Marathon RJ-250SC Installation manual

OPERATION, MAINTENANCE,
AND INSTALLATION
MANUAL
FOR
RJ-88SC RJ-100SC
RJ-250SC RJ-250SC Ultra
Includes HT (Hydraulic Tailgate) Units and
SL (Streamline, Liquid Removal) Units
SELF-CONTAINED
COMPACTOR CONTAINER
Marathon Equipment Co. OMI Manual No. 0018 Rev. 1/11
Table of Contents
OPERATION
Introduction .............................................................................................................. 3
Specifications ............................................................................................................ 4
Pre-Operating Instructions .......................................................................................... 5
Control Panel............................................................................................................. 6
Operating Instructions - Standard Models .................................................................... 7
Operating Instructions - Models with Photoelectric Cycle Control.................................... 8
Optional Controls ....................................................................................................... 9
Decals ...................................................................................................................... 10
Decal Placement ........................................................................................................ 11
Decal Images ............................................................................................................ 12
Decal Placement for Optional Loading Configuration ..................................................... 13
Additional Decals for Hydraulic Tailgate (HT) Units ....................................................... 14
MAINTENANCE
Lock-Out & Tag-Out Instructions .......................................................................... 16
Periodic Maintenance ................................................................................................. 17
Procedures - (Hydraulic System Pressure Check) .......................................................... 18
Principles of Operation ............................................................................................... 19
Cylinder Removal ....................................................................................................... 19
Tailgate Seal Replacement.......................................................................................... 20
Fuse & Circuit Breaker ................................................................................................ 21
Wire Sizes/Heater Element ......................................................................................... 22
Typical Panel Box....................................................................................................... 23
PLC - Layout and Description ...................................................................................... 24
PLC - Maintenance and Programming .......................................................................... 25
Power Unit - Standard 5 HP ....................................................................................... 26
Power Unit - Standard 5 HP - (Parts List) .................................................................... 27
Power Unit - Standard 10 HP - (MECO) ........................................................................ 28
Power Unit - Standard 10 HP - (Parts List) (MECO) ....................................................... 29
Power Unit - Standard 10 HP - (NON MECO) ................................................................ 30
Power Unit - Standard 10 HP - (Parts List) (NON MECO) ............................................... 31
Power Unit - Submerged 10 HP ................................................................................... 32
Power Unit - Submerged 10 HP - (Parts List) ................................................................ 33
Hydraulic Schematic - Typical ..................................................................................... 34
Troubleshooting ....................................................................................................... 35
INSTALLATION
Concrete Pad Requirements ........................................................................................ 37
Steel Installation Procedures ....................................................................................... 38
Electrical & Hydraulic Installation ................................................................................ 39
Through-The-Wall Power Unit Installation .................................................................... 40
HAULER INFORMATION
Hauler
Hauler
Hauler
Hauler
Hauler
Instructions
Instructions
Instructions
Instructions
Instructions
-
General ...................................................................................... 42
Door/Latch Operation .................................................................. 43
Hydraulic Tailgate Operation (for optional HT units) ....................... 44
Tailgate Maintenance Bar (for optional HT units) ........................... 45
Liquid Removal (for optional SL units)........................................... 46
2
© 2011 Marathon Equipment
Company
1 OPERATION
INTRODUCTION
THANK YOU FOR PURCHASING A MARATHON
SELF-CONTAINED COMPACTOR/CONTAINER.
This compactor is designed to give you reliable and superior performance for many
years to come. The purpose of this manual is to provide the owner and operator with
the necessary information to properly and safely install, operate, and maintain your
self contained compactor. 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 must read and thoroughly
understand the instructions in this manual and follow ALL WARNINGS.
The employer involved in the operation, maintenance, and installation of the
compactor must 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:
ANSI
25 West 43rd Street
New York, NY 10036
OSHA 29 CFR, Part 1910.147
“The control of hazardous energy (lockout/tagout)”
Any service or repair instructions contained in this manual should be performed by factory
authorized personnel only. If you should need assistance with your baler, please contact your
distributor.
When contacting your distributor, you will need to provide:
Compactor Serial Number:___________________________
Installation Date:______________________________
Electrical Schematic Number:____________________
IF YOU HAVE ANY SAFETY CONCERNS WITH EQUIPMENT, OR
NEED FURTHER INFORMATION, PLEASE CONTACT US AT:
Marathon Equipment Company
Attn: RamJet® Service Department
P.O. Box 1798
Vernon, Al 35592-1798
1-800-633-8974
3
1 OPERATION
SPECIFICATIONS
“B”
Fire Hose Port
One per Side
“A”
SIDE VIEW
“D”
Container
“C”
Compactor
“E”
100SC
250SC
250SC
ULTRA
250SC HT
"A", Clear Top Opening
30 1/2 x 48
(Length x Width) (inches)
35 x 60
41 1/2 x 60
41 1/2 x 60
41 1/2 x 60
"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
WASTEC Rating
.70
1.32
1.31
1.31
1.31
Cycle Time (seconds)
44
37
33
33
33
88SC
* Determined by the size and capacity of the container.
4
1 OPERATION
PRE-OPERATION INSTRUCTIONS
FEDERAL REGULATION PROHIBITS THE USE OF THIS
EQUIPMENT BY ANYONE UNDER 18 YEARS OF AGE.
THE EMPLOYER SHOULD ALLOW ONLY AUTHORIZED
AND TRAINED PERSONNEL TO OPERATE THIS
COMPACTOR. This compactor is equipped with a key operated
locking system. The key (s) should be in the possession of
authorized personnel.
DANGER
DO NOT
ENTER
STAY CLEAR OF ALL INTERNAL PARTS OF THE
SELF-CONTAINED
COMPACTOR/CONTAINER
DURING OPERATION. FAILURE TO DO SO COULD
RESULT IN SERIOUS INJURY OR DEATH!
NEVER ENTER ANY PART OF THE COMPACTOR UNLESS THE
DISCONNECT SWITCH HAS BEEN LOCKED-OUT AND TAGGED-OUT.
See Lock-Out & Tag-Out instructions in the Maintenance section.
Before starting the compactor, be sure no one is inside. Be certain that everyone is clear of all points of operation and pinch point areas before starting.
DO NOT REMOVE ACCESS COVERS EXCEPT FOR SERVICING. Only authorized
service personnel should be allowed inside. All access doors on the compactor body
should always be secured in place when the unit is operating. See Lock-Out & TagOut instructions in the Maintenance section.
ONLY AUTHORIZED PERSONNEL
SHOULD BE ALLOWED INSIDE
THE MOTOR CONTROL PANEL.
The motor control panel contains
high voltage components. See Lock
-Out & Tag-Out Instructions in
the Maintenance section.
DANGER
460
VOLTS
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.
5
1 OPERATION
CONTROL PANEL
MANUAL - OFF - AUTOMATIC SWITCH*
KEYED START SWITCH
OPERATOR
STATION
FOR 88SC, 100SC,
250SC, & 250 ULTRA
REVERSE PUSHBUTTON
EMERGENCY STOP PUSHBUTTON
*Optional equipment - not included on standard models
CONTROL DESCRIPTION
1. MANUAL - OFF - AUTOMATIC SWITCH - (Optional Equipment - not included on
standard models) 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 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. 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 on the next page for details of the operation.
*For more information on the Multi-Cycle Counter see page 25.
6
1 OPERATION
OPERATING INSTRUCTIONS -
STANDARD MODELS
1. First, place the material to be discarded into the compactor.
Note: 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.
DANGER
DO NOT
ENTER
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 page 25.
IN CASE OF EMERGENCY:
Push the large red button to STOP
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.
NOTE: Refer to Optional Controls for Manual Override on Ram Stop Forward
Machines.
7
1 OPERATION
OPERATING INSTRUCTIONS - Models with Photoelectric Cycle Control
OPERATING INSTRUCTIONS (AUTOMATIC MODE)
DANGER
1. Place the material to be discarded into the compactor.
NOTE: If you are loading the compactor through a door or
gate, close it before starting the compactor.
DO NOT
ENTER
2. Insert the first key into the “MANUAL - OFF - AUTOMATIC”
key switch and turn to the “AUTOMATIC” position.
3. Insert the second key into the “START” switch and turn to the right.
4. Depress the key in the “START” switch and hold it continuously for 20 seconds.
•
Both the audible and visual start-up alarms will energize for 5 seconds.
•
After 5 seconds the audible alarm will stop, but the
visual alarm will continue for an additional 15 seconds
(for a total of 20 seconds).
•
After 20 seconds, the motor will start and the ram will
extend, then retract (one complete cycle).
•
The light will continue to flash until the unit is manually
turned off, automatically shuts down, or is switched
to manual mode.
•
If 15 minutes elapse without a cycle being initiated by
the photocell or without operation of any of the
pushbuttons, the power unit will shut down.
8
1 OPERATION
OPTIONAL CONTROLS
1. SUSTAINED MANUAL PRESSURE CONTROL BUTTON (Hold-To-Run, Release-To-Stop)
This option requires the compactor operator to remain at the push button station while the
compactor is in use. Actuation requires depressing the "Hold-To-Run" and "Start" buttons.
After the unit has started, the "Start" button is released. If the "Hold-To-Run" button is
released, the unit will stop instantly.
2. 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 emergency stop button (The unit
will not run while the light is continuously on).
3. RAM STOP FORWARD - When a machine with this option has been stopped, the ram
automatically begins to move rearward when restarted. To move the ram forward
(when it is stopped), hold the FORWARD button down, turn the key switch clockwise,
depress and release the key switch, then release the FORWARD button. To reverse the
ram while it is moving forward, depress the key switch. To cause the ram to move
forward while it is moving rearward, press the FORWARD button.
4. ACCESS INTERLOCK - This is optional with units equipped with doors, chutes, or access
gates. It prevents the unit from operating while a door or gate is open.
5. PHOTOELECTRIC CYCLE CONTROL - (Photocell) - Consists of a LED light source and a
reflector. It can be mounted on a hopper or chute. Two holes, located so as to prevent any
hazard, are located in opposite walls of the chute. When the light beam is blocked for 15
seconds, the compactor is activated and will continue to run until the obstruction has been
cleared.
6. AUTOMATIC SHUTDOWN - 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.
7. THERMOSTATICALLY CONTROLLED OIL HEATER - This option is installed in the oil
reservoir. The thermostat is adjustable so the heater will heat the oil when the oil
temperature goes below a specified level. It is recommended to set the thermostat
between 70° F - 100° F.
9
1 OPERATION
DECALS
WARNING DECAL REQUIREMENTS
When your compactor leaves the factory, several WARNING DECALS are installed for your
protection. These labels are subject to wear and abuse due to the nature of operation.
The FOLLOWING DECALS MUST BE MAINTAINED. Additional decals may be purchased
through your distributor or from Marathon Equipment Company by either calling the parts
department at 1-800-633-8974 or going to www.parts1stop.com to place an order
online.
When ordering replacement decals, match the reference numbers in the chart below with
the drawing on the next page (and pages 13 & 14 for optional equipment or HT
models) or look for the part number in the lower right hand corner of the decal.
Part #
05-0325
06-0038
06-0039
06-0067
06-0072
06-0093
06-0094
06-0121
06-0124
06-0249
06-0364
06-1839
06-0057
06-0002
06-3123
06-3231
06-0040
06-0052
06-0104
06-0105
Ref. #
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15*
16**
17**
18***
19***
Description
RIVETS, 1/8 X 1/2 ALUM (to go with 06-0364)
WARNING DO NOT REMOVE ACCESS COVER
DANGER DO NOT ENTER
D/N REMOVE CONT TIL REAR...
QUICK CLEAN TANK
FIRE HOSE PORT
NOTICE WIPE OFF SEAL AFTER....
NOTICE FEDERAL REGULATION...NO <18 y.o.
CYCON
DANGER HAZARDOUS VOLTAGE
COMPACTOR SERIAL NUMBER
AMERICAN FLAG
WARNING STAND CLEAR OF COMPACTOR
RAM-JET
CONFINED SPACE
ULTRA DECAL
CAUTION: KEEP OUT
CAUTION: GATE MUST BE CLOSED....
HT OPERATING INSTRUCTIONS
DANGER: STAND CLEAR OF TAILGATE...
Quantity
4
2
3****
2
1
2
2
2
2
2
2
3
3
4
3****
2
****
****
1
3
*ONLY ON “ULTRA” MODELS.
**ONLY ON OPTIONAL EQUIPMENT (ACCESS GATES, HOPPERS, &/OR DOGHOUSE.
***ONLY ON HT UNITS (HYDRAULIC TAILGATE).
****QUANTITY VARIES DEPENDING ON OPTIONAL EQUIPMENT, NOTE QUANTITY ON MACHINE.
10
1 OPERATION
DECALS PLACEMENT
Match reference numbers to chart on previous page. See next page for decal images.
* INSTALLED ON BOTH SIDES OF COMPACTOR IN SAME LOCATION
**ALSO INSTALLED ON REMOTE POWER PACK
11
1 OPERATION
DECAL IMAGES
06-0038
06-0249
06-0057
06-0002
06-0072
06-0121
06-3123
06-0124
06-0067
06-0364
06-0094
06-3231
06-0105
06-1836
06-0093
06-0052
12
06-0057
06-0104
1 OPERATION
DECALS - Optional Loading Configurations
Match reference numbers to “Decals” on page 10 when ordering replacement
decals.
14
2
THRU-THE WALL
SECURITY CHUTE
2
DOGHOUSE
14
14
16**
14*
2*
2 & 17
DOCK
ACCESS GATE & HOPPER
* Located on each inside wall
** Located on each outside wall
13
1 OPERATION
Decals - Additional For Hydraulic Tailgate (HT) Units
In addition to the decals and their placement specified on the previous pages, the self
contained units with the hydraulic tailgate option require the following decals located as shown
below.
HYDRAULIC COUPLING
18
19, BOTH SIDES
SIDE VIEW
19
REAR VIEW
14
This Page Intentionally Left Blank
15
2 MAINTENANCE
LOCK-OUT & TAG-OUT INSTRUCTIONS
FOREWORD: 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. If the ram is pressing
against a load, move the ram rearward before shutting the compactor down.
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. Move the main disconnect lever to the OFF position.
2. Padlock the disconnect lever with a keyed padlock and take the key with you.
3. 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 ________________.”
4. After locking and tagging the compactor, try to start and operate the compactor
(as outlined in the Operating Instructions) to make sure the lock-out and tagout is effective. If the lock-out and tag-out is effective, remove the key from
the key switch and take it with you.
ELECTRICAL: The motor control panel contains high
voltage components. Only authorized service personnel
should be allowed inside the panel. Authorized service
personnel should be allowed inside the panel only after
the compactor has been locked-out and tagged-out.
HYDRAULIC: Stored hydraulic energy must Solenoid Valve
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.
16
Valve Pin
Power Unit
DANGER
460
VOLTS
2 MAINTENANCE
PERIODIC MAINTENANCE
WARNING: RAM SPEED ACCELERATES AS RAM RETRACTS. NEVER ENTER
ANY PART OF THE SELF-CONTAINED COMPACTOR/CONTAINER UNTIL THE
UNIT HAS BEEN LOCKED-OUT AND TAGGED-OUT.
MONTHLY
Check external hoses for chafing, rubbing, or other deterioration and damage.
Check for any obvious unsafe conditions in the compactor area.
Check oil level in hydraulic reservoir. Level should be 3/4 of sight gauge (ram fully retracted).
Clean out or wash out debris from behind compactor ram.
Lubricate the ram guidance tracks using the grease fittings on the compactor side
(For guided ram machines only), and check guide shoes for wear.
THREE MONTHS
1. Check functional operation of controls and options (stop button, timers, lights, etc.).
2. Check hydraulic cylinder, internal hoses, and connections for leakage; check hoses
for chafing and wear.
3. Lubricate the container door hinges.
ANNUALLY
Lubricate electric motor bearings annually per the manufacturers instructions.
FILTER MAINTENANCE
1. The hydraulic filter should be cleaned at regular yearly intervals.
2. The filter may be removed from the unit by disconnecting the union on the suction
side of the pump, removing the four bolts retaining the cover plate, and lifting the
filter from the reservoir.
3. Care should be exercised in cleaning the filter to ensure that the element is not torn.
Clean the element with a soft brush and standard industrial solvent.
4. Replace the filter after cleaning and tighten the union securely. Pump noise and a
"crackle" sound is most often caused by air entering the pump suction line.
Tightening the suction fittings will usually eliminate the problem.
RECOMMENDED OILS FOR THE HYDRAULIC SYSTEM
1. Union - Unax-46, Unax-AW46
6. Shell -Turbo 46, Tellus 46
2. Gulf - Harmony 47, Harmony 48-AW
7. Quaker State - Dextron ll (ATF)
3. Exxon - Teresstic 46, Nuto 46
8. Citgo - Pacemaker 46, Tellus - AW46
4. Texaco - Rando 46
9. Amoco - (Rycon)
5. Chevron - AW 46
17
2 MAINTENANCE
PROCEDURES
PRESSURE SETTING INSTRUCTIONS
When the hydraulic cylinders used in the RamJet Self-Contained compactor are fully extended
or retracted, they bypass internally. This makes it impossible for the hydraulic system to reach
relief pressure. Follow the recommendations below for proper pressure setting.
1.
2.
3.
4.
Disconnect and lock-out power per the procedure on page 16.
Using the quick disconnects, disconnect the hydraulic hoses from the compactor.
Remove the 1/4” plug from the check valve and install a 0-3000 psi pressure gauge.
Loosen the lock nut on the relief valve and turn the adjustment screw several turns
counterclockwise.
5. Remove the lock-out provisions and turn the disconnect to the ON position. Start
the power unit using the OPERATING INSTRUCTIONS on page 7 and 8.
6. With the hoses disconnected, the power unit will build pressure. Adjust the relief
pressure up by turning the relief adjustment screw clockwise. Adjust the relief valve
to the desired pressure setting and tighten the lock nut. See chart below.
7. Press the EMERGENCY STOP button to stop the power unit, and relieve the stored
hydraulic energy as described on page 16.
8. Disconnect and lock-out power as described in Step 1.
9. Remove the pressure gauge and replace the 1/4” plug in the check valve.
10. Reconnect the hydraulic hoses, and remove the lock-out provisions.
PRESSURE SETTINGS
HP
GPM
RELIEF
VALVE
SETTING
RJ-88SC
5
6
1700
15
4
2 1/2
25
RJ-100SC
10
10
1850
20
5
2 1/2
42
RJ-250SC
10
10
1850
20
4
2 1/2
31 5/8
RJ-250 Ultra
10
10
1850
20
4
2 1/2
31 5/8
MODEL NO.
RES.
CAP.
BORE
ROD
STROKE
On units with the Advance Warning Light, set pressure 200 PSI below pressure switch setting.
Includes HT units & SL units.
18
2 MAINTENANCE
PRINCIPLES OF OPERATION
STANDARD SYSTEM OPERATING CHARACTERISTICS, 5 hp & 10 hp
The system uses special cylinders to move the ram and two timers to control the operation of
the ram. When the hydraulic cylinders used in the self-contained compactors are fully
extended or retracted, they bypass internally. This makes it impossible for the hydraulic
system to reach relief pressure. The sequence of operation for this system is as follows:
Upon startup, a contact is made that energizes the motor starter, starting the electric motor
and at the same time energizing T1 timer coil. When T1 is energized, the valve solenoid shifts
the valve so that the hydraulic oil is directed to extend the cylinder which extends the ram.
When T1 timer times out, the contacts reverse causing T2 timer to energize and the solenoid
to shift the valve into the reverse position. In this position, the valve directs the hydraulic oil
into the front end of the cylinder causing the cylinder to retract, therefore causing the ram to
retract. When T2 timer times out, the motor starter contact is opened causing the motor
starter to shut down, therefore causing the motor/power unit to shut down.
2 MAINTENANCE
CYLINDER REMOVAL INSTRUCTIONS
1. Disconnect and lock-out power per the procedure on page 16.
2. Remove access covers from compactor.
2. Remove hoses (4 for 88SC & 250SC, 2 for 100SC & 250 Ultra).
3. Remove cylinder pins.
4. Remove cylinders (2 for 88SC, 250SC, & 250 Ultra, 1 for 100SC).
5. To install the cylinders, reverse the above steps.
19
2 MAINTENANCE
TAILGATE SEAL REPLACEMENT
When the door/tailgate seal becomes damaged or worn, replace the seal.
WARNING: For units with hydraulic tailgates, before performing any inspection or
maintenance on the seal, support the raised tailgate with a crane, forklift, or other
positive maintenance prop..
•
When removing the old seals (top & bottom) mark the position of the seal joints.
•
Pry the seal retainer up slightly to allow removal of the old seals.
•
When installing the new seals, join the seals at the same position.
A
New Seal
A
Pry Bar
New Seal
Seal retainer Pry slightly
upward so new
seal can be
inserted
Use a plastic or rubber
hammer to tamp the seal
retainer snug against the seal
all the way around the seal(s)
20
2 MAINTENANCE
CHARTS
FUSES AND CIRCUIT BREAKERS
MOTOR
SIZE
5 HP, 1 PH
5 HP, 3 PH
10 HP, 1 PH
10 HP, 3 PH
VAC
FULL LOAD
AMPS
DUAL
ELEMENT FUSE
MAX.SIZE
CIRCUIT
BREAKER
MAX. SIZE
SERVICE
DISCONNECT
AMPS
208
22.0
50
80
60
230
20.8
45
70
60
208
13.8
30
40
30
230
13.4
25
40
30
460
6.7
15
20
30
575
5.4
10
15
30
208
43.0
100
125
100
230
39.0
90
125
100
208
27.5
50
80
60
230
25.6
50
70
60
460
12.8
25
35
30
575
11.4
20
30
30
21
2 MAINTENANCE
CHARTS
WIRE SIZE
MOTOR SIZE
5 HP, 1 PH
5 HP, 3 PH
10 HP, 1 PH
10 HP, 3 PH
THW Copper 75°C (165°F)
VOLTAGE
UP TO 100’
UP TO 200’
UP TO 300’
208
8
6
4
230
8
6
4
208
10
6
4
230
10
8
6
460
12
12
10
575
12
12
12
208
4
1
1/0
230
4
2
1/0
208
6
4
2
230
8
4
3
460
12
10
8
575
12
12
10
MOTOR STARTERS AND HEATER ELEMENTS
MOTOR SIZE
5 HP, 1 PH
5 HP, 3 PH
10 HP, 1 PH
10 HP, 3 PH
VOLTAGE
STARTER SIZE
ALLEN BRADLEY
JOSLYN CLARK
208
2
W-61
2452
230
2
W-60
2451
208
1
W-55
2447
230
1
W-55
2446
460
1
W-46
2438
575
1
W-44
2435
208
3
W-66
N/A
230
3
W-65
N/A
208
2
W-63
2454
230
2
W-62
2454
460
1
W-55
2446
575
1
W-53
2445
22
2 MAINTENANCE
TYPICAL PANEL BOX CONFIGURATION
The diagram at right represents a
typical panel box configuration for the
self-contained compactors. The panel
box on your compactor may differ
depending on the model and/or
optional equipment/ controls. Refer to
t h e c h a r t b e l o w t o i d e nt i f y
components. To order replacement
p art s, p l ea se ca ll our P a rt s
Department at 1-800-633- 8974 or
order online by logging
onto www.parts1stop.com.
For information on programming the
PLC, refer to the following 2 pages.
Reference
Part #
Description
A
03-0288
Control Transformer-Micron 150VA, 208/230/460-120 VAC
B
03-0959
Distribution Block
C
03-4729
Zelio Smart Relay - PLC
D
03-4852
Zelio Expansion Module - 6 Inputs, 4 Outputs OR
D
03-5483
Zelio Expansion Module - 8 Inputs, 6 Outputs
E
03-4748
IEC Motor Starter
E
03-4753
Overload for 460V OR
E
03-4763
Overload for 230V
F
03-4437
IEC Finger-Safe Terminal Blocks
G
Call w/SN
Fuse
23
2 MAINTENANCE
PLC MAINTENANCE - LAYOUT & DESCRIPTION
Reference
Description
1
Retractable mounting feet
2
Screw terminal block for the power supply
3
LCD, 4 lines, 18 characters
4
Screw terminal block for inputs
5
Screw terminal block for discrete input
6
Connector for backup memory or PC connection cable
7
Shift key
8
Selection and validation key (Menu / Ok)
9
Relay output screw terminal block
10
Arrow keys
24
2 MAINTENANCE
PLC MAINTENANCE - continued
MULTICYCLE COUNTER SELECTION
STEPS
DIRECTIONS
1
Press the Menu Button
2
Press Arrow Down Button to select PARAMETER (flashing)
3
Press Menu/Ok Button
4
Press Arrow Up Button until CC2 (flashing)
5
Press Arrow Left Button until P=0001 is (flashing)
6
Press Arrow Down or Arrow Down to select cycle count*
7
Press Menu/Ok Button
8
Press Menu/Ok Button with YES to Confirm Changes
9
Press the Menu Button
Ram Stop Rear or Ram Stop Forward Selection
STEPS
1
DIRECTIONS
Press & Hold the Arrow Left Button to Change and display the current ram stop position
NOTE: Repeating this process switches the current postion to ram stop forward or ram stop reverse.
PLC MAINTENANCE - EXTEND/RETRACT TIMER ADJUSTMENT
STEPS
DIRECTIONS
1
Press the Menu Button
2
Press the Up or Down Arrow Button until you get to PARAMETER
3
Press the Menu Button
4
Press the Up or Down Arrow Button until TT1 is flashing (Extend Timer)
5
Press the < Arrow Button
6
Press the Up or Down Arrow Button until the desired time is flashing
7
Press Menu
8
Press Menu with YES blinking
9
Repeat Steps 4-8 with TT2 (Retract Timer)
10
Press the Menu Button to return to normal operation.
TIMER SETTINGS (in seconds)
MODEL NO.
RAM STOP REAR
RAM STOP FORWARD
TT1
TT2
TT1
TT2
RJ-88SC
27
17
17
27
RJ-100SC
21
16
16
21
RJ-250SC
19
13
13
19
RJ-250 Ultra
19
13
13
19
25
2 MAINTENANCE
POWER UNIT - STANDARD 5 HP (MECO)
Match the reference
numbers to the chart
on the next page.
26
2 MAINTENANCE
POWER UNIT - STARDARD 5 HP - Parts Lists (MECO)
Match reference numbers with the chart on the previous page to identify components.
For replacement part ordering, call our parts department at 1-800-633-8974 or log on to
www.parts1stop.com to quickly place your order online.
Part #
Ref. #
Description
Quantity
02-0025
1
NIPPLE 3/8 NPT
1
02-0035
2
TEE 1/2 NPTF
1
02-0037
3
COUPLING 1/2 NPT SCH 80
1
02-0039
4
ELL 1/2 NPTM X 1/2 NPTF 90
1
02-0040
5
ADAPTER 3/8 NPTF X 1/2 NPTM
1
02-0050
6
FILTER SUCTION 1 13 GPM 100 ME
1
02-0065
7
PLUG 1/4 NPT SOCKET HEAD
1
02-0132
8
ADAPTER 1/2 NPTF X 3/4 NPTM
1
02-0197
10
BREATHER 3/4 FILLER
1
02-0198
11
GAUGE SIGHT LEVEL 3 INCH
1
02-0204
12
VALVE CHECK 1/2 NPTF
1
02-0214
13
VALVE RELIEF 20 GPM CART PILOT
1
02-0238
14
ELL 1 NPTM X 1 NPTF 90 SCH 40
2
02-0264
16
SUBPLATE 05 1 STN 1/2 NPTF R O
1
02-0265
17
ELL 1/2 NPTM X 1/2 NPTF W/1/4H
1
02-0328
18
HOSE END 1/2 WB X 1/2 SW NPTM
3
02-0329
19
HOSE END 1/2 WB X 1/2 NPTM
1
02-0363
20
PIPE 1 SCH 40 X 10 1/4
1
02-0555
21
ELL 1/2 NPTM X 1/2 NPTM 90
2
02-0859
22
VALVE CHECK 3/8 NPTF AIR BLEED
1
03-4367
23
MOTOR 5HP 1750 208/230/460 CLO
1
05-0012
24
BOLT 3/8-16 X 1 1/4 HHCS PLT
2
05-0105
25
NUT 5/16-18 HEX SELF-LOCKING
2
05-0154
26
BOLT 5/16-18 X 2 1/4 SHCS
2
05-0159
27
WASHER 3/8 LOCK
2
06-0011
28
DECAL MOTOR ROTATION
1
99-7778
29
PUMP 6 GPM VANE
1
02-0330
30
HOSE 1/2 WB 3500PSI
27
2.25
2 MAINTENANCE
POWER UNIT - DRY 10 HP (MECO)
28
2 MAINTENANCE
POWER UNIT - DRY 10 HP - Parts List (MECO)
MATCH REFERENCE NUMBERS WITH THE DRAWING ON THE PREVIOUS PAGE. TO
ORDER REPLACEMENT PARTS CALL OUR PARTS DEPARTMENT AT
1-800-633-8974 OR ON THE INTERNET AT www.parts1stop.com.
Part #
Ref. #
Description
Qty
02-0044
1
ELL 3/4 NPTM X 3/4 NPTF 90
1
02-0050
2
FILTER SUCTION 1 13 GPM 100 ME
1
02-0157
4
VALVE 4-WAY DIRECTIONAL CONTROL
1
02-0184
5
VALVE CHECK 3/4 NPTM X 3/4 NPT
1
02-0197
6
BREATHER 3/4 FILLER
1
02-0214
7
VALVE RELIEF 20 GPM CART PILOT
1
02-0215
8
GAUGE SIGHT LEVEL 5 INCH
1
02-0219
10
CLEAN OUT COVER 6
1
02-0238
11
ELL 1 NPTM X 1 NPTF 90 SCH 40
2
02-0239
12
UNION 1 NPT
1
02-0240
13
NIPPLE 1 NPT CLOSE
1
02-0264
15
SUBPLATE 05 1 STN 1/2 NPTF R O
1
02-0267
16
PUMP 10 GPM GEAR
1
02-0363
18
PIPE 1 SCH 40 X 10 1/4
1
02-0366
19
PIPE 1/2 SCH 40 X 9 RETURN
1
03-3665
20
MOTOR 10HP 208/230/460V 60HZ 3
1
06-0011
27
DECAL MOTOR ROTATION 3/4 x 4
1
29
2 MAINTENANCE
POWER UNIT - DRY 10 HP (NON MECO)
1 2
3
4
5
6
7
18
17 15
20
8
9
10
11
12
13
14
16 19
EXPLODED VIEW
ISOMETRIC VIEW
TOP VIEW
SIDE VIEW
30
2 MAINTENANCE
POWER UNIT - DRY 10 HP - Parts List (NON MECO)
MATCH REFERENCE NUMBERS WITH THE DRAWING ON THE PREVIOUS PAGE. TO
ORDER REPLACEMENT PARTS CALL OUR PARTS DEPARTMENT AT
1-800-633-8974 OR ON THE INTERNET AT www.parts1stop.com.
Part #
Ref. # Description
Qty
03-5480
1
ENCLOSURE 18x12x6 NEMA 12&4
1
32-4982
2
MOUNTING BRACKETS
1
03-5479
3
10HP 3PH 215TCHZ MOTOR
1
02-4988
4
GEAR PUMP 10.5GPM
1
02-5095
5
INLINE CHECK VALVE 1/2”
1
02-0157
6
VALVE 4-WAY 05 O 2-POS
1
32-3164
7
WEATHER COVER
1
02-5106
8
LID
1
02-5086
9
RELIEF VALVE
2
02-5099
10
SUBPLATE
1
02-5094
11
PRESSURE GAUGE 4000PSI
1
02-0215
12
SIGHT GAUGE 5” SG-5-T-G
1
02-4993
13
STRAINER PEC-8-3/4-100
1
02-0179
14
1/2 PLUG
1
02-5100
15
RESERVOIR 29x13x20 DRY COMP
1
03-5476
16
HEATER (208/230/460)
1
03-5477
16
HEATER (575)
1
02-4992
17
OIL LEVEL SENSOR
32-4983
18
WEATHER COVER BRACKETS (4)
99-7391
19
3/4” BREATHER
03-0658
20
SWITCH PRESSURE W/72” STOW CORD
31
2 MAINTENANCE
POWER UNIT - SUBMERGED 10 HP (NON MECO)
1 2
3
4
6
5 7 9 8
19 20
21
16
10
12
11
14
13
17 15
EXPLODED VIEW
18
ISOMETRIC VIEW
TOP VIEW
SIDE VIEW
SIDE VIEW - with LID
32
2 MAINTENANCE
POWER UNIT - SUBMERGED 10 HP - Parts List (NON MECO)
MATCH REFERENCE NUMBERS WITH THE DRAWING ON THE PREVIOUS PAGE. TO
ORDER REPLACEMENT PARTS CALL OUR PARTS DEPARTMENT AT
1-800-633-8974 OR ON THE INTERNET AT www.parts1stop.com.
Part #
Ref. #
Description
03-5480
1
ENCLOSURE 18x12x6 NEMA 12&4
32-4982
2
MOUNTING BRACKETS
99-7391
3
3/4” BREATHER
03-5481
4
JUNCTION PVC BOX 6x6x4
02-5094
5
PRESSURE GAUGE 4000PSI
03-0658
6
SWITCH PRESSURE W/72” STOW CORD
02-0157
7
VALVE 4-WAY DIRECTIONAL CONTROL
02-5086
8
RELIEF VALVE
02-4991
9
DO2 SUBM.SUBPLATE ALL SAE
02-5095
10
INLINE CHECK VALVE 1/2”
02-4993
11
STRAINER PEC-8-3/4-100
02-0215
12
SIGHT GAUGE 5”
02-5100
13
RESERVOIR 29 x 13 x 20 20GAL
02-0179
14
1/2 PLUG
02-4988
15
GEAR PUMP 10.5GPM
02-4992
16
OIL LEVEL SENSOR
03-5374
17
MOTOR 10HP/3PH SUBMERSIBLE 208/230/460 FR56
03-5476
18
HEATER (208/230/460) OPTIONAL 1-1/4” NPT w/PLUG
03-5477
18
HEATER (575) OPTIONAL 1-1/4” NPT w/PLUG
32-4983
19
WEATHER COVER BRACKET (4)
32-4984
20
LID HOLD UP TAB (2)
32-3164
21
WEATHER COVER
33
2 MAINTENANCE
HYDRAULIC SCHEMATIC - TYPICAL (cycon)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
*
Cylinder
Quick Disconnect (Female)
Quick Disconnect (Male)
Valve, 4-Way
Relief Valve
Check Valve
Pump
Suction Filter
Hub Coupling (Not on Closed-Coupled Units)
Motor
SINGLE CYCLINDER UNIT SHOWN. FOR DUAL CYLINDER
UNITS, CONNECT IDENTICAL CYLINDER IN PARALLEL.
34
2 MAINTENANCE
TROUBLESHOOTING CHART
PROBLEM
CAUSE
SOLUTION
UNIT WILL NOT START
( 1) No electrical power to unit
( 1A) Turn on main disconnect
( 1B) Replace fuses or reset breakers
( 2A) Check primary and secondary
sides of transformer
( 2B) Check for correct voltage. Check
control fuses.
( 2C) Check stop button
( 2D) Check start button to be sure contact
closes when depressed
( 2) No electrical power to control
circuit
UNIT WILL NOT CONTINUE RUNNING
WHEN START BUTTON IS RELEASED
( 3) No electrical power to motor
( 3A) Check heater resets
( 1) Motor starter is in-operative
( 2) Motor starter auxiliary contacts are
inoperative
( 3) Reverse Button is inoperative
( 1A) Check motor starter coil & wiring
( 2A) Check motor starter contacts and
wiring
( 3A) Check reverse button to be sure
contacts are closed
( 3B) Check wiring
( 4A) Check contact, wired black and
orange, to be sure it is operating
properly
( 4B) Check wiring
( 4) Secondary contact on start button
is inoperative
MOTOR RUNS BUT RAM DOES NOT MOVE
NORMALLY
( 1) Insufficient oil in reservoir
( 2) Low relief pressure
( 3) Oil leakage in cylinder
(
(
(
(
4)
5)
6)
7)
Defective pump
Oil leakage from hose fittings
Low voltage
Pump may be driven in the wrong
direction of rotation
( 8) Shaft broken, or shaft key sheared
( 9) Intake pipe from reservoir blocked,
or oil viscosity too heavy to prime
( 10) Intake air leaks (foam in oil or
sounds like gravel in pump)
( 11) Units shift slowly
( 12) Valve response sluggish
UNIT WILL NOT REVERSE
( 1) Solenoid valve is in-operative
( 2) Reverse button in-operative
35
( 1A) Fill reservoir with oil
( 2A) Check relief pressure (refer to
PROCEDURES-HYDRAULIC PRESSURE
CHECK and PRESSURE SETTINGS for
correct pressure.
( 2B) Clean orifice in relief valve and
reset pressure
( 2C) Check ‘O” rings on relief valve for
damage or leakage
( 3A) Check cylinder for bypassing
( 3B) Replace seal kit, inspect rod and
cylinder tube for scoring or nicks
( 3C) Replace cylinder
( 4A) Replace pump
( 5A) Tighten hose fittings
( 6A) Check voltage
( 7A) Stop immediately to prevent seizure.
Check direction of drive rotation
(proper rotation direction is indicated
by arrow on motor)
( 8A) Visually inspect motor and pump
Shaft and hub couplings for damage.
Replace if necessary.
( 9A) Drain system. Add clean fluid of
proper viscosity and specifications.
Filter as recommended. Check system
filter for cleanliness.
(10A)Check intake connections. Tighten
securely
(11A) Flow control valve (restrictor)
clogged, remove and clean orifice.
(12A) Contaminated oil-drain and flush
system.
(12B)Inadequate voltage, check voltage
(12C)Dissamble valve and clean
(1A) Check coil in solenoid valve
(2B) Check reverse button contacts
2 MAINTENANCE
TROUBLESHOOTING CHART
PROBLEM
CAUSE
SOLUTION
PUMP MAKES NOISE-SOUNDS LIKE GRAVEL
( 1 ) Partly clogged intake strainer or
restricted intake pipe
( 1A) Pump must receive intake fluid
freely or cavitation results. Drain system,
clean intake pipe and clean or replace
strainer
( 2A) Replace pump
( 3A) Tighten joints as required.
( 1A) Replace seals or pump.
( 1A) When over 140 degrees F or hot in
comparison with circuit lines, pump
should be shut down immediately.
Before restarting, insure that fluid
cooling capacity is adequate to remove
system generated heat.
( 1B) Install oil cooler (air or water type)
( 1C) Install oil temperature shut down
switch
( 1D) Check to be sure CYCON Power Pack
has not been exchanged for Pressure
Shifting Power Pack.
( 2A) Replace with larger hydraulic lines
( 3A) Use lower viscosity oil
PUMP SHAFT SEAL LEAKING
(
(
(
(
2)
3)
1)
1)
Defective bearing
Air leak at pump intake pipe joints
Seal worn or damaged
Continuous running
EXCESSIVE HEAT
( 2) Undersized hydraulic lines
( 3) High ambient temp in relation to
oil temp.
( 4) Excessive system leakage
RAPID WEAR
( 1) Abrasive matter in the hydraulic oil
being circulated through pump
( 2) Viscosity of oil too low at working
conditions
( 3) Pressure too high
ERRATIC OPERATION
( 4) Air recirculation causing pump noise
( 1) Valve sticking or binding
( 2) Viscosity of oil too high
( 3) Air in system
( 4) Low oil
( 5) Low voltage
OVERLOADS TRIP FREQUENTLY
( 4A) Check system for bypassing or
leaks
( 1A) Install adequate filter or clean.
( 1B) Replace oil more often and clean
tank
( 2A) Replace oil with factory recommended.
( 3A) Reduce pump pressures to factory
specifications.
( 4A) Tighten all fittings.
( 1A) Disassemble & clean as necessary
( 2A) Change oil to factory recommended
viscosity
( 3A) Check for leaks, tighten fittings
( 4A) Fill reservoir with oil
( 5A) Check primary & secondary sides of
transformer for correct voltage.
( 1A) Check for correct voltage (incoming
power.)
( 1B) Check fuses or breakers at disconnect
( 1C) Check heater elements to be sure
they are tight
( 1D) Check wiring from starter to motor
to make sure all connections are tight
( 1E)Check motor leads to be sure all connections are tight surges or voltage
NOTE: Excessive overload tripping and/or
motor or coil failures may occur if voltage
surges or voltage drops are frequent in your
area. This circumstance can be remedied by
the installation of phrase protectors which
drop power to the motor if surges are present.
36
3 INSTALLATION
CONCRETE PAD REQUIREMENTS
CAUTION!
REVIEW THIS MANUAL BEFORE MAKING THE INSTALLATION. STUDY THE JOBSITE
AND INSTALLATION REQUIREMENTS CAREFULLY TO BE CERTAIN ALL NECESSARY
SAFEGUARDS AND 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 EXTRACT
FROM AMERICAN NATIONAL STANDARDS Institute Z245.2.
These operating 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.
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. NOTE: Units with four
ground rollers must be installed on a level pad.
2. To provide accessibility, concrete pad should be positioned to allow 2'0" 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.
Note: The clearances given are minimums. Your installation may require greater
clearances depending on the site and the hauling equipment that will be used.
3 INSTALLATION
CONTAINER GUIDES
If container guides (optional) are used with the self-contained units, the guides should
be anchored to the concrete pad using 3/4" X 6" 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.
37
3 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.
3 INSTALLATION
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 “DECAL PLACEMENT” in the Operation section of this
manual.
NOTE: Installation is not complete until all decals are in place.
38
3 INSTALLATION
ELECTRICAL & HYDRAULIC INSTALLATION
DANGER
460
VOLTS
The motor control panel contains high
voltage components. Only authorized
service personnel should be allowed
inside. See Lock-Out & Tag-Out instructions in the maintenance 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 Fuse and
Circuit Breaker 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-THEWALL
POWER UNIT INSTALLATION in this section. Special care should be taken to protect the
hoses from abrasive objects.
3. 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 Maintenance section of this manual.
39
3 INSTALLATION
ELECTRICAL & HYDRAULIC INSTALLATION
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 Fuse & Circuit Breaker Chart for Motors and Wire Size Chart, in the
Maintenance Section, to determine the proper service disconnect amperage rating and the
proper wire size.
NOTE: 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
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.
2. CAUTION: MAKE SURE PERSONS AND MATERIAL ARE CLEAR OF CHARGE BOX AREA.
3. 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.
4. Make sure that the operators are trained in the proper use of this equipment.
40
3 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
Coupling, Male x Female Swivel
* 1/2” for hose lengths of 20’-0” or less. Consult factor for longer lengths.
WALL
TOP VIEW
COMPACTOR
ITEM # 3
POWER
UNIT
ITEM # 1
ITEM # 5
CYLINDER
ITEM # 6
ITEM # 4
EACH SIDE
ITEM # 2
41
4 HAULER INFORMATION
HAULER INSTRUCTIONS - GENERAL
Before hauling to the landfill:
1. Disconnect all hoses and electrical connections (if applicable) between the power unit and
the compactor. Make sure they are placed in an area where they will not get damaged.
2. Close and secure any hopper doors or gates.
3. Make sure that the container door safety chain is secured in the keyhole on the latch side
of the container floor.
4. If the unit is a Streamline model (SL), disconnect any drain hose(s) connected to the unit
and plug all ports.
5. Make sure that the hoist lifting the unit is compatible with the understructure
on the unit.
NOTE: Hold downs should be used to secure the front and rear of the of the
container understructure to the hoist.
At the landfill:
SEE THE NEXT PAGE FOR DOOR AND LATCH OPERATION INSTRUCTIONS.
1. To prevent leakage, the door seal and mating surface should be wiped clean and
inspected after the unit has been emptied. When cleaning the seal on units with
the hydraulic tailgate option, inspect for damage and replace if necessary.
WARNING: NEVER place any part of your body between the tailgate and the
container. Use a mop or similar cleaning device with a long handle to clean
the seal. Close inspection of the seal should be done only after the container
has been lowered to a level position and the raised tailgate has been
supported with a crane, forklift, or other positive maintenance prop.
After returning from the landfill:
1. After setting the unit down, reconnect all hoses and electrical connections (if applicable) to
the compactor. Make sure they are not laying across sharp corners or any abrasive
surface.
2. Close and secure any hopper doors or gates.
3. Make sure that the container door safety chain is secured in the keyhole on the latch
side of the container floor.
4. If the unit is a Streamline model (SL), connect any drain hose(s) to the unit.
42
4 HAULER INFORMATION
DOOR/LATCH OPERATION
CONTAINER
LATCH ASSEMBLY
ACTUATED BY RATCHET
DOOR
LATCH SIDE VIEW
OF CONTAINER
AUTO RELATCH
SAFETY CHAIN ALWAYS FASTEN
CHAIN IN KEYHOLE
WHEN DOOR IS
CLOSED. WHEN THE
DOOR IS OPEN,
SECURE THE CHAIN
IN THE KEYHOLE ON
THE HINGE SIDE OF
THE CONTAINER
FLOOR.
RATCHET FOR OPENING AND CLOSING
THE LATCH ASSEMBLY
ROTATE THE AUTO RELATCH
UP TO THE POSITION SHOWN
AND OPEN THE LATCH AND
DOOR.
AUTO RELATCH
IN POSITION TO
OPEN DOOR
WHEN CLOSING THE DOOR,
ROTATE THE AUTO RELATCH
DOWN TO THE POSITION
SHOWN AND PUSH THE DOOR
SHUT UNTIL THE AUTO
RELATCH GRABS THE PIN ON
THE DOOR. AFTER THE DOOR IS
SECURED BY THE AUTO
RELATCH, THE LATCH ASSEMBLY
IS CLOSED USING THE
RATCHET. CONNECT THE
SAFETY CHAIN ON THE DOOR
TO THE KEYHOLE ON THE SIDE
OF THE CONTAINER FLOOR.
AUTO RELATCH
IN POSITION TO
GRAB AND HOLD
DOOR DURING
DOOR CLOSING
43
4 HAULER INFORMATION
HYDRAULIC TAILGATE OPERATION (FOR OPTIONAL HT UNITS)
The truck hoist must have a hydraulic selector valve with 1500 psi, min. to operate the
hydraulic tailgate. The hydraulic tailgate is supplied with one 1/2” NPTF male quick disconnect
mounted on the drivers side of the unit. A 1/2” female quick disconnect is supplied for use on
the truck hoist valve plumbing.
CAUTION
∗
STAND CLEAR OF TAILGATE WHEN LIFTED.
∗
TRUCK MUST BE ON FIRM, LEVEL SURFACE BEFORE LIFTING TAILGATE.
∗
FRONT AND REAR HOLDDOWNS MUST BE ENGAGED.
∗
TILT HOIST BEFORE LIFTING TAILGATE.
1. ATTACH HYDRAULIC
CONNECTION.
2. DISENGAGE LATCH.
(EACH SIDE)
LATCH
3. RAISE HOIST
4. LIFT TAILGATE
5. EMPTY CONTENTS
TAILGATE
TRUCK HOIST
CONTENTS
6.
CLEAN SEAL AS DESCRIBED IN THE “HAULER INSTRUCTIONS - GENERAL” IN
THIS SECTION OF THE MANUAL. NOTE WARNINGS.
7. LOWER TAILGATE AS LOW AS POSSIBLE.
8. LOWER HOIST.
9. LOWER TAILGATE COMPLETELY.
10. ENGAGE AND TIGHTEN LATCHES.
11. REMOVE HYDRAULIC CONNECTION.
44
4 HAULER INFORMATION
HYDRAULIC TAILGATE OPERATION (FOR OPTIONAL HT UNITS)
WARNING:
NEVER PLACE ANY PART OF YOUR BODY
BETWEEN THE TAILGATE AND CONTINER.
INSTRUCTIONS FOR USING MAINTENANCE BAR.
1. Lower tailgate approximately 24” between container bottom and compactor tailgate.
2 Remove locking pin from maintenance bar and slide bar toward compactor.
3. Align holes in the position collar and bar and insert pin.
4. Use a mop or similar cleaning device with a long handle to clean the seal.
5. Raise tailgate to relieve pressure on maintenance bar, remove pin, return bar to retracted
position and insert pin through collar and bar.
LOCKING PIN
EXTENDED
MAINTENCE BAR
POSITION
COLLAR
LOCKING PIN
RETRACTED
MAINTENCE BAR
POSITION
COLLAR
45
4 HAULER INFORMATION
LIQUID REMOVAL - (FOR OPTIONAL SL UNITS
The RamJet Self-Contained Streamline compactor/containers are designed with an internal
drain system for liquid removal, ported to each corner of the machine. The unit comes
standard with one ball valve. This valve can be moved to any of the four drain outlets on the
machine. The valve should be located at the lowest outlet on the machine for proper drainage.
The customer can attach a drain hose with a 3” NPT male fitting to the drain valve.
REAR DRAIN GRATING
DIRECTS LIQUID OUT
TO DRAINS
FLOW
FLOW
5” ANGELS PROVIDE PATH
FOR LIQUID REMOVAL
FLOW
SECTION VIEW
TYPICAL DRAIN VALVE LOCATION
AT LOW CORNER OF MAHINE.
(3” NPT FEMALE THREAD)
4” DRAIN OUTLET
AT EACH CORNER
CUSTOMER SUPPLIED
HOSE TO PUMP OR
DRAIN
A
A
SIDE VIEW
46
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