(TE 08) Marathon Operation Service and Installation Manual.pdf

RamJet® Self-Contained Compactor Container

RJ-88SC, RJ-100SC, RJ-250WD, RJ-250SC, RJ-250SC ULTRA

Includes HT (Hydraulic Tailgate) and SL (Streamline, Liquid Removal) Units

OPERATION, SERVICE, AND INSTALLATION

ISSUED NOVEMBER 2015

CUSTOMER NAME: ____________________

SERIAL NUMBER: ____________________

COMPACTION & RECYCLING SOLUTIONS 0018 RJSC-1115

© 2015 Marathon Equipment Company

WARNING

IF INCORRECTLY USED, THIS EQUIPMENT CAN CAUSE SEVERE INJURY. THOSE WHO USE

AND MAINTAIN THE EQUIPMENT SHOULD BE TRAINED IN ITS PROPER USE, WARNED OF ITS

DANGERS, AND SHOULD READ AND FULLY UNDERSTAND THIS ENTIRE MANUAL BEFORE

ATTEMPTING TO SET UP, OPERATE, ADJUST OR SERVICE THE EQUIPMENT. KEEP THIS

MANUAL FOR FUTURE REFERENCE

IMPORTANT SAFETY NOTICE

Proper service and repair are important to the safe, reliable operation of the Marathon Equipment Company products. Service procedures recommended by Marathon Equipment Company are described in this Operation, Service, and Installation Manual and are effective for performing service operations. Some of these service operations may require the use of tools or blocking devices specially designed for the purpose. Special tools should be used when and as recommended. It is important to note that some warnings against the use of specific methods that can damage the product or render it unsafe are stated in the service manual. It is also important to understand these warnings are not exhaustive. Marathon Equipment Company could not possibly know, evaluate and advise the service trade of all conceivable ways in which service might be done or of the possible hazardous consequences of each method.

Consequently, Marathon Equipment Company has not undertaken any such broad evaluations.

Accordingly, anyone who uses service procedures or tools which are not recommended by Marathon Equipment Company must first satisfy himself thoroughly that neither his safety nor the product safety will be jeopardized by the method he selects.

TABLE OF CONTENTS

Printed in U.S.A.

Copyright 2015, Marathon Equipment Company

Issued November 2015 Table of Contents

General Information ........................................................................................................................................................................................4Introduction ........................................................................................................................................................................................5Preface ........................................................................................................................................................................................5Hazard Symbols and Definitions ........................................................................................................................................................................................6Lock-Out/Tag-Out Instructions ........................................................................................................................................................................................8Specifications ........................................................................................................................................................................................9Service/Parts Assistance ........................................................................................................................................................................................9Grease Lubrication Recommendation ........................................................................................................................................................................................9Recommended Oils

........................................................................................................................................................................................10Guards and Access Covers

........................................................................................................................................................................................10Warning Decals on the Unit

........................................................................................................................................................................................10Decal Care

........................................................................................................................................................................................12Hydraulic Symbols

........................................................................................................................................................................................14Electrical Symbols

Installation ........................................................................................................................................................................................16Contact Information ........................................................................................................................................................................................17Concrete Pad Requirements ........................................................................................................................................................................................18Steel Installation Procedures ........................................................................................................................................................................................19Electric and Hydraulic Installation ........................................................................................................................................................................................21Through-the-Wall Power Unit Installation

Operation ........................................................................................................................................................................................24Contact Information ........................................................................................................................................................................................25Compactor Pre-Operation Instructions ........................................................................................................................................................................................26Standard Control Panel ........................................................................................................................................................................................27Operating Instructions - Standard Models ........................................................................................................................................................................................28Control Panel With Integral Dumper ........................................................................................................................................................................................29Operating Instructions - Standard Models with Integral Dumper ........................................................................................................................................................................................30Control Panel - Models with Photoelectric Cycle Control ........................................................................................................................................................................................32Operating Instructions - Models with Photoelectric Cycle Control ........................................................................................................................................................................................33Optional Controls

Hauler Information ........................................................................................................................................................................................36Hauler Instructions - General ........................................................................................................................................................................................37Door/Latch Operation ........................................................................................................................................................................................39Hydraulic Tailgate Operation for Optional HT Units ........................................................................................................................................................................................42Liquid Removal for Optional SL Units ........................................................................................................................................................................................43Integral Dumper Operation

Service ........................................................................................................................................................................................46Contact Information ........................................................................................................................................................................................47Compactor Lock-Out/Tag-Out Instructions ........................................................................................................................................................................................49Periodic Maintenance ........................................................................................................................................................................................51Maintenance Schedule Form ........................................................................................................................................................................................52Pressure Settings ........................................................................................................................................................................................53Principles of Operation ........................................................................................................................................................................................54Fuse, Circuit Breaker, & Wire Size Charts ........................................................................................................................................................................................56Tailgate Seal Replacement

TABLE OF CONTENTS

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Issued November 2015 Table of Contents

........................................................................................................................................................................................58PLC Maintenance - Layout & Description

........................................................................................................................................................................................60Power Unit - Standard 5 HP

........................................................................................................................................................................................61Power Unit - Standard 5 HP Parts Lists

........................................................................................................................................................................................62Power Unit - 10 HP

........................................................................................................................................................................................62Power Unit - 10 HP Parts List

........................................................................................................................................................................................64Power Unit with Integral Dumper - 10HP

........................................................................................................................................................................................65Power Unit with Integral Dumper - 10 Hp - Parts List

........................................................................................................................................................................................66Electrical Schematic

........................................................................................................................................................................................67Electrical Schematic with Integral Dumper

........................................................................................................................................................................................68Hydraulic Schematic - Typical (Cycon)

........................................................................................................................................................................................69Hydraulic Schematic with Integral Dumper

........................................................................................................................................................................................70Troubleshooting Chart

Replacement Parts ........................................................................................................................................................................................74Contact Information ........................................................................................................................................................................................75Cylinders / Miscellaneous Hardware / Electrical ........................................................................................................................................................................................78Typical Panel Box Configuration ........................................................................................................................................................................................79Decal Placement ........................................................................................................................................................................................80Decal Parts List ........................................................................................................................................................................................81Decal Images ........................................................................................................................................................................................84Decals for Optional Loading Configurations ........................................................................................................................................................................................85Decals for Hydraulic Tailgate (HT) Units ........................................................................................................................................................................................86Decals for Integral Dumper

...................................................................................................................................................................... 87Index

Issued November 2015Printed in U.S.A.

Copyright 2015, Marathon Equipment Company

RJ-88SC, RJ-100SC, RJ-250SC, RJ-250SC ULTRA, RJ-250WD

INCLUDES HT (HYDRAULIC TAILGATE) UNITS AND SL (STREAMLINE, LIQUID REMOVAL)

UNITS

OPERATION, SERVICE, AND INSTALLATION

ISSUED NOVEMBER 2015

0018 RJSC-1115

INTENTIONALLY LEFT BLANK

2RamJet® Self-Contained Compactor Container

Issued November 2015 General Information

Printed in U.S.A.

Copyright 2015, Marathon Equipment Company

General Information

SECTION 1

GENERAL INFORMATION

General Information

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Copyright 2015, Marathon Equipment Company

General Information

INTRODUCTION

Thank you for purchasing a Marathon® RamJet Self-Contained Compactor Container!

This product is designed to give you reliable service and superior performance for years to come. The purpose of this manual is to provide the owner and/or operators with the necessary information to properly install, operate, and maintain the machine. Also included are sections regarding troubleshooting and service procedures. The manual is not intended as a primary training source, but as a reference guide for authorized, trained personnel. Each person involved in the operation, maintenance, and installation of the machine should read and thoroughly understand the instructions in this manual and follow ALL warnings.

Employers involved in the operation, maintenance, and installation of the machine should also read and understand the most current version of the following applicable standards:

ANSI STANDARD NO. Z245.2, “STATIONARY COMPACTORS SAFETY REQUIREMENTS”

A copy of this standard may be obtained from:

ENVIRONMENTAL INDUSTRIES ASSOCIATION

4301 CONNECTICUT AVENUE, NW SUITE 300

WASHINGTON, D.C. 20008

OSHA Standards - 29 CFR Refer to:

Part 1910.147: “The Control of Hazardous Energy (Lock-Out/Tag-Out)” Part 1910.212: "Machinery and Machine Guarding: General Requirements for all Machines" All other applicable OSHA Standards

ANY SERVICE OR REPAIRS THAT GO BEYOND THE SCOPE OF THIS MANUAL SHOULD BE PERFORMED BY

FACTORY AUTHORIZED PERSONNEL ONLY!

If you should need further assistance, please contact your distributor. You will need to provide the equipment serial number, installation date, and electrical schematic number to your distributor.

If you have any safety concerns with the equipment or need further information, please contact us at:

Marathon Equipment Company P.O. Box 1798

Vernon, AL 35592-1798 Attn: Field Service Department

877-258-1105

General Information

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Copyright 2015, Marathon Equipment Company

General Information

PREFACE

The following sections are a guide for maintenance and service of the Marathon Equipment Company unit. The sections cover preventive maintenance, adjustment, and troubleshooting hints. Before performing maintenance, check the work area carefully to find all the hazards present and make sure all necessary safeguards or safety devices are used to protect all persons and equipment involved. In order to diagnose a problem quickly and effectively, a service person must be thoroughly familiar with the machine. This Operation, Service, and Installation Manual explains the system and its major components. Diagrams and schematics of the electrical and hydraulic systems are in the Service Section.

IMPORTANT!

Before starting any maintenance, study this section of the manual.

Read all hazard warnings and decals on the unit.

Clear the area of other persons before performing any maintenance.

Know and understand safe use of all controls.

It is your responsibility to understand and follow manufacturer’s instructions on equipment and care.

HAZARD SYMBOLS AND DEFINITIONS

Listed below are the definitions for the various levels of hazards. It is important that the operators of this equipment and people who service units read and understand all warnings as they relate to this equipment operation.

DANGER – indicates an imminently hazardous situation, which WILL result in DEATH or SERIOUS INJURY if you don’t follow proper instructions.

WARNING – indicates an imminently hazardous situation, which COULD result in DEATH OR SERIOUS INJURY if you don’t follow proper instructions.

CAUTION – indicates an imminently hazardous situation, which will result in MINOR to MODERATE INJURY if you don’t follow proper instructions.

NOTICE – means unit or other property may be damaged if these instructions are not followed.

You must read and obey all warnings in any manual produced by Marathon Equipment Company to support your unit.

General Information

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General Information

LOCK-OUT & TAG-OUT INSTRUCTIONS

DANGER

Before entering any part of the compactor, be sure that all sources of energy have been shut off, all potential hazards have been eliminated, and the compactor is locked-out and tagged-out in accordance with OSHA and ANSI requirements.

The specific Lock-Out and Tag-Out instructions may vary from company to company (i.e. multiple locks may be required, or other machinery may need to be locked-out and tagged-out). The following instructions are provided as minimum guidelines.

INSTRUCTIONS

1. Notify all affected employees that servicing or maintenance is required on the compactor and that the compactor must be shut down and locked out to perform the servicing or maintenance.

2. Perform a hazard assessment;

a. The authorized employee shall refer to the company procedure to identify the type and magnitude of the energy that the compactor utilizes, shall understand the hazards of the energy, and shall know the methods to control the energy.

3. Wear proper personal protective equipment.

4. If compactor is operating, it must be shut down by the normal stopping procedure. If the ram is pressing against a load, move the ram rearward before shutting the compactor down.

5. De-activate the energy isolating device(s) so that compactor is isolated from the energy source(s).

a. Shut down all power sources.

b. Move the main disconnect lever to the OFF position.

6. Lockout the energy isolating device(s) with assigned individual lock(s).

a. Padlock the disconnect lever with a keyed padlock and take the key with you.

b. Along with the padlock, place an appropriate, highly visible, warning tag on the disconnect lever. The tag should provide a warning such as:

“Danger: Do not operate equipment. Person working on equipment.” or “Warning: Do not energize without the permission of ________________.”

c. Place operating components in such a position so as not to be subject to possible free fall and/or install additional blocking devices to prevent this potential for any raised or elevated component.

7. Stored hydraulic energy must be removed from the compactor hydraulic circuit for complete Lock-Out and Tag-Out.

Make sure that this energy has been relieved by manually depressing the solenoid valve pin located in the center of each coil end of the directional control valve.

8. After locking and tagging the compactor, ensure that the compactor is disconnected from the energy source by first checking that no personnel are exposed, then verify the isolation of the equipment by operating the push button or other normal operating control(s) or by testing to make certain the equipment will not operate. Try to start and operate the compactor (as outlined in the Operating Instructions) to make sure the Lock-Out and Tag-Out is effective. If the Lock-Out and Tag-Out is effective, remove the key from the key switch and take it with you.

9. Before entering compactor perform hazard assessment for confined space requirements (hazardous fumes, dust, toxic material, or other hazards) per the OSHA confined space standard.

10.The compactor is now locked out.

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General Information

LOCK-OUT & TAG-OUT INSTRUCTIONS (CONTINUED)

RESTORING SERVICE

When the servicing or maintenance is completed and the compactor is ready to return to normal operating condition, the following steps shall be taken:

1. Check the compactor and the immediate area around the compactor to ensure that nonessential items have been removed and that the compactor components, guards and covers are operationally intact.

2. Check the work area to ensure that all employees have been safely positioned or removed from any hazardous area.

3. Verify that the controls are in neutral.

4. Remove the lockout devices and re-energize the compactor.

NOTICE

The removal of some forms of blocking may require re-energizing of the compactor before safe removal.

5. Notify affected employees that the servicing or maintenance is completed and the compactor is ready for use.

6. Reassess area to determine all hazards are protected.

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General Information

SPECIFICATIONS

88SC 100SC 250SC 250SC

ULTRA

250SC HT

"A", Clear Top Opening (Length x Width) (inches)

30 1/2 x 48 35 x 60 41 1/2 x 58 41 1/2 x 58 41 1/2 x 58

"B", (inches) 70 76 1/8 67 67 67 "C", (inches) 43 48 48 48 48 "D", (max.) (inches) 95* 104* 104* 104* 102* "E", (max.) (inches) 284 1/2* 290 299 1/2* 269* 277* Charge Box Capacity (cubic yards)

1.0 1.50 1.70 1.70 1.70

NWRA Rating 0.70 1.32 1.31 1.31 1.31 Cycle Time (seconds) 44 37 33 33 33

*Determined by the size and capacity of the container.

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General Information

SERVICE/PARTS ASSISTANCE

Assistance in troubleshooting, repair and service is available by contacting the authorized Marathon Equipment Company Dealer in your area. Parts are available at your Marathon Equipment Company Dealer or through Marathon Equipment Company. Marathon Equipment Company personnel are trained to give prompt, professional assistance.

ALWAYS give the machine serial number in all correspondence relating to the equipment.

GREASE LUBRICANT RECOMMENDATION

Use a grease gun. Before engaging grease gun, clean the fitting. Always pump enough grease to purge the joint of contaminated grease and wipe off the excess grease. Lubricate a unit as recommended on the lubrication decal on the unit and in the Operation, Service, and Installation Manual. Use NLGI 000 grease.

RECOMMENDED OILS

The following oils by brand name are approved for use in the hydraulic system on this equipment and considered to be all temperature hydraulic fluids.

Union-UNAX-46, UNAX-AW46 Gulf-Harmony 47, Harmony 48-AW Exxon-Teresstic 46, NUTO 46 Texaco-Rando 46 Chevron-AW 46 Shell-Turbo 46, Tellus 46 Citgo-Pacemaker 46, Tellus-AW46 Conoco-Super Hydraulic Oil 46

Automatic Transmission Fluid (for 15 HP and smaller units only)

Quaker State-Dextron II (ATF)

Cold Weather Fluid

Amoco-Rycon MV

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General Information

GUARDS AND ACCESS COVERS

Before operating or performing maintenance, check the work area carefully to find all the hazards present and make sure all guards and safety devices are in place to protect all persons and equipment involved.

WARNING DECALS ON THE UNIT

WARNING

DO NOT operate without all guards and access covers in place.

Make sure you can read all warning and instruction decals. Clean decals if you cannot read the words. See below for directions on cleaning decals. Replace any decal that is damaged, missing, or is not readable. When you replace a part that has a decal, make sure a new decal is installed on the new part. See the Operation, Service, and Installation Manual for replacement decals. Order replacement decals from Marathon Equipment Company or an authorized dealer.

DECAL CARE

It is important that the decals are properly cleaned to make sure that they are readable and do not come off the unit. Use the following steps to clean the decals.

A. General Instructions Following these instructions helps the decals adhere longer.

Wash the decals with a blend of mild car wash detergent and clean water Rinse with clean water Let the unit air-dry or dry with a micro-fiber cloth Do not allow fuels to stay in contact with the decal for an extended period of time. Remove the fuel contamination as quickly as possible Do not use carnauba-based wax over the decals Do not use a mechanical brush while washing the decals.

B. Pressure Washer Precautions Pressure washing can cause damage to decals. It can cause the edges of the decals to lift and peel the decal away from the unit. Over time, the decal can fade, crack or chip away.

Use pressure washing only when other cleaning methods are not effective. If you use a pressure washer, use the following precautions.

Spray nozzle opening: 40° wide pattern Spray angle: 65° from vehicle’ s body Distance of nozzle to decal: 15” minimum Water pressure: less than or equal to 800 psi Length of time: not more than 30 sec.

Do not use sharp angles to clean the decals – this can lift the decals from the unit.

NEVER use a “turbo pressure nozzle”.

C.Remove Difficult Debris When normal cleaning procedures do not remove difficult debris from the decals, try the following:

Spot clean the decal with Isopropyl Alcohol and a micro-fiber cloth (rag) If these methods do not work on a problem area, call a Marathon Equipment Company Dealer or Marathon Equipment Company Customer Support.

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General Information

DECAL CARE - CONTINUED

General Information

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General Information

HYDRAULIC SYMBOLS

General Information

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General Information

HYDRAULIC SYMBOLS (CONTINUED)

General Information

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General Information

ELECTRICAL SYMBOLS

Installation

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Installation

SECTION 2

INSTALLATION

Installation

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Installation

CONTACT INFORMATION

Technical Service and Warranty:

877-258-1105 Parts:

800-528-5308 For parts visit our e-commerce market place at www.mecomerchant.com.

If you do not have a user name and password, contact our Parts Department and they will assist with your registration.

Normal Business Hours:

Monday-Friday 8:00am - 5:00pm

(Central Standard Time) http://www.mecomerchant.com

Installation

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Installation

CONCRETE PAD REQUIREMENTS

These installation instructions are not intended as a substitute for training and experience in proper use and safety procedures in operating this equipment. Marathon Equipment Co. does not assume responsibility for the installation procedures of this equipment. Conformance to applicable local, state, and federal laws concerning installation rests with the customer.

CAUTION

Review this manual before making the installation. Study the job site and installation requirements carefully to be certain all necessary safeguards or safety devices are provided to protect all personnel and equipment during the installation and as a completed system. Special attention is directed to the most current ANSI Z245.2 standard.

Concrete Pad

1. Preferred dimensions of the concrete pad are 10'0" wide and a length of 5'0" greater than the length of the compactor/container. It should be level and of minimum 3000 PSI concrete steel reinforced, 6" thick. It is preferred that the concrete pad be flush with the surrounding ground level.

NOTICE

Units with four ground rollers must be installed on a level pad.

2. To provide accessibility, concrete pad should be positioned to allow 28" between machine and building wall if installed parallel with building. Allow a minimum of 45' of clear space from end of pad for container handling vehicle.

NOTICE

The clearances given are minimums. Your installation may require greater clearances depending on the site and the hauling equipment that will be used.

Container Guides If container guides (optional) are used with the self-contained units, the guides should be anchored to the concrete pad with 3/4" X 6" (minimum) anchor bolts. These bolts should be concrete anchors or expansion type anchor bolts. To allow for construction variations, it is best if these holes are drilled in the concrete after pre-locating the container guides in their desired location. Drill holes and place anchor bolts in each location provided on the guides. When the guides have been placed in position, and the anchor bolts have set, tighten all nuts securely.

Installation

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Installation

STEEL INSTALLATION PROCEDURES

Dock Installation If the appropriate accessories are ordered from Marathon Equipment Co., the compactor/ container will be furnished with either a four-sided hopper or a three-sided hopper with a hinged gate. THESE ACCESSORIES SHOULD NOT BE ALTERED AS THEY ARE MANUFACTURED IN ACCORDANCE WITH THOSE STANDARDS WHICH PREVAIL AT THE

TIME OF MANUFACTURE.

If the compactor/container cannot be directly abutted to the dock or if there is any difference in height between the dock and the compactor/container, an appropriately sturdy transition section should be provided by the customer and securely affixed to the dock. Along with the transition section, a compactor/container guidance/stop mechanism should be installed to assure that the unit does not bottom out against the transition section or dock during dock placement (See ANSI Z245.2 Safety Standards). Optional container guides with stops are available from Marathon and are recommended for proper dock placement of the compactor/ container.

Chute-Fed Installation Compactors installed in this arrangement are normally fed "through-the-wall". The lower edge of the access hole in the wall should be a MINIMUM of 42" (and, if possible, not more than 58") from the inside floor level. A security door (in accordance with local code) should be installed in the wall opening. In the absence of a local code, this door should be constructed of 3/16" thick steel or of steel hollow core design and be lockable from the inside of the building.

Decals Be certain that the appropriate decals are in their proper locations at all times on the machine. For decal locations, see Decals and Decals Placement in the "Replacement Parts" section of this manual.

NOTICE

Installation is not complete until all decals are in place.

81 79

Installation

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Installation

ELECTRICAL AND HYDRAULIC INSTALLATION

The motor control panel contains high voltage components. Only authorized service personnel should be allowed inside. See Lock-Out & Tag- Out Instructions in the Service section.

A lockable fused disconnect switch (customer furnished) must be installed and be within sight of the compactor motor control panel location, not to exceed 50'0" from the compactor. This fused disconnect switch should be sized in accordance with the compactor (See Fuses and Circuit Breakers chart).

DANGER

All equipment must be grounded per National Electric Code.

Grounding Instructions: This appliance must be connected to a grounded, metal, permanent wiring system; or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the compactor.

If there is any doubt whether the appliance is properly grounded, a qualified electrician should be consulted.

Remote Power Pack Installation

1. The remote power pack should be installed and anchored as required by the customer. If the operator station is mounted in the face of the motor control panel, be certain these controls are located as to be in a convenient, but not hazardous, location to the customer.

CAUTION

Operator Station must be located so that the Emergency Stop Button is readily accessible to the operator and within three

(3) feet of the charging chamber access door. If installation requires the operator station to be located in a more remote area, a second Emergency Stop Button should be added and installed in the manner described above.

2. For a through-the-wall power pack installation, see the diagram Through-The-Wall Power Unit Installation in this section. Special care should be taken to protect the hoses from abrasive objects.

Connect the hydraulic hoses to the power pack, exercising care to follow the port decals (A or B) on the packer and the power pack. In the event the decals have been obliterated, the hose leading from the rear of the cylinder should be installed in the side port of the block to which solenoid valve is bolted (A Port). The hose leading from rod end of the cylinder should be connected to the end of the block to which the solenoid valve is bolted (B Port). Refer to Power Unit diagrams in the Service section of this manual.

Installation

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Installation

ELECTRICAL AND HYDRAULIC INSTALLATION (CONTINUED)

Pushbutton Control Panel If a remote operator station is furnished, it will be factory wired using Sealtite. If it is necessary to disconnect it from the wires (to install the operator station inside a building), exercise care that these wires are reconnected as originally furnished. (Check local codes to be certain that sealtite is acceptable.)

CAUTION

Operator Station must be located so that the Emergency Stop Button is readily accessible to the operator and within three

(3) feet of the charging chamber access door. If installation requires this operator station to be located in a more remote area, a second Emergency Stop Button should be added and installed in the manner described above.

Electrical Connections Run power lines, between fused disconnect switch (customer furnished) and compactor's motor control panel, in accordance with local electrical codes, using knock-outs in bottom of motor control panel. See Fuses and Circuit Breakers chart and Wire Size chart, in the Service section, to determine the proper service disconnect amperage rating and the proper wire size.

NOTICE

High legs should be installed to L3 on motor starter.

Check voltage at fused disconnect switch to be certain it is the same as is shown on compactor or remote power pack. If voltage is correct, put fused disconnect switch in "ON" position.

Start-Up Instructions

NOTICE

Make sure that the operators are trained in the proper use of this equipment prior to operation.

1. With the ram fully retracted, check to be sure the oil reservoir is full to the 3/4 level on the sight gauge (Refer to the maintenance chart for hydraulic oil recommendations). The hydraulic system pressure has been factory set and the entire unit has been operated prior to shipment.

CAUTION

Make sure persons and material are clear of charge box area.

2. Depress the start button and check the pump shaft for proper rotation.

CAUTION

If the pump rotates backward, stop immediately. The pump will be damaged if it is operated in reverse even for short periods. Reversing any two incoming power lines will change the motor/pump rotation.

3. Make sure that the operators are trained in the proper use of this equipment

Installation

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Installation

THROUGH-THE-WALL POWER UNIT INSTALLATION

If the remote power unit is to be mounted through-the-wall, the following list of material and diagram is the suggested method.

LIST OF MATERIAL

ITEM # QUANTITY DESCRIPTION

1 2 Hydraulic Hose, Hi-Pressure (sized to power unit*), 36” long 2 2 Pipe, Schedule 80 (sized to power unit*), 36” long 3 2 Hydraulic Hose, Hi-Pressure (sized to power unit*), 48” long 4 2 Steel plate with holes for Item # 2, 3/16” x 8” x 12” 5 4 Coupling, Female (sized to fit hose & pipe*) 6 3 Quick disconnect

* 1/2” for hose lengths of 20’-0” or less. Consult factory for longer lengths.

22RamJet® Self-Contained Compactor Container

Operation

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Operation

SECTION 3

OPERATION

Operation

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Operation

CONTACT INFORMATION

Technical Service and Warranty:

877-258-1105 Parts:

800-528-5308 For parts visit our e-commerce market place at www.mecomerchant.com.

If you do not have a user name and password, contact our Parts Department and they will assist with your registration.

Normal Business Hours:

Monday-Friday 8:00am - 5:00pm

Operation

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Operation

PRE-OPERATION INSTRUCTIONS

Employers should allow only authorized and thoroughly trained personnel to operate this compactor.

This compactor is equipped with a key operated locking system. Keys should be in possession of only authorized personnel. Turn off and remove the key after use.

ONLY TRAINED AND AUTHORIZED PERSONNEL SHOULD BE ALLOWED INSIDE PANEL BOX. The panel box contains high voltage components. See Lock-Out/Tag-Out Instructions .

Do not operate compactor until operating instructions are thoroughly understood. Wear safety glasses and gloves when operating this equipment.

WARNING

Stay clear of all internal compactor parts and all moving external compactor parts when in operation. Failure to do so could result in serious personal injury or death!

WARNING

Never enter any part of compactor unless the disconnect switch has been turned off, padlocked, and all stored energy sources have been removed. See Lock-Out/Tag-Out Instructions .

WARNING

Do not remove access covers except for servicing. Only trained and authorized service personnel should be allowed to service this equipment. All access doors on the compactor body should always be secured in place when the unit is operating. See Lock-Out/Tag-Out Instructions .

WARNING

Before starting compactor, be sure no one is inside. Be certain that everyone is clear of all operation points and pinch point areas before starting.

If the compactor is equipped with a security gate or doghouse with security door, be sure that the security gate or door is closed before the compactor is started.

NOTICE

Federal regulation prohibits the use of this equipment by anyone under 18 years of age.

Operation

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Operation

STANDARD CONTROL PANEL

CONTROL DESCRIPTION

1. KEYED START SWITCH - This switch requires a key for operation. Insert the key and turn clockwise to the START position. Depress the key for one to two seconds and release. The compactor will cycle one time (complete extension and retraction of the ram) then stop. After use, turn the key to the counterclockwise position and remove the key.

2. EMERGENCY STOP PUSHBUTTON - When depressed, this pushbutton will stop all powered operation of the compactor.

3. REVERSE PUSHBUTTON - This pushbutton will reverse the compaction ram when depressed. The motor must be running for the REVERSE button to operate. See the Manual Override Instructions for details of the operation.27

Operation

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Operation

OPERATING INSTRUCTIONS - STANDARD MODELS

1. First, place the material to be discarded into the compactor.

2. Insert the key into the key switch. Turn it clockwise and depress for 1 to 2 seconds and release. The unit will cycle the preset number of times determined by the Multi-Cycle Counter*, then stop.

3. Repeat, if necessary, after the compactor has stopped.

4. When you have finished using the compactor, remove the key from the key switch.

*For more information on the Multi-Cycle Counter see PLC Maintenance.

I N C A S E O F E M E R G E N C Y : P u s h t h e l a r g e R E D b u t t o n t o S T O P !

Manual Override Instructions (Ram Stop Rear Only) If the ram is stopped in any position:

To move the ram forward, turn the key switch clockwise and depress.

To move the ram rearward, hold the reverse button down, turn and depress the key switch, release the key switch, then release the reverse button.

While the ram is moving:

To reverse the ram while it is moving forward, press the reverse button.

To cause the ram to move forward while it is moving rearward, depress the key switch.

Refer to Optional Controls for Manual Override on Ram Stop Forward Machines.

Operation

Printed in U.S.A.

Copyright 2015, Marathon Equipment Company

Operation

CONTROL PANEL WITH INTEGRAL DUMPER

CONTROL DESCRIPTION WITH INTEGRAL DUMPER

1. KEYED START SWITCH - This switch requires a key for operation. Insert the key and turn left to START compactor. Turn and hold the key for one to two seconds and release. The compactor will cycle the preset number of times determined by the Multi-Cycle Counter*, then stop. Turn the key to the right to start dumper. Remove key in center.

2. EMERGENCY STOP PUSHBUTTON - When depressed, this pushbutton will stop all powered operation of the compactor.

3. REVERSE PUSHBUTTON - This pushbutton will reverse the compaction ram when depressed. The motor must be running for the REVERSE button to operate. See the Manual Override Instructions for details of the operation.

4. DUMPER UP/DOWN - This manually controls the direction of the dumper.

*For more information on the Multi-Cycle Counter see PLC Maintenance page .

Operation

Printed in U.S.A.

Copyright 2015, Marathon Equipment Company

Operation

OPERATING INSTRUCTIONS - STANDARD MODELS WITH INTEGRAL DUMPER

1. First, place the material to be discarded into the compactor.

NOTICE

If you are loading the compactor through a door or gate, close it before starting the compactor. Refer to "Optional Loading Configurations” on page 13 to determine how your compactor is configure.

2. Insert the key into the key switch. Turn to left for 1 to 2 seconds and release. The unit will cycle the preset number of times determined by the Multi-Cycle Counter*, then stop.

3. Repeat, if necessary, after the compactor has stopped.

4. When you have finished using the compactor, remove the key from the key switch.

5. Insert the key into the keyswitch and turn right to start dumper.

6. Turn the UP/DOWN switch to the UP position and hold to raise and empty the dumper/cart.

7. When the cart is empty, turn the UP/DOWN switch to the DOWN position and hold to the lower the dumper/cart.

8. After use, depress the STOP button and turn key counterclockwise and remove the key. The key should always be in the possession of authorized personnel.

*For more information on the Multi-Cycle Counter see PLC Maintenance .

I N C A S E O F E M E R G E N C Y : P u s h t h e l a r g e R E D b u t t o n t o S T O P !

Manual Override Instructions (Ram Stop Rear Only) If the ram is stopped in any position:

To move the ram forward, turn the key switch to the left.

To move the ram rearward, hold the reverse button down, turn the key switch to the left, release the key switch, then release the reverse button.

While the ram is moving:

To reverse the ram while it is moving forward, press the reverse button.

To cause the ram to move forward while it is moving rearward, turn the key switch to the left.

NOTICE

Refer to Optional Controls for Manual Override on Ram Stop Forward Machines.

INTEGRAL DUMPER SYSTEM OPERATING CHARACTERISTICS

When the key is inserted into the key switch, turn right, a contact is made that energizes the motor starter, starting the electric motor which rotates the hydraulic pump. At the same time, the UP/DOWN switch is energized. This switch is spring-centered and is connected to the solenoid on each end of the control valve. Also, when the UP/DOWN switch is energized, TI timer begins counting for 5 minutes. If the dumper sits idle for 5 minutes, the timer will time out and T1 timer contact will open which will shut down the power unit.

When the UP/DOWN switch is turned to the UP position and held, the valve solenoid shifts the valve spool so that the hydraulic oil is directed to extend the cylinders which raises the dumper forks (or box). When the UP/DOWN switch is turned to the DOWN position and held, the valve solenoid shifts the valve spool so that the hydraulic oil is directed to retract the cylinders which lowers the dumper forks (or box).

The EMERGENCY STOP button will shut the dumper down when depressed by breaking the circuit to the motor starter.

Always remove the key from the key switch when the dumper is not in use.

Operation

Printed in U.S.A.

Copyright 2015, Marathon Equipment Company

Operation

CONTROL PANEL - MODELS WITH PHOTOELECTRIC CYCLE CONTROL

CONTROL DESCRIPTION

1. MANUAL-OFF / AUTOMATIC SHUTDOWN - This switch controls the compactor operation mode, manual or automatic (automatic is photocell mode).

2. KEYED START SWITCH - This switch requires a key for operation. Insert the key and turn clockwise to the START position. Depress the key for one to two seconds and release. The compactor will cycle the preset number of times determined by the Multi-Cycle Counter, then stop. After use, turn the key to the counterclockwise position and remove the key.

3. EMERGENCY STOP PUSHBUTTON - When depressed, this pushbutton will stop all powered operation of the compactor.

4. REVERSE PUSHBUTTON - This pushbutton will reverse the compaction ram when depressed. The motor must be running for the REVERSE button to operate. See the Manual Override Instructions for details of the operation.27

Operation

Printed in U.S.A.

Copyright 2015, Marathon Equipment Company

Operation

CONTROL DESCRIPTION (CONTINUED)

5. ADVANCE WARNING / CONTAINER FULL LIGHT - When the light starts flashing (ADVANCE WARNING), then

200 PSI is left before the pressure switch is activated to shut the unit off and container is full (unit will run when light flashes). When the light stays on continuously (CONTAINER FULL), the container is full and is ready to be emptied before its next use. To deactivate the light, depress the illuminated light (the unit will not run while the light is continuously on).

6. AUTOMATIC SHUTDOWN LIGHT - Used with the photoelectric cycle control. If a blockage in the charge chamber causes the compactor to continue cycling, the timer will shut the compactor down after the preset time has passed.

To deactivate the timer, the illuminated pushbutton is pressed after clearing the blockage.

*For more information on the Multi-Cycle Counter, see PLC Maintenance .58

Operation

Printed in U.S.A.

Copyright 2015, Marathon Equipment Company

Operation

OPERATING INSTRUCTIONS - MODELS WITH PHOTOELECTRIC CYCLE CONTROL

NOTICE

This compactor features an ANSI Z245.21 (2013) SECTION 5.12.1 compliant start-up alarm that is both audible and visible during the activation of the AUTOMATIC mode.

Operating Instructions (Automatic Mode)

1. Place the material to be discarded into the compactor.

NOTICE

If you are loading the compactor through a door or gate, close it before starting the compactor.

2. Insert the first key into the “MANUAL - OFF - AUTOMATIC” key switch and turn to the…