SIMPRO Dumpmaster Empty Any Bin at Any Height User Manual

: June 1, 2024
: Simpro

Table of Contents

SIMPRO Dumpmaster Empty Any Bin at Any Height
Product Information
Product Usage Instructions
Frequently Asked Questions
Product Overview
Operating Instructions
Care and Maintenance
Assembly, Handling and Storage
Safety Assessment
Technical Data
With 200L Eurobin
Spare Parts
Warranty
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

SIMPRO Dumpmaster Empty Any Bin at Any Height

SIMPRO-Dumpmaster-Empty-Any-Bin-at-Any-Height-image

Product Information

Product Overview

Congratulations on your purchase of a Simpro Dumpmaster bin-tipping machine. Dumpmaster is a versatile bin lifter suitable for various applications, known for its safety, reliability, and cost-effectiveness.

Key Features

A unique tipping action lifting bins straight up and then gently rolling them forward around the lip of the skip or hopper.
Modular design for versatility in applications.
Wide range of tipping heights available from 700mm to more than six meters.

Product Usage Instructions

1. Safety Precautions

Before using the Dumpmaster, ensure you have read the safety instructions in the manual carefully. Always wear appropriate safety gear when operating the machine.

2. Setup

Place the Dumpmaster on a flat, stable surface with enough clearance around it for operation. Ensure all components are securely connected and in place.

3. Operating the Dumpmaster

Turn on the powerpack according to the manufacturer’s instructions.
Position the bin to be tipped securely on the machine.
Engage the tipping mechanism as per the operational guidelines.
Monitor the tipping process and ensure the contents are emptied safely.

Frequently Asked Questions

Q: How do I clean the Dumpmaster?
- A: To clean the Dumpmaster, use a damp cloth with mild detergent to wipe down the surfaces. Avoid using harsh chemicals that may damage the machine.
Q: Can I use the Dumpmaster for hazardous materials?
- A: It is recommended to consult with the manufacturer before using the Dumpmaster for hazardous materials to ensure safety and compliance with regulations.

// User Manual
User Manual // Simpro Dumpmaster® Original Instructions // English // v126.0 // July 2023

Copyright © 2023 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.

This document belongs to the machine specified below, and should accompany the machine in the event that it is leased, sold, or otherwise transferred.

Model

Serial

Owner

Delivery Date

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) 1 litre (L) = 1000 cubic centimetres (cc) = 0.264 US liquid Gallons (Gal) 1 kilopascal (kPa) = 0.01 bar (bar) = 0.145 pounds per square inch (psi)
The following stylistic conventions are used throughout this document: Point of interest Safety hazard
§ Section reference (hyperlink in PDF edition)
Simpro partcode (hyperlink in PDF edition)
Errors in this document should be reported by email to info@simpro.world

Product Overview

Congratulations on your purchase of a Simpro Dumpmaster bin-tipping machine. In production for more than three decades, Dumpmaster may be the most sophisticated and versatile bin lifter on the market today.
With a modular design, Dumpmaster can be used in numerous applications, ranging from emptying rubbish bins into skips to pouring food ingredients into mixers. No matter the application, Dumpmaster continues proving to be a safe, reliable, and economical solution, for year after year.
1.1 Key features
Key features of 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 reliable, low-maintenance design; 4. A hot-dip galvanised frame and cradle (also available in
304-grade stainless steel); 5. Standard cradles to suit a variety of wheelie bins,
rollout carts, Eurobins, drums, and containers; 6. A modular design which can be easily
modified to suit a wide range of non-standard bin sizes, shapes, and weights.
1.2 Construction
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.
1.3 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.

1.4 Safe Working Load
The Safe Lifting Capacity of the standard Dumpmaster is 250kg (550lb).
Safe Working Load (SWL) is a gross figure, referring to the weight of the bin, its contents, and any other objects placed on the cradle. Custom machines may be specified with different Safe Working Loads. The rating plate should be the first point of reference to determine SWL on any given machine.
Never attempt to lift bins that are heavier than the factory-specified Safe Working Load.

1.5 Duty cycle
The duty cycle of Dumpmaster depends on the type of powerpack that is fitted to the machine, environmental factors, and the manner in which the machine is used. The figures provided below are indicative only.

Power supply

Duty Cycle (tipping ~100kg bins at 1800mm)

Net throughput Number of bins

Units

Battery, 24V/20Ah GEL*

10,000kg

100 bins

Per charge

Battery, 24V/20Ah GEL with continuous charge Battery 24V/20Ah GEL with solar panel kit

3,000kg 3,000kg

30 bins 30 bins

Per hour Per day

Mains, 3-Phase ~415VAC

6,000kg

60 bins

Per hour

Mains, 1-Phase ~230VAC

4,000kg

40 bins

2x 12V/20Ah batteries in series

Subject to weather, latitude, and panel orientation; see §3.4.8

Per hour
Deprecated since 2019

Power supply specifications can be found on the machine’s rating plate.

1.6 Service life
The nominal service life of Dumpmaster is as follows:

Average Gross Bin Weight < 100kg 100kg 200kg 200kg 250kg 250kg 300kg

Nominal service life 200,000 cycles 150,000 cycles 100,000 cycles 75,000 cycles

1.7 Noise emissions
The noise emissions of Dumpmaster do not typically exceed ~60 dB(A) at the operator’s ear. Hearing protection is recommended if operating the machine for extended periods.
ISO standards for machinery safety specify that noise emissions are to be measured in Aweighted 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.

User Manual // Simpro Dumpmaster® Original Instructions // English // v126.0 // July 2023 // Page 6

1.8 Environmental restrictions
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 Dumpmaster in explosive, corrosive, acidic or alkaline environments.

1.9 Ingress protection
Item Push buttons, switches, and lamps Door interlock Coded magnetic switch Motor Overall

IP Rating IP66 IP66 IP66 IP54 (additional protection is provided by covers) IP56 (optionally upgraded to IP66 or IP69)

1.10 Notes
1. This User Manual describes approved procedures for the operation, maintenance, and routine inspection of the Simpro 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. 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 info@simpro.world.

User Manual // Simpro Dumpmaster® Original Instructions // English // v126.0 // July 2023 // Page 8

Operating Instructions

Before the machine is used for the first time, a site-specific Hazard and Risk Assessment should be completed as per §5.3.

2.1 Before operation
Before operating a Dumpmaster, make sure that it is stable and safe to use as follows;-
1. CHECK that the machine is on firm ground with a slope of not more than 8%. 2. CHECK that all covers and guard panels are in place. 3. CHECK that both wheel brakes are applied. 4. CHECK that all personnel other than the operator are well clear of the machine. 5. CHECK that the key is inserted and turned to the ON position. 6. CHECK that the battery indicator (if fitted) shows an acceptable level of charge.

2.2 Emplacing and removing bins
Dumpmaster can be fitted with a range of different cradles, allowing different types of bin to be emptied. The cradles are designed to allow the bins to be emplaced and removed easily, while also holding them securely throughout the tipping cycle.
In the following section, use the image on the right to identify the cradle fitted to your Dumpmaster, and follow the corresponding instructions to emplace and remove bins.

Bins which are not correctly emplaced in the cradle may be damaged by the frame and guarding while being lifted, or fall out of the cradle when inverted.

2.2.1 Type-E cradle
The Type-E cradle can be used to empty almost all 80L, 120L, 140L and 240L wheelie bins, as per §3.3.1.

2.2.1.1 Emplacing bins Open the door and place the wheelie bin onto the cradle. For 240L wheelie bins, both wheels should be located in a catch, one on each side of the cradle. For smaller bins such as 80L, 120L and 140L, only the left-hand wheel should be located in a catch.

If the bin is difficult to emplace in the cradle, or the wheels appear to be jamming against the wheel catches, see §3.3.1.

When the bin is correctly emplaced, close the door.

2.2.1.2 Removing bins

The Type-E cradle (also known as the standard cradle) consists of a steel bucket pressing with wheel catches mounted on each side.

Open the door and pull the wheelie bin backwards out of the cradle.

2.2.2 Type-C cradle
The Type-C cradle can be used to empty almost all 80L, 120L, 140L, 240L and 360L wheelie bins, as per §3.3.2.

2.2.2.1 Emplacing bins Open the door and place the wheelie bin into the machine, centred and firm against the cradle backplate. Take care that the lifting teeth are properly hooked into the bin combing; smaller bins such as 60L and 80L may need to be tilted or lifted slightly to ensure a proper `catch’.

When the bin is correctly emplaced, close the door.

2.2.2.2 Removing bins Open the door and pull the wheelie bin backwards out of the cradle. The bin may need to be tilted slightly to disengage the comb from the cradle `teeth’.

The Type-C cradle consists of a powdercoated steel backplate with a gravity- locked comb lift mechanism.

2.2.3 Type-A cradle
The Type-A cradle can be used to empty almost all 24-Gal, 32-Gal, 48-Gal, 64-Gal, and 96-Gal carts, as per §3.3.3.

2.2.3.1 Emplacing bins Open the door and place the rollout cart into the machine, centred and firm against the cradle backplate. Make sure the cart is correctly engaged with the catches on the cradle; some carts may need to be tilted or shaken slightly to ensure a proper `catch’.

When the cart is correctly emplaced, close the door.

2.2.3.2 Removing bins

Open the door and pull the rollout cart backwards out of

the cradle. Some carts may need to be tilted or shaken

slightly to disengage them from the lifting catches.

The Type-A cradle consists of a powdercoated steel backplate with two adjustable bin catches.

2.2.4 Type-D cradle
The Type-D cradle can be used to empty almost all 200L and 300L Eurobins, as per §3.3.4.

2.2.4.1 Emplacing bins Open the door and wheel the Eurobin into the cradle, centred and firm against the cradle backplate. Make sure both trunnions are properly seated in the lifting arms.

When the Eurobin is correctly emplaced, close the door.

2.2.4.2 Removing bins Open the door and pull the Eurobin backwards out of the cradle.

The Type-C cradle consists of two steel arms with counterweights and lasercut trunnion slots.

User Manual // Simpro Dumpmaster® Original Instructions // English // v126.0 // July 2023 // Page 10

2.2.5 Type-X/CB/AB cradles
Type-X, Type-CB and Type-AB cradles can be used to empty various non-standard bins, buckets, drums, and containers, as per §3.3.5.

Open the door and place the bin, bucket, drum, or container onto the cradle, centred and firm against the cradle backplate.

When the bin is correctly emplaced, close the door.

Type-X cradles (also known as Combo Cradles) consist of a steel bucket pressing with attachment points for catches and packers.

Type-CB and Type-AB cradles consist of a steel bucket pressing with attachment points for catches and packers, mounted onto a Type-C or Type-A cradle backplate.

2.2.5.1 Removing bins Open the door and pull the bin, bucket, drum, or container backwards out of the cradle.

2.3 Operating the controls
Dumpmaster can be fitted with a range of different control panels, depending on the operational and safety requirements of the machine. The controls are designed to be as simple and intuitive as possible, while providing the necessary functionality.
In the following section, use the image on the right to identify the control panel fitted to your Dumpmaster, and follow the corresponding instructions to operate the machine.
The control panel is normally atop the powerpack cover, but on machines with a CAT3/CAT4 safety-monitoring system it is mounted on the door of the control cabinet.

Improper operation of the controls can result in damage to the machine, the bin, and/or other property, and can place the operator and other personnel at risk of injury.

2.3.1 Standard Control Panel
How to operate a standard Dumpmaster.

1. CHECK the machine is safe to use as

per §2.1.

2. OPEN the safety door.

3. LOAD the full bin onto the cradle as per

§2.2 then SHUT the safety door. 4. PRESS AND HOLD the UP button until the

The control panel on a standard Dumpmaster with a battery powerpack. Mains- powered machines have a similar control panel, but no voltmeter.

cradle reaches the inverted position.

5. RELEASE the UP button and WAIT while the contents of the bin are emptied.

6. PRESS AND HOLD the DOWN button until the cradle returns to ground level.

RELEASE the UP/DOWN button to stop the cradle at any time.

7. OPEN the safety door and REMOVE the empty bin as per §2.2. 8. REPEAT from step 2. as required.

2.3.2 Autocycle Control Panel
How to operate an autocycle Dumpmaster.

2.3.2.1 AUTO MODE operation

1. CHECK the machine is safe to use as per §2.1.

2. TURN the CONTROL MODE switch to AUTO.

3. OPEN the safety door (if the door is locked,

PRESS the DOOR UNLOCK button first).

4. LOAD the full bin onto the cradle as per §2.2 then SHUT the safety door.
5. PRESS the UP button for ~0.5 seconds.

The control panel on a Dumpmaster with an autocycle controller and mains powerpack. Battery-powered machines have a similar control panel, but with a voltmeter and pushbutton CONTROL MODE selector.

6. WAIT while the bin is automatically lifted, emptied, and returned to ground level.

PRESS the EMERGENCY STOP button to stop the cradle at any time.

7. OPEN the safety door and REMOVE the empty bin as per §2.2. 8. REPEAT from step 3. as required.
2.3.2.2 MANUAL MODE operation 1. CHECK the machine is safe to use as per §2.1. 2. TURN the CONTROL MODE switch to MANUAL. 3. OPEN the safety door (if the door is locked, PRESS the DOOR UNLOCK button first). 4. LOAD the bin onto the cradle as per §2.2 then SHUT the safety door. 5. PRESS AND HOLD the UP button until the cradle reaches the inverted position. 6. RELEASE the UP button and WAIT while the contents of the bin are emptied. 7. PRESS AND HOLD the DOWN button until the cradle returns to ground level. 8. OPEN the safety door and REMOVE the empty bin as per §2.2. 9. REPEAT from step 3. as required.

When the cradle returns to ground level, the safety door is unlocked for ~15 seconds. PRESS the DOOR UNLOCK button to unlock the door for a further ~15 seconds if needed.

2.3.3 Joystick Control Panel
How to operate a Dumpmaster with a Variable Speed Drive and joystick.

1. CHECK the machine is safe to use as per §2.1.

2. OPEN the safety door.

3. LOAD the full bin onto the cradle as per §2.2

then SHUT the safety door. 4. PRESS FORWARDS on the joystick to lift the
cradle at full speed until it starts to rotate.

The control panel on a Dumpmaster with a Variable Speed Drive and joystick. These features are only available on mains-powered machines.

5. ADJUST the joystick to reduce the cradle speed and empty the bin progressively.

6. PRESS BACKWARDS on the joystick until the cradle returns to ground level.

RELEASE the joystick to stop the cradle at any time.

7. OPEN the safety door and REMOVE the empty bin as per §2.2. 8. REPEAT from step 2. as required.

User Manual // Simpro Dumpmaster® Original Instructions // English // v126.0 // July 2023 // Page 12

2.3.4 Safety-Monitored Control Panel
How to operate a machine with a CAT3/CAT4 safety-monitoring system.

Machines with a CAT3 safety-monitoring system can be operated in either MANUAL or AUTO mode, selected using the CONTROL MODE switch. In both modes, the safety system must be RESET before use, as set out below.

2.3.4.1 SAFE MODE reset To reset the safety-monitoring system, close the safety door, release the E-stop, then press and hold the SAFE MODE RESET button for ~2 seconds. A diagnostic check will be carried out on the safety functions, with the following results;-

1. If no faults are detected, the SAFE MODE

RESET button will stop glowing this means

that the system has entered READY MODE,

and the machine can be operated.

2. If any faults are detected, the SAFE

MODE RESET button will continue glowing this means that the system has

The control panel on a Dumpmaster with a CAT3 safety-monitoring system. These features are only available on mains-powered machines.

remained in SAFE MODE, and the machine cannot be operated until the fault has

been found and rectified, as per §3.8.4.

2.3.4.2 AUTO mode operation 1. CHECK the machine is safe to use as per §2.1. 2. TURN the CONTROL MODE switch to AUTO. 3. OPEN the safety door (if the door is locked, PRESS the DOOR UNLOCK button first). 4. LOAD the full bin onto the cradle as per §2.2 and SHUT the safety door. 5. RESET the safety-monitoring system as per §2.3.4.1. 6. PRESS the UP button for ~0.5 seconds. 7. WAIT while the bin is automatically lifted, emptied, and returned to ground level.

PRESS the EMERGENCY STOP button to stop the cradle at any time.

8. OPEN the safety door and REMOVE the empty bin as per §2.2. 9. REPEAT from step 3. as required.
2.3.4.3 MANUAL mode operation 1. CHECK the machine is safe to use as per §2.1. 2. TURN the CONTROL MODE switch to MANUAL. 3. OPEN the safety door (if the door is locked, PRESS the DOOR UNLOCK button first). 4. LOAD the bin onto the cradle as per §2.2 and SHUT the safety door. 5. RESET the safety-monitoring system as per §2.3.4.1. 6. PRESS AND HOLD the UP button until the cradle reaches the inverted position.

7. RELEASE the UP button and WAIT while the contents of the bin are emptied. 8. PRESS AND HOLD the DOWN button until the cradle returns to ground level. RELEASE the UP/DOWN button to stop the cradle at any time. 9. OPEN the safety door and REMOVE the empty bin as per §2.2. 10. REPEAT from step 3. as required. When the cradle returns to ground level, the safety door is unlocked for ~15 seconds. PRESS the DOOR UNLOCK button to unlock the door for a further ~15 seconds if needed.
2.4 Battery charging
Battery Dumpmasters should be recharged anytime the voltmeter reads less than 24 Volts. The procedure to recharge the batteries is as follows;-

Place the machine in a secure area and lock both foot-brakes. 2) Connect a 1-phase extension cord into the IP66 appliance inlet on the side of the
machine (opposite the control panel). 3) Connect the extension lead into a 1-phase power outlet, and turn the wall switch ON. 4) Wait while the batteries are recharged. If the batteries a completely flat, a full charge
will take around four hours. The machine can be used while being recharged. The onboard charger automatically adapts to different inputs (85-264VAC 50/60Hz 1-ph), manages the charging cycle to maximise battery life, and prevents overcharging. For optimum battery life, Dumpmaster should be placed on charge overnight and on weekends (even if the batteries are already fully charged), as per §3.4.3.1. The charger delivers enough power to empty a 100kg bin in about 3 minutes, which means that a battery-powered Dumpmaster can be left plugged in and used as a mains-powered machine, as per §1.5.
User Manual // Simpro Dumpmaster® Original Instructions // English // v126.0 // July 2023 // Page 14

2.5 Safety norms
The following safety norms must be observed for the safe use of a Dumpmaster bin lifter.
Only trained and authorised personnel may use the machine.
Operators must read and obey all instructions displayed on the machine.
Never operate the machine on soft ground, or ground with a slope ratio greater than 1:12.
Never operate machine on the edge of a raised dock or platform, unless designed for that application.
Never operate the machine with any covers or guards removed.
Never attempt to empty the contents of closed-top drums, unless the machine is securely bolted down.
All persons other than the operator must keep at least two metres clear while the machine is in use.
Always keep hands and feet well clear of the bin and cradle when operating.
Never place limbs, feet or foreign objects under the side guards or safety door.
Never attempt to empty over-filled bins, or bins that weigh more than the machine’s rated capacity.

Before connecting machine to mains supply, ensure voltage and frequency correspond with that listed on the rating plate.
Do not use an extension lead longer than 15 metres to connect the machine to mains power.
Do not operate if power lead, insulation or power plugs are damaged.
Do not connect a damp power plug or socket.
Ensure the power supply socket is fitted with a residual current device.
Ensure there is complete continuity between the machine and an effective earthing system which complies with local and national regulations. The manufacturer cannot be held liable for the consequences of an inadequate earthing system.
User Manual // Simpro Dumpmaster® Original Instructions // English // v126.0 // July 2023 // Page 16

Care and Maintenance

Dumpmaster 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 §3.1 before contacting your Simpro agent for support.
Contact your Simpro agent if repair or service work is required. All repair and service work must be carried out by qualified, authorized personnel. Replacement parts must be supplied by Simpro or an authorized Simpro agent, and must be of the same design and specification as the original parts.

3.1 Quick Troubleshooting Guide
Refer to the Quick Troubleshooting Guide below before contacting your agent for support.

Problem
The machine will not lift bins, and the motor does not run
The machine will not lift bins, although the motor runs
Cradle will not come down from the fully raised position
Cradle jamming part-way down

Possible Causes
Flat battery
Triggered circuit breaker (60A fuse on older models) Faulty up/down switch or wiring Faulty 24VDC motor solenoid or 415VAC motor contactor
Interlock switch on door not working
Bin too heavy
Pressure-relief valve set incorrectly 3-phase motor running backwards
Faulty up/down switch, wiring, or lowering valve coil
Cradle jamming in mast
Lift ram jammed or seized
Follower roller not turning freely Roller arm twisted or cradle sitting out of level

Remedy
The battery needs to be charged if voltmeter reads less than 24 volts.
Wait 1-2 minutes for circuit breaker to auto-reset. Avoid operating the machine with a flat battery. Check and rectify. Replace switch if necessary. Solenoid/contactor should click’ when the UP button is pressed if not it may need to be replaced. Check interlock and wiring replace if necessary. Remove material to reduce weight. Contact your agent for instructions on how to adjust the valve. Switch two of the phase wires in the power plug or inlet. Lowering valve shouldclick’ when the DOWN button is pressed if not, check the up/down switch, wiring and lowering valve coil. Spray inside of masts at top of slots. Smear grease on top of the curved tipping tracks. Lubricate roller arm at top of cradle.
Contact your agent for support.
Lubricate roller; replace if necessary.
Check and straighten roller arm; replace if necessary.

See also §2.4 §3.4.3
Battery 0250050004
§3.4.5
Breaker 0790050374
Up/Down Switch 0790050454
Solenoid 0880050015
Contactor 0250050069
§3.8.3
Interlock 0790050408
§1.4 §3.3.6.1
§3.7.1.2
§3.5.2
§3.3.7.1
Up/Down Switch 0790050454
Lowering Valve Coil 0250090067
§3.3.7.2
§3.7.4
DM1500/DM1800 0330090003
§3.3.7.2
Roller 0090120000 Bush 0140120000
§3.3.7.2
Single 0640200005 Double 0640200003

3.2 Cleaning
The machine should be cleaned with a low-pressure water jet, a microfiber cloth, and a mild cleaning solution. Cleaning should only be carried out with the cradle lowered.
Do not clean the machine with a high-pressure water jet or waterblaster.
See §1.9 for IP ratings of the machine and major subcomponents. If it is necessary to clean underneath the cradle, the control system can be modified to allow this while maintaining operator safety contact your Simpro agent for assistance.
3.3 Cradle Systems
Dumpmaster can be fitted with a variety of cradles, all of which share a common arrangement of axles, sliding blocks and rollers. These components are simple and robust, and require little maintenance.
The cradle is not powered down it is lowered only by gravity.
3.3.1 Type-E cradle
Dumpmaster is fitted as standard with a Type-E cradle, which lifts wheelie bins from the base and retains them using bolt-on wheel catches. The Type-E cradle can empty almost all 80L, 120L, 140L and 240L wheelie bins that comply with the EN840 standard.
– The Type-E cradle wheel catches are suitable for standard EN840 wheelie bins from brands such as Europlast, Sulo, ESE, Weber, Craemer, OnePlastics and Trident.
– If the wheel spacing on a 240L wheelie bin is slightly differently to the catch spacing, the wheels may jam against the catches, making it difficult to fully emplace the bin. If this occurs, the right-hand wheel catch can be simply removed all wheelie bins can be securely retained using the left-hand catch only.
– If the bin wheels are more than ~50mm wide, they may jam between the turndown on the wheel catch and the side of the cradle, making it difficult to fully emplace the bin. If this occurs, flat washers can be inserted onto the catch mounting bolts to increase the available spacing.
3.3.1.1 Type-E cradle maintenance The Type-E cradle requires no regular maintenance, but the cradle axle can benefit from an occasional light application of silicone lubricant as per §3.9.
User Manual // Simpro Dumpmaster® Original Instructions // English // v126.0 // July 2023 // Page 18

3.3.2 Type-C cradle
Dumpmaster can be optionally fitted with a Type-C cradle, which lifts and retains wheelie bins using a comb-lift mechanism. The Type-C cradle can empty almost all 80L, 120L, 140L, 240L and 360L wheelie bins that comply with the EN840 standard.
3.3.2.1 Type-C cradle maintenance The Type-C cradle requires no regular maintenance, but the cradle axle can benefit from an occasional light application of silicone lubricant as per §3.9.
3.3.3 Type-A cradle
Dumpmaster can be optionally fitted with a Type-A cradle, which lifts and retains rollout carts using a bar and latch mechanism. The Type-A cradle can empty almost all 24-Gal, 32-Gal, 48-Gal, 64-Gal, and 96-Gal carts that comply with the ANSI Z245.60 (Type B) standard.
3.3.3.1 Type-A cradle maintenance The Type-A cradle requires no regular maintenance, but the cradle axle can benefit from an occasional light application of silicone lubricant as per §3.9.
3.3.4 Type-D cradle
Dumpmaster can be optionally fitted with a Type-D cradle, which lifts and retains Eurobins using a trunnion-lift mechanism. The Type-D cradle can empty almost all 200L and 300L Eurobins that comply with the DIN9797 standard. A smaller version be fitted for 120L Eurobins.
3.3.4.1 Type-D cradle maintenance The Type-D cradle requires no regular maintenance, but the cradle axle can benefit from an occasional light application of silicone lubricant as per §3.9.
3.3.5 Type-X/CB/AB cradle
Dumpmaster can be optionally fitted with a Type-X cradle, which can be adapted to lift and retain various non-standard bins, buckets, drums, and containers. The Type-X cradle has steel bucket pressing with a pattern of lasercut holes, allowing hoops, catches and packers to be attached in the required location.
Additionally, the Type-C and Type-A cradles can be fitted with a steel bucket pressing, allowing them to be adapted to lift and retain various non-standard bins, buckets, drums, and containers. The bucket pressing has a pattern of lasercut holes, allowing hoops, catches and packers to be attached in the required location.
Type-C and Type-A cradles with the bucket pressing installed are known respectively as TypeCB and Type-AB cradles.
When using a hoop retainer to empty bins, it should be positioned so that the bin falls no more than 25mm (1in) when the cradle is inverted. A hand truck, dolly or other lifting aid should be used when moving heavy non-wheeled containers such as 205L drums.
3.3.5.1 Type-X/CB/AB cradle maintenance The Type-X, Type-CB and Type-AB cradles require no regular maintenance, but the cradle axle can benefit from an occasional light application of silicone lubricant as per §3.9.

3.3.6 Cradle jams while raising
Most cradle jams while raising can be classed as either an overload fault or mechanical fault. The problem can often be identified and resolved onsite, as set out below.
3.3.6.1 Overload fault If the cradle starts to lift when the RAISE button is pressed, but then stalls out even though the motor continues to run, the problem may be an overload fault;-
1. Lower the cradle to ground level, open the door and remove the bin. 2. Manually remove some material from the bin to lighten it. 3. Try emptying the bin again.
If the pressure-relief valve is set incorrectly, the cradle can stall even when lifting bins that are within the Safe Working Load listed on the rating plate. The pressure-relief valve may only be adjusted by competent personnel, with prior authorisation from Simpro.
3.3.6.2 Mechanical fault If the cradle starts to lift when the RAISE button is pressed, but then stalls out even with no bin in the cradle, the problem may be a mechanical fault;-
1. If possible, lower the cradle to ground level, open the door and remove the bin. 2. Attempt to visually identify the cause of the jamming. The most likely faults are:
a. The lifting chain being derailed from the plastic chain guide at the top of the mast (accessed by removing the small cover at the top of the mast).
b. The mast being bent or damaged, jamming one of the mast rollers. c. Part of one of the curved tipping tracks’ being bent, interfering with the correct movement of the follower roller. d. Lack of lubrication on the follower roller or the main cradle axle. e. The cradle being out of level, due to poor adjustment of the lifting chains or a breakage. f. The roller arm(s) being pressed too firmly against thetipping track’ due to the
cradle sitting out of level, or not being properly centred between the masts. 3. Lubricate, straighten and/or repair the components that are causing the jam.
Contact your Simpro agent for support if required. 4. Close the door and test to see if the cradle raises correctly. 5. Once repairs are complete, carry out two complete tipping cycles to make sure the
problem is fully resolved.
3.3.7 Cradle jams while lowering
Most cradle jams while lowering can be classed as either a hydraulic fault, electrical fault, or mechanical fault. The problem can often be identified and resolved onsite, as set out below.
The cradle is not powered down it is lowered only by gravity. See §3.7.5 for a schematic diagram of the hydraulic system.
3.3.7.1 Hydraulic or electrical fault When the LOWER button is pressed, the lowering valve should emit a `click’ sound as it opens. If it does not, the problem may be either a hydraulic or electrical fault;-
1. Disable the safety interlock as per §3.8.3.1 and open the safety door.
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a. If the door needs to be opened to access the interlock, it can be unlocked by removing the ram cover beside the control panel, and manually activating the cradle lowered’ microswitch at the base of the mast. The interlock should then be disabled, and the ram cover replaced before proceeding. b. If the machine has a CAT3 safety-monitoring system, the door can be unlocked by making specific control inputs contact your Simpro agent. 2\. Attach a lifting sling to a forklift or crane, and slowly take the weight of the cradle. Never place any part of your body underneath the cradle unless it is securely supported. 3\. Remove the powerpack cover. 4. Unscrew the fitting attaching the steel hydraulic pipe to the powerpack, and hold the end of the pipe over a container with a capacity of at least two litres. 5. Lower the cradle slowly with the forklift, collecting the oil in the container. 6. Once the cradle is fully lowered, remove the bin. 7. Reconnect the hydraulic pipe and fitting, and refill the oil tank. 8. Check that the lowering valve coil is receiving an electrical signal. An LED lamp should glow on the coil plug when the LOWER button is pressed. If it does not, check the up/down switch and wiring for loose or broken connections. 9. If the coil is receiving an electrical signal but not opening, it may need to be cleaned: a. Remove the coil from the valve stem. b. Unscrew the lowering valve cartridge. c. Clean the cartridge with compressed air. d. Once cleaned, replace the lowering valve by reversing this procedure. 10. Close the door and test to see if the cradle lowers correctly. a. If the machine has a CAT3 safety-monitoring system, before testing it will be necessary to re-enable the safety door interlock as per §3.8.3.1 and RESET the safety system as per §2.3.4.1. 11. If the problem persists, the lowering valve coil 0250090067 or cartridge 0250090055 may need to be replaced contact your Simpro agent for support. 12. Once repairs are complete, re-enable the safety door interlock as per §3.8.3.1 and carry out two complete tipping cycles to make sure the problem is fully resolved. 3.3.7.2 Mechanical fault If the lowering valve is operating correctly (emits a click’ sound when the LOWER button is pressed), the problem may be a mechanical fault;-
1. Disable the safety door interlock as per §3.8.3.1 and open the door. a. If the door needs to be opened to access the interlock, it can be unlocked by removing the ram cover beside the control panel, and manually activating the `cradle lowered’ microswitch at the base of the mast. The interlock should then be disabled, and the ram cover replaced before proceeding. b. If the machine has a CAT3 safety-monitoring system, the door can be unlocked by making specific control inputs contact your Simpro agent.
2. Provide support for the cradle, either with a structure beneath or with a sling holding it to a forklift or crane. Allow for it to fall no more than 50mm.

Never place any part of your body underneath the cradle unless it is securely supported. 3. Attempt to visually identify the cause of the jamming. The most likely faults are:
a. The lifting chain being derailed from the plastic chain guide at the top of the mast (accessed by removing the two cover-plates at the top of the mast).
b. The mast being bent or damaged, jamming one of the mast rollers. c. Part of one of the curved tipping tracks’ being bent, interfering with the correct movement of the follower roller. d. Lack of lubrication on the follower roller or the main cradle axle. e. The cradle being out of level, due to poor adjustment of the lifting chains or a breakage. f. The roller arm(s) being pressed too firmly against thetipping track’ due to the
cradle sitting out of level, or not being properly centred between the masts. 4. Lubricate, straighten and/or repair the components that are causing the jam.
Contact your Simpro agent for support if required. 5. Close the door and test to see if the cradle lowers correctly.
a. If the machine has a CAT3 safety-monitoring system, before testing it will be necessary to re-enable the safety door interlock as per §3.8.3.1 and RESET the safety system as per §2.3.4.1.
6. Once repairs are complete, re-enable the safety door interlock as per §3.8.3.1 and carry out two complete tipping cycles to make sure the problem is fully resolved.
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3.4 Electrical Systems (battery)
If you do not operate a battery-powered machine, please disregard this section.
Battery Dumpmasters are fitted with two 12V/20Ah deep-cycle GEL VRLA batteries in series, a digital smart charger, and a series-wound 800W/24VDC motor. The control circuit is 24VDC.
The motor only runs when the RAISE button is pressed; the cradle is lowered by gravity alone. As a rule, a full charge is sufficient to empty 10 tonnes of material, but this is dependent on a number of factors, including the tipping height and the age of the batteries.
3.4.1 International conformance
Dumpmaster is fitted with a digital smart charger which accepts 1-phase mains power at voltages of 85-264VAC and frequencies of 50/60Hz, with a maximum current draw of 3 Amps. This allows the machine to be charged using 1-phase power in almost any country or region.
3.4.2 Appliance inlet NZ/AU 0790050272
Dumpmaster is fitted with an IP66-rated appliance socket on the right-hand side of the machine (opposite the control panel). This allows the machine to be charged using a regular 1-phase mains extension lead. The standard inlet is designed to suit IEC Type-I plugs, but other inlets can be specified.
3.4.3 Batteries 0250050004
Dumpmaster is fitted with two 12V/20Ah deep-cycle GEL VRLA batteries in series, providing 24VDC (nominal) to the powerpack and control circuit. The batteries should be recharged anytime the voltmeter reads less than 24 Volts, as set out in §2.4.
The batteries are sealed and maintenance-free, with an operating lifetime of up to five years. However, battery life is dependent on a number of factors, including the number of charge cycles, the average discharge depth, and environmental conditions.
3.4.3.1 Maximising battery life Observing the following rules can help to maximize the life of the batteries:
– Place the batteries on charge every night (not just when they are flat). – Do not allow the machine to sit with flat batteries for more than 24 hours. – Do not operate the machine when the voltmeter reads less than 24V.
Dumpmaster batteries are supplied with a 12-month warranty, separate from the warranty on the rest of the machine.
3.4.4 Battery charger 0390050006
Dumpmaster is fitted with a digital multi-voltage charger, which accepts 85-264VAC 50/60Hz 1-phase input, drawing up to 3 Amps of current. The charger outputs up to 6 Amps at 27.2VDC, for a power rating of 160 Watts.
The battery charger is in an enclosed plastic case and protected against short-circuit, current overload, over-voltage, and over-temperature conditions.

3.4.5 Circuit breaker 0790050374
Dumpmaster has an auto-resetting 75A circuit breaker fitted to the main battery cable. This cuts power to the machine if excessive current is being drawn, helping to protect the electrical systems. It automatically resets after a period of 1-2 minutes.

Because electric motors draw more current as the voltage decreases, operating the machine with a flat battery may trigger the circuit breaker. Machines produced prior to 2020 were fitted with an 60A automotive blade-fuse instead of a circuit breaker. Fuses are available from Simpro 0790050101 or automotive retailers.

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

On some older machines, the batteries will not charge if the isolator switch is turned OFF.

3.4.7 Voltmeter 0790050067
Dumpmaster is fitted with a voltmeter on the control panel, which is used to indicate the level of charge in the batteries. The batteries should be recharged anytime the voltmeter reads less than 24 Volts, as set out in §2.4.

Because the voltage will fluctuate when the machine is operated, the charge level should be checked while the machine is at rest. Operating a machine with a flat battery may trip the circuit breaker, as set out in §3.4.5. This helps protect the motor from excessive current draw.

3.4.8 Solar panel Complete Kit 0090040077

Panel 0250050530

Controller 0250050462

If you do not operate a machine with a solar panel, please disregard this section.

Dumpmaster can be fitted with a solar panel kit for use in off-grid locations. The 80W monocrystalline solar panel (dimensions 930x673x35mm) is mounted on an adjustable steel bracket at the top of the mast, and charges the battery via a 12V/24V digital regulator.
As per §1.5, in ideal conditions the solar panel provides enough power to dump about 3,000kg of material each day, which is equivalent to about 30 full 240-litre wheelie bins. There are many factors affecting this figure, including the season, the amount of sunlight available, cloud cover, panel alignment and cleanliness, and the condition of the batteries.

To deliver maximum power the solar panel must be correctly aligned, clean, and exposed to direct sunlight throughout the day.

3.4.8.1 Solar panel alignment The solar panel is mounted on an adjustable steel bracket with one axis of movement. To deliver maximum power, the panel should be aligned to cast the largest-possible shadow when the sun is at its highest point in the sky. However, because the bracket has only one axis of movement, the orientation of the machine itself affects the optimum panel alignment.
Use the following guidelines to align the solar panel:

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1. Ideally, orient the machine so that adjustment arc of the panel mounting bracket runs from North to South.
2. If the adjustment arc cannot be oriented North-South, the panel should be angled at 0° degrees (vertical). While this is suitable close to the equator, it will progressively reduce the power output at latitudes beyond ±20° degrees.
3. With the machine in its long-term location, tilt the panel towards the equator by the same number of degrees as the machine’s geographic latitude.
4. If required, a further 5-10% increase in output can be achieved by tuning the panel alignment for the Summer and Winter months: a. At the beginning of Spring, reduce the angle of the panel so it is equal to the machine’s geographic latitude less 15° degrees. b. At the beginning of Autumn (Fall), increase the angle of the panel so it is equal to the machine’s geographic latitude plus 15° degrees.
The panel angles referred to above are measured in degrees of arc from vertical. Without correct adjustment the solar panel may deliver as little as 20% of the theoretical maximum output. Correctly adjusting the panel when the machine is installed can increase this figure to ~70%, and adjustment twice a year can increase output to ~75% of the theoretical maximum.
3.4.8.2 Solar panel cleaning The solar panel should be cleaned every six months, using a microfiber cloth or damp rag.
Use appropriate height-safety equipment when servicing or cleaning the solar panel.

3.5 Electrical Systems (3-phase mains)
If you do not operate a 3-phase mains machine, please disregard this section.
Dumpmasters with a 3-phase mains powerpack are generally the same as other models, but use a 3-phase 2-pole electric motor to drive the hydraulic pump. A transformer provides 24VDC current to the control systems. In some regions a VSD is also fitted to provide suitable current to the motor.
The motor only runs when the RAISE button is pressed; the cradle is lowered by gravity alone.
3.5.1 International conformance
The exact specifications of 3-phase machines differ depending on the standard voltage and frequency of 3-phase mains power in the intended country of use.
In regions where 3-phase/~400VAC/50Hz power is standard (primarily in Europe, Australasia, and Asia) the motor is driven directly by the mains current in delta configuration’. In locations where different voltages and frequencies are common (primarily in North and South America) an electronic Variable Speed Drive (VSD) is fitted, which modulates the local mains supply and outputs 3-phase/400VAC/50Hz current to the motor instar configuration’.
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 Dumpmaster to a power supply for which it is not designed may damage the motor and other components. Consult an electrician if you are unsure.
3.5.2 Appliance inlet 0790050174
Dumpmaster 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.
3-phase electric motors turn in different directions depending on the polarity of the input current, so a mismatch will make the motor run backwards. This does not damage the motor, but prevents the hydraulic system from lifting the cradle. An electrician can correct this problem by switching any two of the `phase wires’ in the power plug.
3.5.3 Isolator switch 0210050002
Dumpmaster is fitted with an isolator switch on the forward side of the powerpack cover. This isolates the electrical systems from the power supply. It should be turned OFF if the machine is to be placed in storage, or if the powerpack cover needs to be removed.
The isolator switch must be turned OFF before the powerpack cover is removed.
3.5.4 Transformer NZ/AU/UK/EU 0250050123
Dumpmaster is fitted with a transformer to supply 24VDC current to the control systems. The input voltage and frequency are specified to suit standard 3-phase mains power in the intended country of use.
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3.6 Electrical Systems (1-phase mains)
If you do not operate a 1-phase mains machine, please disregard this section.
Dumpmasters with a 1-phase mains powerpack are generally the same as other models, but use a Variable Speed Drive (VSD) to drive a 3-phase 2-pole electric motor, which drives the hydraulic pump. A transformer provides 24VDC current to the control systems.
The motor only runs when the RAISE button is pressed; the cradle is lowered by gravity alone.
3.6.1 International conformance
The exact specifications of 1-phase machines differ depending on the standard voltage and frequency of 1-phase mains power in the intended country of use. Both the transformer (§3.6.4) and Variable Speed Drive (§3.6.5) must be specified to suit local norms.
A list of 1-phase power standards in different countries and territories may be viewed here: https://www.worldstandards.eu/electricity/plug-voltage-by- country/.
Connecting Dumpmaster to a power supply for which it is not designed may damage the motor and other components. Consult an electrician if you are unsure.
3.6.2 Appliance inlet NZ/AU 0790050272
Dumpmaster is fitted with an IP66-rated appliance inlet, allowing it to be operated with a regular 1-phase extension lead.
3.6.3 Isolator switch 0210050002
Dumpmaster 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.
The isolator switch must be turned OFF before the powerpack cover is removed.
3.6.4 Transformer NZ/AU 0250050122
Dumpmaster is fitted with a transformer which outputs 24VDC current to the control systems. The input voltage and frequency are specified to suit standard 1-phase mains power in the intended country of use.
3.6.5 Variable Speed Drive
Dumpmaster is fitted with an electronic Variable Speed Drive (VSD), which outputs 3phase/400VAC/50Hz current to the electric motor in `star configuration’. The input voltage and frequency are specified to suit 1-phase mains power in the intended country of use.
The VSD has many parameters that can be set to suit specific applications. They can be modified or calibrated by a PC that has the appropriate program and cable drivers loaded.
Machines with a Variable Speed Drive can be fitted with a joystick, offering progressive control over the lifting speed as per §2.3.3.
Residual voltages may be retained in the VSD after it has been disconnected from the power supply. Use extreme caution when servicing all electrical components.

3.7 Hydraulic Systems
3.7.1 Hydraulic control valves
The hydraulic system has four primary control valves:
3.7.1.1 Check valve This is a one-way valve which prevents oil from flowing back through the pump when the motor is stopped.
3.7.1.2 Pressure-relief valve This is a spring-loaded valve which allows oil to flow back into the reservoir when the hydraulic pressure exceeds its rated limit usually from lifting an overweight bin, or from operating the machine when the cradle is already at the top of the cycle.
3.7.1.3 Lowering valve This is a solenoid-operated valve which opens when the LOWER button is pressed and allows oil to flow back to the reservoir, lowering the cradle.
3.7.1.4 Lowering-speed valve This is a pressure-compensating valve which limits the maximum flow rate of oil passing back to the reservoir through the lowering valve thus regulating the descent speed of the cradle (regardless of the weight of the bin).
3.7.2 Hydraulic fluid
The hydraulic system is designed to use mineral oil-based fluid with a viscosity grade of 22 (ISO VG22). Fluid with a higher viscosity grade may be used, but this will reduce the lowering speed of the cradle and increase the likelihood of jams.
The hydraulic fluid should have physical lubricating and chemical properties as specified by:
– Mineral Oil Based Hydraulic Fluids HL (DIN 51524 part 1) – Mineral Oil Based Hydraulic Fluids HL P (DIN 51524 part 2)
Ensure the cradle is completely lowered before replacing the hydraulic fluid. The hydraulic reservoir has markings showing the recommended fill level. Do not fill beyond this level unless specifically instructed by the manufacturer.
3.7.3 Hydraulic powerpack 24VDC 1.0cc 0940090001 415VAC 1.2cc 0940090007
The hydraulic powerpack is supplied as a complete unit. The motor, pump, oil tank, and all control valves are mounted into the centre manifold.
3.7.4 Hydraulic ram DM1500/DM1800 0330090003
The hydraulic ram is a single-action displacement type, with a 1-inch chrome bar and single rubber seal 0330090000 . Two hydraulic lines run from the powerpack to the ram, and two ram rollers 0140120002 transfer the motion of the ram into the lifting chains.
The hydraulic ram is very robust and reliable, but easy to maintain should the need arise.
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3.7.5 Hydraulic system diagram
3.7.6 Hydraulic system maintenance
After every 12 months of operation the hydraulic fluid should be drained and replaced, and the intake suction-filter and lowering valve cleaned, as per §3.9.
3.8 Safety Systems
3.8.1 Side-hinge safety door (standard)
Dumpmaster is fitted as standard with a single side-hinge safety door, consisting of a steel tube frame with 25x25x2mm wire mesh guarding. This door is very simple and robust, but will benefit from occasional servicing as follows:
1. Lightly lubricate the door pivot points with silicone spray. 2. Check that the screws holding the interlock actuators to the door frames are secure.
3.8.2 Swing-up safety door (optional)
Dumpmaster can be optionally specified 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 occasional servicing as follows:
1. Lubricate the arm pivot points with silicone spray (both ends of all four arms). 2. Check that the screws holding the interlock actuators to the door frames are secure. 3. Check the weight of the door is correctly balanced by the gas struts, so the door can
be opened and closed with a minimum of effort. If the door is difficult to open, or does not remain open, one or both gas struts will likely need to be replaced.

3.8.3 Safety interlock Interlock 0250050162 Actuator 0250050038
Dumpmasters that were manufactured prior to April 2023 (serial S7329 and below) are fitted with Idec interlocks, which can only be disabled or enabled using an Idec Override Key. For more information on the Idec interlocks, see Dumpmaster User Manual v119. Dumpmaster is fitted as standard with a single Pilz 6L000022 solenoid-operated safety interlock. This is a `power-to-unlock’ type, with two internal contacts to authenticate that the door is closed and locked. Machines with a swing-up door are fitted with two interlocks, mounted close to the ground on either side of the frame; both must be unlocked before the door can be opened.
3.8.3.1 Interlock manual override This work should only be carried out by competent and authorised personnel. This procedure does not apply to machines with a CAT3 safety-monitoring system. Contact your Simpro agent for advice on bypassing the interlock on a CAT3 machine.
All routine Dumpmaster cleaning and maintenance should be carried out with the cradle in the lowered position, allowing the safety door to be opened without risk. To open the safety door with the cradle raised, the interlock must be manually overridden as set out below;-
1. Move the cradle to the lowered position and open the safety door. 2. Loosen the Lock-Screw on interlock the using a small flathead screwdriver. 3. Use a 4mm Allen key to turn the interlock Override Key to the UNLOCK position,
making sure it rotates a full 180 degrees.
The safety door can now be opened even while the cradle is raised. The interlock will still function as a cutout switch, preventing the cradle from moving while the door is open. Never open the safety door with the Override Key partly turned (less than 180°). Never apply excessive force to the Override Key or interlock components. Never leave the Override Key set to UNLOCK during regular operation. 4. Close the safety door and move the cradle to the required position. 5. Open the safety door and carry out cleaning, repairs or service work as required. 6. Once the work is complete, turn the interlock Override Key back to the LOCK position
and tighten the Lock-Screw. 7. Carry out a complete tipping cycle to test the operation of the machine and safety
functions before returning it to service.
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3.8.4 Safety controller
If you do not operate a Dumpmaster with a CAT3/CAT4 safety-monitoring system, please disregard this section. Dumpmasters with a CAT3/CAT4 safety-monitoring system that were manufactured prior to April 2023 (serial S7329 and below) are fitted with a Rockwell 440C-CR30 Safety Controller. For more information about the Rockwell controller see Dumpmaster User Manual v119.
Dumpmaster models with CAT3/CAT4 safety architecture are fitted with a Pilz Safety Controller to monitor the operation of the safety functions in accordance with ISO13849 and AS/NZS4024. The controller continuously monitors the status of the Emergency Stop contacts, door interlocks, cradle limit sensors, and other safety devices that may be fitted.
The controller must be in READY MODE before the machine can be operated. It goes into SAFE MODE immediately whenever an unsafe condition is detected, such as;-
1. The Emergency Stop button is pressed; 2. The safety door is unlocked and/or opened; 3. An interlock fault is detected; 4. A sensor fault is detected.
When the controller is in SAFE MODE, the RESET button on the control panel glows blue. The controller must be `reset’ to READY MODE before the machine can be operated, as set out in §2.3.4.1.
Depending on the operating requirements, the safety controller may be either a PNOZ mm0p 0960050048 (non-expandable model) or a PNOZ m B0 0960050032 (expandable model). The
model code is printed on the front panel of the controller, as seen in the image above.
3.8.4.1 Controller troubleshooting The following documentation is provided to assist authorised technical personnel to find and correct faults which are preventing the safety controller from being reset.
This work should only be carried out by competent and authorised personnel, in strict accordance with electrical and machinery safety practises.
Dumpmasters with CAT3/CAT4 safety architecture are supplied with a Technical Specification document, which contains a circuit diagram and comprehensive report on the safety controller functions. This document, together with the LCD screen on the controller, can be used to trace faults which are preventing the safety controller from being reset.
Typically, the following inputs must be HI before the controller can be reset:
– TWO Emergency Stop channels (IM0, IM1) – ONE or TWO Door Locked channels (normally IM2 and IM3)

– ONE or TWO Door Closed channels (see Assignment List in report to identify terminals) – ONE or TWO External Emergency Stop channels, where provided (see Assignment List
in report to identify terminals) The other inputs are not safety-related and are not necessary to be HI for a system reset. If the controller will not reset, it is necessary to open the cabinet then turn the isolator switch on to power up the control circuits.
The control circuit is 24VDC but there are 400VAC connections inside the cabinet. Identify the high-voltage connections before proceeding and take precautions to keep well clear of them while the cabinet is open. 3.8.4.2 Controller status LEDs The five LEDs on the front-left of the safety controller provide basic status information, as shown below.
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3.8.4.3 Controller LCD display The LC display on the front of the safety controller can display the status of all inputs and outputs using four rows of symbols, as shown below.
The red button on the front of the controller can be pressed and/or turned to access a range of additional error messages, statuses, and device information, as shown below.

To access error messages on the LCD display that do not lead to a SAFE condition, press the red button once. Current error messages will display immediately, and can be interpreted using the table below.
Once the cause of the error message has been rectified, the safety controller can be reset by pressing the red button for 3-8 seconds. 3.8.4.4 Controller configuration software The safety controller can be monitored and configured in place by using a USB-A Male to USB-Mini Male cable to connect it to personal computer running the correct version of the PNOZmulti Configurator software.
– The PNOZ mm0p Safety Controller requires the PNOZmulti Configurator v10.14 software, which must be purchased from an authorised Pilz distributor.
– The PNOZ m B0 Safety Controller requires the PNOZmulti Configurator v11.1.0 software, which is available as a free download at the following link: https://www.pilz.com/enNZ/products/small-controllers/software/pnozmulti-tools
Both safety controller models store the configuration program on a removable memory card 0960050035 . This allows the program to be easily updated or modified offsite. Safety Controller programs should only be modified by competent and authorised personnel, with prior permission from Simpro.
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3.9 Preventative Maintenance Inspections
Regular preventative maintenance inspections (PMIs) should be carried out on Dumpmaster. This helps ensure operator safety and extend the service life of the machine.
The PMI schedule is divided into two parts: monthly and annual inspections. The relevant procedures and logs are provided in the following section.

In the United Kingdom, the Lifting Operations and Lifting Equipment Regulations 1998 specifies that Preventative Maintenance Inspections be carried out on all workplace lifting equipment. These are sometimes known as LOLER checks. The following schedules and logs may be used to demonstrate conformance with UK LOLER regulations.

Operators should immediately stop using the MegaDumper and request an inspection if any abnormal operation, fault, or failure is observed.

3.9.1

3. 4.

Pre-inspection checklist
Wear suitable Personal Protective Equipment (PPE), including safety boots and protective eyewear. Check that there are no ignition sources nearby. Lower the cradle and remove bin. Turn off the key switch and unplug the charging lead.

5. Remove the powerpack cover. 6. Clean the powerpack and electric
circuitry with compressed air. 7. Always use height safety
equipment when servicing elevated areas.

General

3.9.2 PMI procedures
Cat. No. Item 1 Operators
2 Entire machine

PMI procedure
Check that all operators are trained and authorised by the PCBU*. Check that the machine is not being used by unauthorised personnel.
Carry out a complete tipping cycle and check for faults or abnormal behaviour.

Monthly Annually

3 Decals and labels

Check that all decals and labels are attached and legible

Electrical Systems

4 Battery

Visually inspect battery for acid leaks and case damage

Control switches, contact blocks and wiring

Visually inspect for rodent damage, frayed or melted insulation, etc.

6 Power cord

Visually inspect for rodent damage, frayed or melted insulation, etc.

Cat. No. Item

PMI procedure

Hydraulic ram
Ram seal 0090090006

Check for leaks.

Lowering valve

Coil 0250090067

Remove and clean.

Cartridge 0250090055

9 Oil intake filter

Remove and clean

Monthly Annually

Hydraulic systems

10 Hydraulic fluid 11 Hydraulic fluid 12 Lifting chains

Check the level of hydraulic fluid and top-up if necessary as per §3.7.2.
Drain and replace the hydraulic fluid in accordance with §3.7.2.
Lightly lubricate with silicone spray. Visually inspect for corrosion or wear.

Ram rollers
0140120002