go around rollers on the bottom end of the ram, then up to the ‘top roller’;... -
Page 37: Dumpmaster Lifting Arrangement
Dumpmaster Lifting Arrangement Service Manual | Simpro Dumpmaster | v25.0 | February 2017 | Page 36... -
Page 38: Common Spare Parts
10 Common Spare Parts The following table includes only the most common parts. A full list of parts is available on request from Simpro, or may be viewed on our support site http://support.simpro.world Diagram Ref Part Number Description 0640200064 Top roller... - Page 39 Service Manual | Simpro Dumpmaster | v25.0 | February 2017 | Page 38...
- Page 40 Solar Powered Dumpmaster Many other options available http://simpro.world/dumpmaster © Simpro Handling Equipment Ltd | v25.0 | February 2017...
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