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Simpro MegaDumper User Manual

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USER MANUAL
User Manual
// Simpro MegaDumper®
Original Instructions // English // v86.0 // February 2022

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  • Page 1 USER MANUAL User Manual // Simpro MegaDumper® Original Instructions // English // v86.0 // February 2022...
  • Page 2 Copyright © 2022 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 // v86.0 // February 2022 // Page...

  • Page 4: Table Of Contents

    C ont ent s Product Overview ......................... 5 Key features ............................5 Construction ............................6 Mechanism ............................6 Safe Lifting Capacity .......................... 6 Duty cycle ............................6 Service life ............................7 Noise emissions ............................ 7 Environmental restrictions ........................7 Ingress protection ..........................7 1.10 Notes ..............................
  • Page 5 Monthly inspection ..........................49 Annual inspection ..........................51 Spare Parts ........................... 53 Warranty ............................55 EC Declaration of Conformity ....................57 10. Notes ............................. 58 User Manual // Simpro MegaDumper® Original Instructions // English // v86.0 // February 2022 // Page...

  • Page 6: Product Overview

    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. With a modular design, the MegaDumper is suitable for many different applications – from emptying rubbish into compactors, to pouring ingredients into mixers.

  • Page 7: Construction

    1.2 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: Service Life

    ’ w k 1.8 Environmental restrictions The MegaDumper may be used indoors or outdoors. However the following restrictions apply: 1. Minimum floor area 4 square metres, with a clear passage to exits; 2. Height above sea level not more than 1000m;...

  • 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. In cases where a discrepancy exists between the manual and the actual product, the manual is to be used as a reference only.

  • Page 10: Operating Instructions

    2 . O p e rat in g Instru ct io n s Before the MegaDumper is used for the first time, a Hazard and Risk Assessment should be completed as per §3.3. The cradle may also need to be adjusted as per §4.3.
  • Page 11 - 780L Type-N smaller (1200x1200 - Max §2.2.4 Nally bin dims base-lift 1200W x cradle) 1200L x 1200H Type-X Custom Custom bins §2.2.5 applications (Custom) User Manual // Simpro MegaDumper® Original Instructions // English // v86.0 // February 2022 // Page...

  • Page 12: Type-S And Type-E Cradles

    Type-S and Type-E Cradles Type-S and Type-E cradles should be adjusted before first use, as set out in §4.3.1. 2.2.2.1 Emplacing bins Open the door and place the bin onto the cradle: Large four-wheeled bins (660L/770L/1100L) should be positioned central and firm against the cradle backplate.

  • Page 13: Type-M And Type-N Cradles

    Removing bins Open the door and remove the bin from the cradle. Type-X (Custom) Cradle The exact procedure for emplacing bins into a custom cradle may vary. Contact your Simpro agent for advice or training if required. 2.2.5.1 Emplacing bins Open the door and place the bin, drum, or container onto the cradle, positioned centrally against the backplate.

  • Page 14: Operating The Controls

    The MegaDumper controls are designed to allow safe, intuitive operation of the machine. Control Panel identification The MegaDumper may be fitted with a variety of different controls, depending on the operational and safety requirements of the machine. Use the following table to identify the correct instructions for your machine.

  • Page 15: Standard Control Panel

    How to operate the controls of a machine with an autocycle controller, allowing bins to be emptied without continuous input. MegaDumper models that are fitted with an autocycle control system may be used in either MANUAL or AUTO mode, selected using a switch on the control panel.

  • Page 16: Vsd Control Panel

    How to operate a machine with a safety- rated PLC control unit and CAT3/CAT4 monitoring system. MegaDumper models that are fitted with a safety-monitored control system may be used in either MANUAL or AUTO mode, selected using a switch on the control panel.
  • Page 17 Once the cradle has lowered, the door is automatically unlocked for about 15 seconds. If the door re-locks, press the LOWER button to unlock it at any time. User Manual // Simpro MegaDumper® Original Instructions // English // v86.0 // February 2022 // Page...

  • Page 18: Safety Information

    The MegaDumper has been designed to be as safe as possible without restricting the ease- of-use and versatility of the machine. Before the MegaDumper is used for the first time, a Hazard and Risk Assessment should be completed as per §3.3.
  • Page 19 Risks evaluated as Very High, Extreme or Unacceptable are likely to require additional or uprated safety functions, as set out in §3.4. These must be specified at the time of order. User Manual // Simpro MegaDumper® Original Instructions // English // v86.0 // February 2022 // Page...
  • Page 20 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 also provided to identify, assess, and describe control measures for application-specific hazards.
  • Page 21 Powder should only be tipped when there is no wind, and/or a wind shield should be installed. Substances of a toxicity that cannot be protected against with PPE should Comments not be emptied with a MegaDumper. Alternative methods should be used. Damage to skin when used in extreme weather conditions Risk DPH:...
  • Page 22 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 23 Using rewards and/or disciplinary measures to encourage safe behaviours Posting signage, floor marking, or other warnings as appropriate Encouraging a culture of safety within the workplace User Manual // Simpro MegaDumper® Original Instructions // English // v86.0 // February 2022 // Page...

  • Page 24: Iso13849 Conformance Guide

    Any application-specific hazards must be assessed and if necessary, mitigated by custom guarding, interlocks, signage, or other safety features. The following section is provided to assist prospective MegaDumper owners in carrying out this process.
  • Page 25 5. Training of operators 6. Custom signage or floor markings The CAT3 Kit is the most common MegaDumper safety upgrade. It is recommended and usually specified if one or more of the following conditions apply: - Intensive 24/7 operating cycle...

  • Page 26: 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.
  • Page 27 The manufacturer cannot be held liable for the consequences of an inadequate earthing system. User Manual // Simpro MegaDumper® Original Instructions // English // v86.0 // February 2022 // Page...

  • Page 28: Care And Maintenance

    4 . C are and Main te na nc e 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 Troubleshooting Guide in §4.1 before contacting your Simpro agent for support.

  • Page 29: Cleaning

    Use of a Type-S or Type-E cradle that is not correctly adjusted may result in wheelie bins falling out of the cradle when tipped. In 2021 the MegaDumper model codes were simplified to a string of 8 or 9 characters, indicating the model, tipping height, cradle type and powerpack. The letter in the seventh position indicates the type of cradle;...
  • Page 30 2. Place a sample of the largest bin that is to be regularly emptied onto the cradle, ensuring it is centrally positioned and firm against the backplate. 3. Standing at the tipping face of the MegaDumper, use a 13mm torque wrench or spanner to release the bolts holding the lip catches to the cradle.
  • Page 31 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 // v86.0 // February 2022 // Page...

  • Page 32: Cradle Jams

    Lack of lubrication of the follower rollers or main cradle axle e. The cradle being out of level due to poorly adjusted or broken lifting chains. A technical guide on adjusting the MegaDumper lifting chains is available from Simpro. 0680200013...
  • Page 33 Lack of lubrication of the follower rollers or main cradle axle e. The cradle being out of level due to poorly adjusted or broken lifting chains. A technical guide on adjusting the MegaDumper lifting chains is available from Simpro. User Manual // Simpro MegaDumper®...

  • Page 34: Electrical System (Battery)

    0790050067 Voltmeter The MegaDumper is fitted with a voltmeter on the control panel, which is used to indicate the level of charge in the batteries. When the voltmeter reads below 24 volts the batteries are flat. The machine should not be used, and should be recharged as soon as possible.

  • Page 35: Batteries

    Batteries 0250050004 The MegaDumper is fitted with four 12V/20Ah deep-cycle gel VRLA batteries in two parallel series circuits to deliver 24VDC (nominal) to the motor and control circuits. The batteries are sealed and maintenance-free, with a nominal lifespan of five years.

  • Page 36: Appliance Inlet

    If you do not operate a machine with a solar panel, please disregard this section. The MegaDumper can be fitted with a solar panel kit for use in off-grid locations. The two 80W monocrystalline solar panels (dimensions 930x673x35mm) are mounted on adjustable steel brackets at the top of the mast, and charge the battery via a 12V/24V digital regulator.

  • Page 37: Electrical System (3-Phase Mains)

    A list of 3-phase power standards in different countries and territories may be viewed here: https://www.worldstandards.eu/three-phase-electric-power/. Connecting the MegaDumper to a power supply for which it is not designed may damage the motor and other components. Consult an electrician if you are unsure.

  • Page 38: Appliance Inlet

    415VAC 0790050174 Appliance inlet The MegaDumper is fitted with an IP66-rated appliance inlet, allowing it to be operated with a regular 3-phase extension lead. Depending on the phase polarity of the AC power supply, the power plug may need to be rewired to make the motor turn in the right direction.

  • Page 39: Isolator Switch

    Isolator switch 0210050002 The MegaDumper is fitted with an isolator switch on the forward side of the powerpack cover. This isolates the electrical systems from the power supply and should be turned OFF if the machine is to be placed in storage, or if the powerpack cover needs to be removed.

  • Page 40: Lift Rams

    – thus regulating the descent speed of the cradle (regardless of the weight of the bin). Lift rams The MegaDumper has two lift rams of the single-action displacement type. Each ram has a 0090090002 0140120002 1¼...

  • Page 41: Safety Door And Interlock System

    Swing-up safety door 1000000278 Standard MegaDumper models are fitted with a swing-up safety door, consisting of a steel tube frame with wire mesh or sheet-metal guarding, supported by two gas struts. This type of door takes up a minimum of space, but has several moving parts and will benefit from annual servicing as follows: 1.
  • Page 42 3. Open the safety door and carry out cleaning or maintenance as required. 4. Once the work is complete, shut the safety door and turn both interlock cams back to the LOCK position. 5. Remove the Override Key and store in a safe location. 6.
  • Page 43 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 // v86.0 // February 2022 // Page...

  • Page 44: Safety-Monitoring System (Cat3/Cat4 Only)

    4.10 Safety-Monitoring System (CAT3/CAT4 only) If you do not operate a machine with a CAT3 or CAT4 safety monitoring system, please disregard this section. Machines with CAT3 or CAT4 safety architecture are supplied with a Rockwell CR-30 Safety 0960050027 Relay to monitor the safety functions.
  • Page 45 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 // v86.0 // February 2022 // Page...

  • Page 46: Assembly, Handling, Transport & Storage

    5.2 Moving When the MegaDumper is standing upright it may be easily moved on its castor wheels, using the two grab-handles provided. To ensure stability the cradle should be positioned 100mm off the ground when moving.
  • Page 47 5.5 Storage If the MegaDumper is not to be used for a period of two months or more, it should be stored in a clean, dry place with good ventilation, at temperatures not below 0℃. Before placing the machine into storage, carry out the following procedures: 1.

  • Page 48: Preventative Maintenance Inspections

    6. P r e ve ntat ive Mainte na nc e In spe ct io ns Regular preventative maintenance inspections (PMIs) should be carried out on the MegaDumper. This helps ensure operator safety and extend the service life of the machine. The MegaDumper PMI schedule is divided into three parts: weekly, monthly, and annual inspections.
  • 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 // v86.0 // February 2022 // Page...

  • Page 50: Monthly Inspection

    6.3 Monthly inspection The following inspection should be carried out every month, and the results recorded in the log sheet 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 // v86.0 // February 2022 // Page...

  • Page 52: Annual Inspection

    6.4 Annual inspection The following inspection should be carried out every 12 months, and the results recorded in the log sheet 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 // v86.0 // February 2022 // Page...

  • Page 54: Spare Parts

    7 . S p are Parts The following table includes the most common MegaDumper spare parts as at the time of publication. Additional parts, accessories and prices may be viewed at the following web address: https://simpro.world/megadumper-spare-parts Where a part has been introduced or discontinued, the Date Of Manufacture (DOM)
  • Page 55 0220110000 Cradle Axle, drilled and zinc-plated 0060010013 Bronze Bush for cradle axle, Ø20-24 x 50mm long 0250040084 Castor, 200mm, unbraked 0250040085 Castor, 200mm, braked User Manual // Simpro MegaDumper® Original Instructions // English // v86.0 // February 2022 // Page...

  • 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

    9. 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 0 . N ote s User Manual // Simpro MegaDumper® Original Instructions // English // v86.0 // February 2022 // Page...
  • Page 60 +64 9 634 7445 Takanini 2105 sales@simpro.world Auckland, New Zealand shop.simpro.world PO Box 74 @simpro.world Takanini 2245 Auckland, New Zealand @SimproWorld_Lifters User Manual // Simpro MegaDumper® Original Version // English // v86.0 // February 2022 // ©2022 Simpro Handling Equipment Ltd...

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