Simpro Dumpmaster Manuale utente

User Manual | Simpro Dumpmaster®

Original Instructions | English | v59.0 | December 2019

USER MANUAL

S i m p r o D u m p m a s t 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 [email protected]

User Manual | Simpro Dumpmaster®

Original Instructions | English | v59.0 | December 2019 | Page 2

 
 
Contents 
Contents....................................................................................................................... 3 
Product Overview........................................................................................................ 5 
1 Key features........................................................................................................................... 5 
2 Construction .......................................................................................................................... 5 
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 EN840 Base-lift Cradle (standard) ............................................................................................... 21 
2.3 EN840 Comb-lift Cradle................................................................................................................ 21 
2.4 ANSI Bar-lift Cradle........................................................................................................................ 21 
2.5 ANSI Bar-lift Cradle with base ...................................................................................................... 22 
2.6 Trunnion-lift Cradle (DIN9797 Eurobins & Foodcap®)................................................................ 22 
2.7 Combi-Cradle and 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 

 
 
User Manual | Simpro Dumpmaster® 
Original Instructions | English | v59.0 | December 2019 | Page 4
Care and Maintenance............................................................................................ 27 
1 Quick Troubleshooting Guide............................................................................................ 27 
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........................................................................................................... 32 
4.5 Smart charger ............................................................................................................................... 32 
4.6 Appliance socket.......................................................................................................................... 32 
4.7 Lockout switch............................................................................................................................... 32 
4.8 Overload fuse................................................................................... Error! Bookmark not defined. 
4.9 Solar panel..................................................................................................................................... 33 
5 Electrical System (3-phase mains) .................................................................................... 34 
6 Electrical System (1-phase mains) .................................................................................... 35 
7 Hydraulic System ................................................................................................................. 37 
7.1 Powerpack .................................................................................................................................... 37 
7.2 Control valves................................................................................................................................ 37 
7.3 Lift Ram .......................................................................................................................................... 37 
7.4 Hydraulic fluid................................................................................................................................ 37 
7.5 Maintenance................................................................................................................................. 37 
7.6 Hydraulic system schematic ........................................................................................................ 37 
8 Safety door and interlock .................................................................................................. 38 
9 Safety-Monitoring System (PL(d)/PL(e) only) ...................................................................41 
Assembly, Handling, Transport & Storage................................................................ 43 
Safety Inspections...................................................................................................... 45 
1 Pre-inspection checklist ..................................................................................................... 45 
2 Weekly inspection............................................................................................................... 45 
3 Monthly inspection .............................................................................................................47 
4 Annual inspection ............................................................................................................... 49 
Spare Parts ................................................................................................................. 51 
Warranty..................................................................................................................... 53 
EC Declaration of Conformity............................................................................... 55 
Notes ....................................................................................................................... 56 
 

2.Product Overview

Congratulations on your purchase of a Simpro Dumpmaster bin-tipping machine. The

Dumpmaster is probably the safest, fastest and most reliable bin tipper on the market, and

has been continuously developed over more than thirty years.

The Dumpmaster is very versatile and can be used in numerous applications, ranging from

emptying rubbish bins into skips to pouring food ingredients into mixers. Regardless of the

application, the Dumpmaster has proven to be safe, reliable and

economical to operate, year after year.

2.1 Key features

Key features of the Dumpmaster include:

1. A unique tipping action

whereby bins are lifted

straight up, and then gently

rolled forward around the lip

of the skip or hopper being

emptied into. Benefits of this

design include a small

‘footprint’, and a wide range

of tipping heights available, from

700mm to more than six metres.

2. A standard weight capacity of 250kg.

3. A very reliable, maintenance-free design.

4. A fully hot-dip galvanised frame and cradle

as standard (with options for full or partial

stainless steel for hygiene-critical areas).

5. A standard cradle which lifts almost all

EN840 wheelie bins without clamping or

retaining.

6. A modular design which can be easily modified to suit a wide range of non-standard

bin sizes, shapes, and weights.

2.2 Construction

The Dumpmaster consists of a steel frame with vertical masts and stabilizing legs, bin cradle,

hydraulic ram, hydraulic powerpack, powerpack cover, control panel, electronic control

systems, guarding, castor wheels, and power lead or charging cable.

User Manual | Simpro Dumpmaster®

Original Instructions | English | v59.0 | December 2019 | Page 6

2.3 Mechanism

When the RAISE button is pressed, a hydraulic ram is extended, which pulls 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 ram is 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 Dumpmaster is 250 kilograms (550lb).

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

to the machine’s 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 Dumpmaster 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

Throughput (net

tipped material)

No. of bins equivalent

(average ~100kg each)

Measurement Unit

Battery

10,000kg

100 bins

per charge

Battery + Continuous

Charge

2,000kg

20 bins

per hour, nonstop

Battery + Solar Panel

3,000kg

30 bins

per day (in mostly

sunny conditions)

1-Phase Mains

6,000kg

60 bins

per hour, nonstop

3-Phase Mains

12,000kg

120 bins

per hour, nonstop

The standard Dumpmaster uses a battery power supply. Check the rating plate of your

machine if you are unsure of what type of power it uses.

2.6 Intended operational life

The intended operational life of the Dumpmaster is as follows:

Average Gross Bin Weight

Intended Operational Life

< 100kg

200,000 cycles

100kg –200kg

150,000 cycles

200kg –250kg

100,000 cycles

250kg –300kg

75,000 cycles

> 300kg

50,000 cycles

2.7 Noise emissions

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

as not exceeding ~60 dB(A) at the operator’s ear.

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’s working position.

2.8 Environmental restrictions

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

1. Minimum floor area 2 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 Dumpmaster®

Original Instructions | English | v59.0 | December 2019 | Page 8

2.10 Notes

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

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

2. This manual is written in English, and is to be considered the ‘Original Instructions’ for

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 info@simpro.world.

3.Safety Assessment

The Dumpmaster 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 Dumpmaster is used for

the first time, as described in Section 3.4.

3.1 Safety features

The safety features of the standard Dumpmaster 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 Dumpmaster 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

‘safe to operate’ if it 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 Dumpmaster owners to determine whether special safety features may be

required on their machine.

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