Simpro MegaDumper Bedienungsanleitung

User Manual | Simpro MegaDumper®

Original Instructions | English | v44.0 | March 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 the publisher.

For the purpose of standards compliance and international conformity, this document uses

Système International (SI) units. These may be converted to their Imperial equivalents 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 textual 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.

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

User Manual | Simpro MegaDumper®

Original Instructions | English | v44.0 | March 2019 | Page 2

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1Contents

1Contents ............................................................................................................................3

2Overview ...........................................................................................................................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

3Safety .................................................................................................................................9

Safety features ........................................................................................................................... 9

Reasonably foreseeable misuse ............................................................................................. 9

OSH compliance specification guide ................................................................................... 9

Hazard and Risk Assessment guide ...................................................................................... 11

Safety Norms............................................................................................................................. 17

4Operating Instructions ...................................................................................................19

Operating instructions - standard control system ............................................................. 19

Operating instructions - autocycle control system ........................................................... 20

Operating instructions - safety-monitored control system............................................... 21

5Maintenance..................................................................................................................23

Quick Troubleshooting Guide ............................................................................................... 23

Cleaning.................................................................................................................................... 24

Cradle jams............................................................................................................................... 24

Battery electrical system ........................................................................................................ 27

3-phase mains electrical system........................................................................................... 29

1-phase mains electrical system........................................................................................... 30

Hydraulic system ...................................................................................................................... 31

5.7.1 Powerpack .......................................................................................................31

5.7.2 Control valves ..................................................................................................31

5.7.3 Lift Rams ............................................................................................................31

5.7.4 Hydraulic fluid ..................................................................................................31

User Manual | Simpro MegaDumper®

Original Instructions | English | v44.0 | March 2019 | Page 4

5.7.5 Maintenance ...................................................................................................31

5.7.6 Hydraulic system schematic ..........................................................................32

Safety door and interlock ...................................................................................................... 32

5.8.1 Standard safety door (swing-up) ..................................................................32

5.8.2 Safety door interlock.......................................................................................33

Safety-monitoring system (PL(d)/PL(e) only) ...................................................................... 35

5.9.1 440C-CR30 Safety Relay .................................................................................35

5.9.2 Troubleshooting ...............................................................................................36

5.9.3 Configuration ...................................................................................................36

6Assembly, Handling, Transport & Storage...................................................................37

Assembly ................................................................................................................................... 37

Moving....................................................................................................................................... 37

Lifting .......................................................................................................................................... 37

Transportation........................................................................................................................... 37

Storage ...................................................................................................................................... 38

7Safety Inspections ..........................................................................................................39

Pre-inspection checklist.......................................................................................................... 39

Weekly inspection ................................................................................................................... 39

Monthly inspection .................................................................................................................. 41

Annual inspection.................................................................................................................... 43

8Spare Parts ......................................................................................................................45

9Warranty ..........................................................................................................................47

Definitions .................................................................................................................................. 47

Coverage.................................................................................................................................. 47

Exclusions................................................................................................................................... 47

End User Claim Procedure ..................................................................................................... 48

Agent Claim Handling Procedure........................................................................................ 48

10 EC Declaration of Conformity ..................................................................................49

11 Notes ............................................................................................................................50

2Overview

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 from

emptying rubbish bins into compactors, to pouring

food ingredients into mixers. But no matter how

it is used, the MegaDumper has proven to

be safe, economical and easy to

operate, year after year.

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 include high

stability, 

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 | v44.0 | March 2019 | Page 6

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.

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.

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 ~250kg each)

Units

Battery

16,000kg

64 bins

per charge

Battery + Continuous

Charge

2,500kg

10 bins

per hour, nonstop

Battery + Solar Panel

3000kg

12 bins

per day (in

mostly sunny

conditions)

1-Phase Mains

7,500kg

30 bins

per hour, nonstop

3-Phase Mains

10,000kg

40 bins

per hour, nonstop

The standard 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.

Intended operational life

The intended operational life of the MegaDumper is as follows:

Average Gross Bin Weight

Intended operational life

< 200kg

200,000 cycles

200kg 300kg

150,000 cycles

300kg 500kg

100,000 cycles

500kg 600kg

75,000 cycles

> 600kg

50,000 cycles

Noise emissions

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

as not exceed

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 to be taken at a point 1.6 metres

above the ground, immediately adjacent to the ope

Environmental restrictions

The MegaDumper may be used indoors or outdoors. However the following restrictions apply:

1. A minimum floor area of 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;

5. Never operate in flammable, explosive, corrosive, acidic or alkaline environments.

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)

Notes

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

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

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

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

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

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.

Contact your authorized Simpro agent in the first instance if you encounter any

problems or faults with the machine.

Any errors in this manual should be reported by email to [email protected].

User Manual | Simpro MegaDumper®

Original Instructions | English | v44.0 | March 2019 | Page 8

3Safety

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.

Safety features

The safety features of the MegaDumper are as follows:

1. Sheet-metal panels which prevent personnel access to all moving parts.

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

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.

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

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 customers to determine whether special safety features are

required on their machine.

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