Related Manuals for Dover Marathon V-4830 HD
Summary of Contents for Dover Marathon V-4830 HD
- Page 1 OPERATION, MAINTENANCE, AND INSTALLATION MANUAL SPECIALTY VERTICAL BALERS MODELS V-4830 HD V-6030 LP Marathon Equipment Co. OMI Manual No. 0003SVB, Rev. 1/08...
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Page 2: Table Of Contents
CONTENTS OPERATION Introduction....................1-1 Pre-Operating Instructions ................1-2 Specifications....................1-3 Control Layout Drawings................1-4 Controls Description..................1-5 Operating Instructions (how to make a bale)..........1-6 Bale Tie-Off Instructions................1-7 Decal Placement................... 1-8 Decal Description..................1-9 Decal Images…………………………………………………………………..1-10 MAINTENANCE Lock-Out and Tag-Out Instructions............... 2-1 Supporting Platen (for cylinder removal) ............2-2 Periodic Maintenance &... -
Page 3: Introduction
OPERATION INTRODUCTION THANK YOU FOR PURCHASING A MARATHON VERTICAL BALER. This baler is designed to give you reliable service and superior performance for years to come. Marathon is dedicated to ensuring every machine manufactured in our state-of-the-art facilities strengthens the legacy of innovation and quality that we have provided to our customers for over 40 years. -
Page 4: Pre-Operating Instructions
OPERATION PRE-OPERATING INSTRUCTIONS WARNING: DO NOT OPERATE BALER UNTIL OPERATING INSTRUCTIONS ARE THOROUGHLY UNDERSTOOD. WEAR SAFETY GLASSES, AND GLOVES WHEN OPERATING THIS EQUIPMENT. DANGER STAY CLEAR OF ALL INTERNAL, AND EXTERNAL MOVING PARTS WHEN OPERATING BALER. D D O NOT FAILURE TO DO SO COULD RESULT IN SERIOUS ENTER PERSONAL INJURY OR DEATH! -
Page 5: Specifications
OPERATION SPECIFICATIONS MODEL # V-4830-HD V-6030-LP Performance Cycle Time:(empty) 58 seconds 34 seconds Total Force: 56,550 lbs 56,550 lbs Platen Face PSI: 43 PSI 37 PSI Electrical Control Voltage 120 VAC 120 VAC Motor: 10 HP 10 HP RPM: 1750 RPM 1750 RPM Hydraulic Pump:... - Page 6 OPERATION CONTROL LAYOUT WITH OPERATING INSTRUCTIONS 11. E n la parte tras era de la enfardadora, ins ertar las manijas del eyec tor de c adena s ogre los dos ganchos que s obres alen por la parte tras era de la platina. 11.
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Page 7: Controls Description
OPERATION CONTROLS DESCRIPTION 1. EMERGENCY STOP — (Red Pushbutton) Pressing the EMERGENCY STOP button will stop the machine immediately. 2. OFF-ON-AUTO — (Key Switch) (a) Turn OFF-ON-AUTO switch to OFF position and remove key when not in use. (b) Turn OFF-ON-AUTO switch to the ON position to operate baler with MANUAL RAISE and MANUAL LOWER SWITCH. -
Page 8: Operating Instructions (How To Make A Bale)
OPERATION OPERATING INSTRUCTIONS - MAKING A BALE DANGER IN CASE OF EMERGENCY: PRESS the large D D O NOT button to ENTER PRESS “STOP” WARNING: SAFETY INTERLOCKS AND DEVICES ARE INSTALLED ON THIS MACHINE FOR YOUR PROTECTION. NEVER DISABLE OR BYPASS ANY SAFETY DEVICE. - Page 9 OPERATION BALE TIE-OFF / BALE EJECT When the BALE MADE DECALS ARE ALIGNED, follow tie-off procedure and eject finished bale from bale chamber. FOR BALE TIE-OFF & BALE EJECT: CAUTION: WEAR SAFETY GLASSES AND LEATHER GLOVES DURING THE FOLLOWING PROCEDURE. Turn PLATEN switch to RAISE and hold, until the feed gate opens.
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Page 10: Decal Placement
OPERATION DECAL PLACEMENT Refer to the decal descriptions chart on the following page to match the reference num- bers below to the description and part number for each decal. For images of decals, see page 1-10. NOTE: LOCATIONS OF DETAILS 1 & 2 ARE CRITICAL! The “BALE MADE”... -
Page 11: Decal Description
OPERATION DECAL DESCRIPTIONS WARNING DECAL REQUIREMENTS When your baler leaves the factory, several WARNING DECALS are installed for your protection. These labels are subject to wear & abuse due to the nature of the operation. THESE DECALS MUST BE MAINTAINED. Additional decals may be purchased through your distributor, by calling 1-800-633-8974, or by logging onto www.parts1stop.com. -
Page 12: Decal Images
OPERATION DECAL IMAGES To order replacement decals, contact your distributor or call our service department at 1-800-633-8974 or you can log on to www.parts1stop.com. 06-0651 06-0121 ATTENTION 06-0652 CAUTION ATENCION Bale is made if arrow does not pass this point on Los reglamentos Federal regulation down stroke. -
Page 13: Maintenance
MAINTENANCE LOCK-OUT & TAG-OUT INSTRUCTIONS Before entering any part of the baler, be sure that all sources of energy have been shut off, all potential hazards have been eliminated, and the baler is locked-out, and tagged-out in accordance with OSHA, and ANSI requirements. Before servicing the hydraulic system or the inside of the bale cham- ber, the platen must be properly supported as shown on the next page. - Page 14 MAINTENANCE SUPPORTING OF PLATEN WARNING: LOCK-OUT & TAG-OUT PRIOR TO ANY SERVICE OR REPAIR. Before entering bale chamber for service, be sure that the platen is securely supported. At a minimum, use two wooden 4” x 4” beams (good condition), fixed to fit securely in each rear corner of the chamber while supporting the platen in the up position.
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Page 15: Periodic Maintenance & Recommended Oil
MAINTENANCE PERIODIC MAINTENANCE & RECOMMENDED OIL WARNING: BEFORE PERFORMING ANY MAINTENANCE OR SERVICE PROCE- DURES ON THE BALER, MAKE SURE THE BALER IS LOCKED-OUT AND TAGGED- OUT PER THE INSTRUCTIONS ON PAGE 2-1. FOR MAINTENANCE INSIDE THE BALE CHAMBER, SEE THE PLATEN CHOCKING PROCEDURE ON PAGE 2-2. MONTHLY 1. -
Page 16: Procedure -Cylinder Removal
MAINTENANCE PROCEDURES - CYLINDER REMOVAL DANGER: DO NOT CLIMB ON SIDES OF BALER. USE A LADDER OR PLATFORM WHEN WORKING ON TOP OF THE BALER OR OTHER AREAS OF THE BALER THAT CANNOT BE REACHED FROM GROUND LEVEL. DANGER: PARTS OF THE PLATEN EXTEND ABOVE THE TOP OF THE BALER WHEN PLATEN IS FULLY RAISED. -
Page 17: Procedure - Pressure Setting
MAINTENANCE PROCEDURES - PRESSURE SETTING DANGER: DO NOT CLIMB ON SIDES OF BALER. USE A LADDER OR PLATFORM WHEN WORKING ON TOP OF THE BALER OR OTHER AREAS OF THE BALER THAT CANNOT BE REACHED FROM GROUND LEVEL. DANGER: PARTS OF THE PLATEN EXTEND ABOVE THE TOP OF THE BALER WHEN PLATEN IS FULLY RAISED. -
Page 18: Electrical Charts
MAINTENANCE ELECTRICAL CHARTS ELECTRICAL RECOMMENDATIONS DUAL CIRCUIT SERVICE TOTAL FULL ELEMENT BREAKER MOTOR SIZE DISCONNECT LOAD AMP FUSE - MAX. MAXIMUM AMP SIZE SIZE SIZE 10 HP MAIN MOTOR WIRE SIZE RECOMMENDATIONS MOTOR SIZE UP TO 100' UP TO 200' UP TO 300' Above 300' consult factory... -
Page 19: Replacement Parts List
MAINTENANCE REPLACEMENT PARTS LIST PART # HARDWARE 4830HD 6030LP 05-0256 WIRE BALE TIES 250/pcs 06-3471 6 X 48 X 3.5 CYL OSB 06-3472 EJECTOR CHAIN ASSY OSB 06-3473 EJECTOR CHAIN QUICK LINK OSB 06-3474 MAIN GATE HANDLE OSB 06-3475 WHEEL TURNBUCKLE OSB 06-3476 GT GUIDE TUBE ASSY EA OSB 06-3477... - Page 20 MAINTENANCE PANEL BOX LAYOUT & PARTS REFERENCE LIST PART # REF # DESCRIPTION QTY # 03-1344 LIGHT PILOT 22.5 RED LED 120VOLT GE 03-4729 PLC TELEMECANIQUE 6 IN 4 OUT 03-0939 OPERATOR 22 PUSH/PULL MSHRM HD RED GE 03-2865 CONTACT BLOCK FLANGE FOR 5 CONTACTS 03-0933 OPERATOR 22 SELECTOR 3 POS RTTO CENTER GE 03-2689...
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Page 21: Power Unit Drawing - A-Type
MAINTENANCE POWER UNIT DRAWING - “A” TYPE See next page for reference chart End View Left Hand Side View Right Hand Side View Top View... -
Page 22: Power Unit Reference List - A-Type
MAINTENANCE POWER UNIT REFERENCE LIST - “A” TYPE Match the reference numbers to the drawing on the previous page. To order replace- ment parts, please call our parts department at 1-800-633-8974 or log on to www.parts1stop.com to order online. PART # REF # DESCRIPTION QTY # 02-4703 PUMP 9 GPM VANE W/DO5 PAD... -
Page 23: Power Unit Drawing - T-Type
MAINTENANCE POWER UNIT DRAWING - “T” TYPE See next page for reference chart 20 * *Relief valve not seen from this angle. 2-11... -
Page 24: Power Unit Reference List - T-Type
MAINTENANCE POWER UNIT REFERENCE LIST - “T” TYPE Match the reference numbers to the drawing on the previous page. To order replace- ment parts, please call our parts department at 1-800-633-8974 or log on to www.parts1stop.com to order online. Part # Ref # Description 03-5374... - Page 25 MAINTENANCE TROUBLESHOOTING PROBLEM CAUSE SOLUTION (1) No electrical power to unit UNIT WILL NOT START (1A) Turn on main disconnect (2) No electrical power to control circuit (2A) Check primary, and secondary sides of transformer (2B) Check for correct voltage. Check control fuses.
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Page 26: Troubleshooting Guide
MAINTENANCE TROUBLESHOOTING (Continued) PROBLEM CAUSE SOLUTION (1A) When over 140° Fahrenheit, the EXCESSIVE HEAT (1) Continuous running equipment should be shut down immediately, and allow time to cool. (1B) Install oil cooler (air or water type) (1C) Install oil temperature shut down switch (2) Excessive system leakage (2A) Check system for bypassing or... -
Page 27: Hydraulic Schematic
MAINTENANCE TYPICAL HYDRAULIC SCHEMATIC CYLINDER 2-15... -
Page 28: Electrical Schematic - A-Type Power Unit
MAINTENANCE ELECTRICAL SCHEMATIC for A-Type Power Unit 2-16... -
Page 29: Electrical Schematic - T-Type Power Unit
MAINTENANCE ELECTRICAL SCHEMATIC for T-Type Power Unit 2-17... -
Page 30: Plc Maintenance
PLC MAINTENANCE LAYOUT & DESCRIPTION OF PLC 123456 STOP LD FRI 26 OCT 13:24 1234 Reference Description Retractable mounting feet. Screw terminal block for the power supply. LCD, 4 lines, 18 characters Screw terminal block for inputs Screw terminal block for 0-10 Volt analog inputs usable in discrete mode on some models Connector for backup memory or PC connection cable Shift key... -
Page 31: Description Of Lcd
PLC MAINTENANCE DESCRIPTION OF LCD 123456 STOP LD FRI 26 OCT 13:24 1234 Reference Description Input status display Display of the operating mode (RUN/STOP) and programming mode (LD/FBD) Display of the date (day and time for products with clock) Output status display Contextual menus / pushbuttons / icons indicating the operating modes 2-19... -
Page 32: Run / Stop Program Directions
PLC MAINTENANCE RUN / STOP PROGRAM DIRECTIONS PROGRAMMING PARAMETER RUN/STOP CONFIGURATION Steps Directions Press Menu/Ok Button this switches the screen to the Main Menu. Press Arrow Up or Arrow Down to scroll to Run / Stop. (Flashing indicates location) Press Menu/Ok. Yes will be flashing to Run or Stop Program. - Page 33 PLC MAINTENANCE E - PROM TRANSFER MEMORY TO ZELIO Description of the LCD NOTE: Program must be stopped before transferring memory or changing program. Refer to page 2-19 for Stop program directions. Steps Directions Press Menu/Ok. Press Arrow Up and scroll to Transfer. Flashing indicates location. Zelio to Memory will be Flashing If correct Press Menu/Ok, If not go to next step.
- Page 34 PLC MAINTENANCE TIMER SETTING PROCEDURE Description of the LCD Steps Directions Press Menu/Ok. Press Arrow Up and scroll to PARAMETERS. Flashing indicates location. Press Menu/Ok. Press Arrow Up and scroll to T T5. (timer 5) Press Arrow Left to select. (t=000.0 will flash) Press Arrow Up/Arrow Down to adjust timer setting.
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Page 35: Clear Fault & Start Program
PLC MAINTENANCE CLEAR FAULT & START PROGRAM Steps Directions Press Menu/Ok Button this switches the screen to the Main Menu. Press Arrow Up and scroll to Fault. (Flashing indicates location) Press Menu/Ok. Yes will be flashing to Clear the fault. Press Menu/Ok. -
Page 36: Fault List
PLC MAINTENANCE FAULT LIST Number Description of Error No faults Fault in writing to EEPROM This fault defines transfer problems between the memory cartridge and the controller. If the fault occurs frequently, contact the after-sales service. Fault in writing to the clock. If the fault occurs frequently, contact the after-sales service. - Page 37 PLC MAINTENANCE FAULT LIST (Continued) Number Description of Error A fault is present in the firmware (software specific to the controller) or on a part of the controller hardware. If the fault is permanent, reload the firmware on the module and the user program.
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Page 38: Installation
INSTALLATION OFF-LOADING & UP-ENDING BALER THE FOLLOWING REQUIRES AN EXPERIENCED FORK LIFT DRIVER, 8,000 # CAPACITY FORKLIFT, AND 8,000 # CAPACITY CHAINS OR CABLES. 1. INSERT THE FORKLIFT FORKS UNDER THE BALER IN THE APPROXIMATE LOCATIONS SHOWN BELOW, AND MARKED BY “X”. -
Page 39: Raising The Platen (Units Shipped W/Cylinder Lowered)
INSTALLATION RAISING THE PLATEN (UNITS SHIPPED W/CYLINDER LOWERED) DANGER: Only qualified service technicians should perform the following procedure. The hydraulic cylinder operates at high pressure and can cause serious injury or death. When the baler is shipped in a vertical position the cylinder and platen are lowered and supported as shown in the drawing to the right*. -
Page 40: General Installation
INSTALLATION GENERAL INSTALLATION INSTRUCTIONS CAUTION: Review this manual before beginning 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. These instructions are not intended as a substitute for training, and experience in proper use, safety procedures, maintenance, or installation of this equipment. -
Page 41: Electrical Installation
INSTALLATION ELECTRICAL INSTALLATION DANGER The panel box contains high voltage components. Only authorized service personnel should be allowed inside. See Lock-Out & Tag-Out instructions in VOLTS the Maintenance section. WARNING: BEFORE MAKING ANY ELECTRICAL CONNECTION, BE SURE THAT THE DISCONNECT SWITCH HAS BEEN LOCKED-OUT, AND TAGGED-OUT PER THE INSTRUCTIONS ON PAGE 2-1. -
Page 42: Start-Up Instructions
INSTALLATION START-UP INSTRUCTIONS WARNING: BEFORE START-UP, REPLACE THE 3/4” PLUG ON THE POWER UNIT RESERVOIR WITH THE FILLER BREATHER CAP. THIS CAP IS SHIPPED INSIDE OF THE PANEL BOX. DANGER: DO NOT CLIMB ON SIDES OF BALER. USE A LADDER OR PLATFORM WHEN WORKING ON TOP OF THE BALER OR OTHER AREAS OF THE BALER THAT CAN NOT BE REACHED FROM GROUND LEVEL. -
Page 43: Index
INDEX ANSI..................1-1, 2-1 BALE EJECT..............1-7 BALE TIE-OFF ..............1-7 CONCRETE PAD.............. 3-3 CONTROLS..............1-5, 3-2 BALE MADE LIGHT..........1-4, 1-5, 1-6 CYCLE READY LIGHT........1-5 EMERGENCY STOP..........1-5 EXTERNAL RESET..........1-5 LAYOUT............... 1-4 OFF-ON-AUTO KEY SWITCH......1-5 PLATEN RAISE — PLATEN LOWER....1-5 CYLINDER................
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Questions and answers
Model 630 HD what would cause the press cylinder to slowly drop or extend?
A slow drop or extension of the press cylinder in the Dover Marathon V-4830 HD could be caused by hydraulic pressure loss. This may result from a faulty relief valve, internal leakage in the hydraulic cylinder, or a malfunctioning control valve that fails to hold pressure when the system is off.
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