Simpro MegaDumper Series Bedienungsanleitung

User Manual | Simpro MegaDumper®

Original Instructions | English | v47.0 | December 2019

USER MANUAL

S i m p r o M e g a D u m p e r ®

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. These may be converted to Imperial units as follows:

1 kilogram (kg) = 2.2 pounds (lb)

1 metre (m) = 1000 millimetres (mm) = 39.37 inches (in) = 3.28 feet (ft) = 1.09 yards (yd)

The following stylistic conventions are used throughout this document:

Text in GREEN indicates a point of interest.

Text in RED indicates a point of warning or a safety hazard.

Errors in this document should be reported by email to i[email protected]

User Manual | Simpro MegaDumper®

Original Instructions | English | v47.0 | December 2019 | Page 2

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Contents 
Contents....................................................................................................................... 3 
Product Overview........................................................................................................ 5 
1 Key features........................................................................................................................... 5 
2 Construction .......................................................................................................................... 6 
3 Mechanism ............................................................................................................................ 6 
4 Safe Lifting Capacity ............................................................................................................ 6 
5 Duty cycle..............................................................................................................................6 
6 Intended operational life ..................................................................................................... 7 
7 Noise emissions ...................................................................................................................... 7 
8 Environmental restrictions .................................................................................................... 7 
9 Ingress protection ................................................................................................................. 7 
10 Notes ...................................................................................................................................... 8 
Safety Assessment ....................................................................................................... 9 
1 Safety features ...................................................................................................................... 9 
2 Reasonably foreseeable misuse ......................................................................................... 9 
3 OSH Compliance Specification Guide ..............................................................................9 
4 Hazard and Risk Assessment Guide ..................................................................................11 
5 Safety Norms........................................................................................................................ 17 
Operating Instructions ............................................................................................... 19 
1 Before operation................................................................................................................. 19 
2 Emplacing and removing bins .......................................................................................... 19 
2.1 Cradle identification..................................................................................................................... 19 
2.2 Type B/E Cradle............................................................................................................................. 21 
2.3 Type H Cradle................................................................................................................................ 21 
2.4 Type MB1/MB2 Cradle.................................................................................................................. 22 
2.5 Custom Cradle.............................................................................................................................. 22 
3 Operation of controls ......................................................................................................... 23 
3.1 Control Panel identification ......................................................................................................... 23 
3.2 Standard Control Panel................................................................................................................ 24 
3.3 Autocycle Control Panel.............................................................................................................. 24 
3.4 VSD Control Panel......................................................................................................................... 25 
3.5 Safety-Monitored Control Panel.................................................................................................. 25 
Care and Maintenance............................................................................................ 27 
1 Quick Troubleshooting Guide............................................................................................ 27 

 
 
User Manual | Simpro MegaDumper® 
Original Instructions | English | v47.0 | December 2019 | Page 4 
2 Cleaning ..............................................................................................................................28 
3 Cradle jams ......................................................................................................................... 28 
4 Electrical System (battery) ................................................................................................. 31 
4.1 Localisation.................................................................................................................................... 31 
4.2 Voltmeter ....................................................................................................................................... 31 
4.3 Battery charging ........................................................................................................................... 31 
4.4 Batteries and battery care........................................................................................................... 31 
4.5 Smart charger ............................................................................................................................... 32 
4.6 Battery enclosure box................................................................................................................... 32 
4.7 Appliance socket.......................................................................................................................... 32 
4.8 Lockout switch............................................................................................................................... 32 
4.1 Circuit breaker............................................................................................................................... 32 
4.2 Solar panel..................................................................................................................................... 33 
5 Electrical System (3-phase mains) .................................................................................... 34 
5.1 Localisation.................................................................................................................................... 34 
5.2 Appliance socket.......................................................................................................................... 34 
5.3 Lockout switch............................................................................................................................... 34 
5.4 Transformer .................................................................................................................................... 34 
6 Electrical System (1-phase mains) .................................................................................... 35 
6.1 Localisation.................................................................................................................................... 35 
6.2 Appliance socket.......................................................................................................................... 35 
6.3 Lockout switch............................................................................................................................... 35 
6.4 Transformer .................................................................................................................................... 35 
6.5 Variable Speed Drive ................................................................................................................... 35 
7 Hydraulic System .................................................................................................................37 
8 Safety door and interlock .................................................................................................. 38 
9 Safety-Monitoring System (PL(d)/PL(e) only) ...................................................................41 
Assembly, Handling, Transport & Storage................................................................ 43 
Safety Inspections...................................................................................................... 47 
1 Pre-inspection checklist ..................................................................................................... 47 
2 Weekly inspection...............................................................................................................47 
3 Monthly inspection ............................................................................................................. 49 
4 Annual inspection ............................................................................................................... 51 
Spare Parts ................................................................................................................. 53 
Warranty..................................................................................................................... 55 
EC Declaration of Conformity............................................................................... 57 
Notes ....................................................................................................................... 58 
 

2.Product Overview

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.

With a modular design, the MegaDumper is

suitable for many different

applications from emptying

rubbish into compactors, to

pouring ingredients into mixers.

No matter how it is used, the

MegaDumper has proven to be

safe, economical and easy to

operate, year after year.

2.1 Key features

Key features of the MegaDumper include:

1. A unique tipping action whereby bins are

lifted straight up, and then gently rolled

forward around the lip of the receptacle

being emptied into. Benefits of this design

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and a wide range of tipping heights, from

900mm to more than six metres.

2. A standard lifting capacity of 600kg.

3. An electro-hydraulic mechanism which is

extremely reliable and requires little

maintenance.

4. A fully hot-dip galvanised frame and

cradle.

5. A versatile cradle system which lifts many

common waste bins without modification,

clamping or retaining. The standard cradle

lifts 660L, 770L and 1100L wheelie bins from

the base, therefore preventing damage to

the lifting comb and extending bin life.

6. A modular design which can be easily

adapted to unique requirements, including

non-standard bins, custom tipping heights

or larger weight capacities.

User Manual | Simpro MegaDumper®

Original Instructions | English | v47.0 | December 2019 | Page 6

2.2 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.

2.3 Mechanism

When the RAISE button is pressed, two hydraulic rams are extended, which pull on an

arrangement of chains, causing the bin cradle to travel vertically in the masts. The cradle is

inverted at the appropriate height by an arrangement of arms, rollers, and a curved track.

The rams are supplied by a hydraulic power pack, which may have a 3-phase, 1-phase,

battery, or compressed-air motor. Electrical, hydraulic, and / or mechanical control

mechanisms allow the operator to raise or lower the bin in a controlled manner.

2.4 Safe Lifting Capacity

The Safe Lifting Capacity of the standard model MegaDumper is 600 kilograms (1320lb).

Some machines may be specified with different capacities to suit custom requirements. Refer

to the rating plate to verify the factory-designated Safe Lifting Capacity on any

given machine.

Safe Lifting Capacity is a gross figure, referring to the weight of the bin, its contents, and

any other external objects which have been placed on the cradle.

Never attempt to lift more than the factory-designated Safe Lifting Capacity noted on

the rating plate.

2.5 Duty cycle

The duty cycle of the MegaDumper depends on the type of power supply and powerpack

that is fitted to the machine, as well as various environmental factors and the manner in

which the machine is used. The figures given below are estimates only.

Power Supply

Duty Cycle (tipping at 1800mm)

Throughput (net

tipped material)

No. of bins equivalent

(average ~300kg each)

Units

Battery

16,000kg

53 bins

per charge

Battery + Continuous

Charge

2,500kg

8 bins

per hour, nonstop

Battery + Solar Panel

6,000kg

20 bins

per day (in mostly

sunny conditions)

1-Phase Mains

7,500kg

25 bins

per hour, nonstop

3-Phase Mains

10,000kg

33 bins

per hour, nonstop

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.

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

> 600kg

10,000 cycles

2.7 Noise emissions

The noise emissions of the MegaDumper bin lifter in standard operation have been assessed

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Operators are not required to wear hearing protection but are recommended to do so if

using the machine on a constant basis.

ISO standards for machinery safety specify that noise emissions are to be measured in A-

weighted decibels (dB(A)), a unit of volume which is adjusted to reflect the sensitivity of

human hearing. The measurements are taken at a point 1.6 metres above the ground at

the operator

2.8 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;

3. Ambient temperature not higher than +40℃and not lower than -10℃;

4. At ambient temperatures above 35℃, the relative humidity should not exceed 50%; at

lower temperatures, higher relative humidity is permitted;

Never operate the machine in flammable, explosive, corrosive, acidic or alkaline

environments.

2.9 Ingress protection

Item

IP Rating

Push buttons, switches and lamps

IP66

Door interlock

IP66

Coded magnetic switch

IP66

Motor

IP54 (note additional protection provided by covers)

Overall

IP56 (optional upgrade to IP66 or IP69K)

User Manual | Simpro MegaDumper®

Original Instructions | English | v47.0 | December 2019 | Page 8

2.10 Notes

1. This User Manual describes approved procedures for the operation, maintenance,

and routine inspection of the MegaDumper hydraulic bin-tipping machine.

2. This 

the purposes of EU Machinery Directive 2006/42/EC.

3. Operator(s) must read and understand this manual before using the machine.

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.

6. Contact your authorized Simpro agent if you encounter any problems or faults with

the machine.

7. Errors in this manual should be reported by email to [email protected]orld.

3.Safety Assessment

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.

3.1 Safety features

The safety features of the standard MegaDumper design are as follows:

1. Welded mesh and sheet-metal panels prevent personnel access to all moving parts.

2. A safety interlock system which disables the machine unless the door is shut, and

electrically locks the door as soon as the cradle leaves the ground.

3. A tipping action which maintains the weight of the bin within the machine footprint.

4. A pressure-compensating lowering valve which automatically regulates the lowering

speed regardless of the weight of the bin.

5. A control system which either:

a. stops the machine unless continuous operator input is received, or;

b. features a prominent EMERGENCY STOP button to disable the machine.

3.2 Reasonably foreseeable misuse

The reasonably foreseeable misuse considered in the standard MegaDumper design is as

follows:

1. Attempts to use the machine by untrained operators;

2. Attempts to empty bins that the cradle is not specifically designed to hold;

3. Attempts to bypass the door interlock or other safety systems;

4. Attempts to clear spilt material from inside the guarding without proper procedures;

5. Attempts to clean the machine without following proper procedures.

3.3 OSH Compliance Specification Guide

Companies in most jurisdictions (including Australia, NZ, UK, USA, Canada and the EU) are

required by law to provide a safe workplace for their staff, including ensuring that all new

and existing machinery is safe to operate.

Although the particulars of safety legislation differ, most countries accept that machinery is

can be demonstrated to comply with ISO 13849-1:2015 (or a regional

equivalent thereof).

ISO 13849-1:2015 may call for additional guarding and safety features, depending on the

particular circumstances in which a machine is to be used. The purpose of this section is to

assist potential MegaDumper owners to determine whether special safety features may be

required on their machine.

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