Simpro MegaDumper Manuale utente

User Manual // Simpro MegaDumper®

Original Instructions // English // v86.0 // February 2022

USER MANUAL

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:

Point of interest

Point of warning

§Internal cross-reference (hyperlink in PDF edition)

Simpro partcode (hyperlink in PDF edition)

Errors in this document should be reported to info@simpro.world

User Manual // Simpro MegaDumper®

Original Instructions // English // v86.0 // February 2022 // Page 2

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Contents

1. Product Overview ......................................................................................................................... 5

1.1 Key features ......................................................................................................................................... 5

1.2 Construction ........................................................................................................................................ 6

1.3 Mechanism .......................................................................................................................................... 6

1.4 Safe Lifting Capacity .......................................................................................................................... 6

1.5 Duty cycle ............................................................................................................................................ 6

1.6 Service life ............................................................................................................................................ 7

1.7 Noise emissions .................................................................................................................................... 7

1.8 Environmental restrictions ................................................................................................................... 7

1.9 Ingress protection................................................................................................................................ 7

1.10 Notes..................................................................................................................................................... 8

2. Operating Instructions .................................................................................................................. 9

2.1 Before use ............................................................................................................................................ 9

2.2 Emplacing and removing bins........................................................................................................... 9

Cradle identification........................................................................................................................................9

Type-S and Type-E Cradles............................................................................................................................ 11

Type-C Cradle ................................................................................................................................................ 11

Type-M and Type-N Cradles.......................................................................................................................... 12

Type-X (Custom) Cradle ................................................................................................................................12

2.3 Operating the controls ..................................................................................................................... 13

Control Panel identification...........................................................................................................................13

Standard Control Panel ................................................................................................................................. 14

Autocycle Control Panel ...............................................................................................................................14

VSD Control Panel.......................................................................................................................................... 15

Safety-Monitored Control Panel ................................................................................................................... 15

3. Safety Information.......................................................................................................................17

3.1 Safety features................................................................................................................................... 17

3.2 Reasonably foreseeable misuse ...................................................................................................... 17

3.3 ISO12100 Hazard and Risk Assessment Guide ................................................................................ 17

3.4 ISO13849 Conformance Guide........................................................................................................ 23

3.5 Safety Norms...................................................................................................................................... 25

4. Care and Maintenance.............................................................................................................27

4.1 Quick Troubleshooting Guide .......................................................................................................... 27

4.2 Cleaning............................................................................................................................................. 28

4.3 Cradle adjustment ............................................................................................................................ 28

4.4 Cradle jams........................................................................................................................................ 31

4.5 Electrical System (battery)................................................................................................................ 33

User Manual // Simpro MegaDumper®

Original Instructions // English // v86.0 // February 2022 // Page 4

International conformance...........................................................................................................................33

Voltmeter ........................................................................................................................................................33

Batteries ..........................................................................................................................................................34

Battery charger .............................................................................................................................................. 34

Battery box ..................................................................................................................................................... 34

Appliance inlet ............................................................................................................................................... 35

Isolator switch ................................................................................................................................................. 35

Circuit breaker................................................................................................................................................ 35

Solar panel kit ................................................................................................................................................. 35

4.6 Electrical System (3-phase mains) ................................................................................................... 36

International conformance...........................................................................................................................36

Appliance inlet ............................................................................................................................................... 37

Isolator switch ................................................................................................................................................. 37

Power supply unit ........................................................................................................................................... 37

4.7 Electrical System (1-phase mains) ................................................................................................... 37

International conformance...........................................................................................................................37

Appliance inlet ............................................................................................................................................... 37

Isolator switch ................................................................................................................................................. 38

Transformer .....................................................................................................................................................38

Variable Speed Drive..................................................................................................................................... 38

4.8 Hydraulic System ............................................................................................................................... 38

Powerpack .....................................................................................................................................................38

Control valves................................................................................................................................................. 38

Lift rams ...........................................................................................................................................................39

Hydraulic fluid................................................................................................................................................. 39

Maintenance.................................................................................................................................................. 39

Hydraulic system schematic.......................................................................................................................... 39

4.9 Safety Door and Interlock System.................................................................................................... 40

4.10 Safety-Monitoring System (CAT3/CAT4 only).................................................................................. 43

5. Assembly, Handling, Transport & Storage ................................................................................ 43

6. Preventative Maintenance Inspections ................................................................................... 45

6.1 Pre-inspection checklist .................................................................................................................... 45

6.2 Weekly inspection ............................................................................................................................. 45

6.3 Monthly inspection............................................................................................................................ 49

6.4 Annual inspection ............................................................................................................................. 51

7. Spare Parts ................................................................................................................................... 53

8. Warranty....................................................................................................................................... 55

9. EC Declaration of Conformity ................................................................................................... 57

10. Notes............................................................................................................................................. 58

1. 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.

1.1 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



and a wide range of tipping heights, from

900mm to more than six metres.

2. A standard lifting capacity of 600kg.

3. A reliable electro-hydraulic mechanism

which requires very little maintenance.

4. A hot-dip galvanised frame and cradle.

5. A versatile cradle system which lifts many

common waste bins without modification,

clamping or retaining. The standard Type-E

cradle lifts EN840 wheelie bins from the

base, avoiding damage to the 

combing and extending bin life.

6. A modular design which can be easily

adapted to unique requirements, including

non-standard bins, tipping heights and

power supplies.

User Manual // Simpro MegaDumper®

Original Instructions // English // v86.0 // February 2022 // Page 6

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.

1.3 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 curved tracks.

The rams are supplied by a hydraulic pump, which may be driven by a 3-phase, 1-phase,

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

the operator to lift and lower the bin in a controlled manner.

1.4 Safe Lifting Capacity

The Safe Lifting Capacity of the standard MegaDumper is 600kg (550lb).

Some machines may be specified with different capacities. Refer to the rating plate to verify

the  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 bins heavier than the Safe Lifting Capacity.

1.5 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 ~300kg bins at 1800mm)

Net throughput

Number of bins

Units

24V/40Ah Gel Battery*

15,000kg

300 bins

Per charge

24V/40Ah Gel Battery with

continuous charge

3,000kg

10 bins

Per hour

24V/40Ah Gel Battery with solar

panel kit**

6,000kg

20 bins

Per day

Mains, 3-Phase ~415VAC

12,000kg

40 bins

Per hour

Mains, 1-Phase ~230VAC***

9,000kg

30 bins

Per hour

*4x 12V/20Ah batteries in series; default from 2015 **Subject to weather, latitude, and panel orientation; see §4.5.9 ***Deprecated since 2019

Powerpack specifications ca

1.6 Service life

The nominal service 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

1.7 Noise emissions

The noise emissions of the MegaDumper do not usually 

ear. Hearing protection is recommended if operating the machine for extended periods.

ISO standards specify that machinery noise emissions be measured in A-weighted

decibels, or dB(A). This is a unit of volume adjusted to reflect the sensitivity of human

hearing. Measurements for a dB(A) assessment are taken at a point 1.6 metres above the

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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;

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 MegaDumper in explosive, corrosive, acidic or alkaline environments.

1.9 Ingress protection

Item

IP Rating

Push buttons, switches, and lamps

IP66

Door interlock

IP66

Coded magnetic switch

IP66

Motor

IP54 (additional protection is provided by covers)

Overall

IP56 (optionally upgraded to IP66 or IP69)

User Manual // Simpro MegaDumper®

Original Instructions // English // v86.0 // February 2022 // Page 8

1.10 Notes

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

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

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

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. In cases where a discrepancy exists between the manual and

the actual product, the manual is to be used as a reference only.

6. Contact your authorized Simpro agent if any problems or faults are encountered with

the machine.

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

2.Ope rating Instruct ions

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.

2.1 Before use

Before operating a MegaDumper, check the following points to ensure that the machine is

stable and safe to use:

1. The machine is on firm ground, with a slope ratio less than 1:12.

2. All covers and safety guards are in place.

3. The wheel brakes are applied, and/or the feet are wound down onto the ground.

4. All personnel other than the operator are well clear of the machine.

5. The cradle is fully lowered.

6. The key is inserted and turned to the ON position.

7. The battery indicator (if fitted) shows an acceptable level of charge.

2.2 Emplacing and removing bins

The MegaDumper cradle is designed to allow bins to be emplaced and removed easily,

while also holding them securely throughout the tipping cycle.

Cradle identification

A range of different cradles may be fitted to the MegaDumper, depending on the types of

bin that the machine needs to empty. Use the following table to identify the correct

instructions for your machine.

It is important to understand how to correctly emplace bins onto the cradle. Bins that are

not correctly emplaced may come loose and damage the machine while being lifted,

or fall out when inverted.

Cradle Type

Primary Use

Bin Compatibility

Cradle Image

Refer

Type-S

(Short

EN840

base-lift

cradle)

General waste

and recycling

applications

EN840 mobile

garbage bins

(wheelie

bins)

-60L

-80L

-120L

-140L

-240L

-660L

§2.2.2

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