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Summary of Contents for Dover MARATHON M Series
- Page 1 PLAY IT SAFE! OPERATION, MAINTENANCE, AND INSTALLATION MANUAL M-SERIES COMPACTORS INCLUDING THESE MODELS: M-450X, M-600X, M-600XW, M-800XW VERNON, AL - FAYETTE, AL YERINGTON, NV - CLEARFIELD, PA Marathon Equipment Co. 0042-M-SERIES-0420...
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Page 2: Table Of Contents
CONTENTS SECTION 1 OPERATION Introduction Pre-Operating Instructions Controls Operating Instructions Decal Placement Decals SECTION 2 MAINTENANCE Lockout & Tagout Instructions Periodic Maintenance Limit Switch Adjustment Charts Panel Box Arrangement Power Unit 20hp/18gpm Pressure Setting 20hp/18gpm Hydraulic Schematic 20hp/18gpm 2-10 Power Unit 20hp/50gpm 2-11 Pressure Setting 20hp/50gpm 2-12... -
Page 3: Operation
1 OPERATION INTRODUCTION THANK YOU FOR PURCHASING A MARATHON RAMJET “M” SERIES HORIZONTAL COMPACTOR. This product is designed to give you reliable service and superior performance for years to come. To guarantee top performance and the safest operation of the compactor, each person involved in the operation, maintenance, and installation of the compactor should read and thoroughly underst and the instructions in this manual and follow all warnings. -
Page 4: Pre-Operating Instructions
1 OPERATION PRE-OPERATION INSTRUCTIONS STAY CLEAR OF ALL INTERNAL PARTS OF THE COMPACTOR DURING OPERATION. FAILURE TO DO SO COULD RESULT IN SERIOUS INJURY OR DEATH! NEVER ENTER ANY PART OF THE COMP ACTOR UNLESS THE DISCONNECT SWITCH HAS BEEN LOCKED-OUT AND TAGGED-OUT. See Lock-Out &... -
Page 5: Controls
1 OPERATION CONTROLS FOR UNITS WITH 20HP POWER PACK Optional: OPERATOR CONTROLS HAULER (ON SEALTITE) CONTROLS (MOUNTED ON CONTAINER END OF MACHINE) CONTROL DESCRIPTION OPERATOR CONTROLS: 1. KEYED START(FORWARD) SWITCH - Starts the machine in the forward direction. Insert key into switch, rotate key approximately 130 degrees to the right (clockwise direction), and push the key in. - Page 6 1 OPERATION CONTROLS FOR UNITS WITH 30HP POWER PACK OPERATOR CONTROLS: 1. KEYED ON/OFF SWITCH - Turns power to the (Mounted programmable controller on and off. Switch must be in the “ON” position for the Hauler Controls to sealtite) operate. 2.
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Page 7: Operating Instructions
1 OPERATION OPERATING INSTRUCTIONS MACHINES WITH 20HP POWER UNITS: 1. Place material into charge chamber. 2. Insert key into the Keyed START Switch. 3. Rotate key clockwise approximately 130 degrees and press the key inward to start motor. NOTE: If the motor does not start, check to insure the jog control switch is in the “ON”... -
Page 8: Decal Placement
1 OPERATION DECAL PLACEMENT WARNING DECAL REQUIREMENTS When your compactor leaves the factory, the following warning decals are installed for protection. These decals are subject to wear and abuse due to the nature of the refuse handling operation. THESE DECALS MUST BE MAINTAINED. Additional decals may be purchased from your distributor or from Marathon Equipment Company. - Page 9 1 OPERATION DECAL PLACEMENT PART # DESCRIPTION 06-0002 RAMJET STATIONARY AND SELF-CONTAINED COMPACTORS 06-0038 DANGER: CRUSHING/SHEARING HAZARD! 06-0039 DANGER: DO NOT ENTER 06-0097 MARATHON SERIAL PLATE 06-0121 CAUTION: FEDERAL REGULATION PROHIBITS... 06-0249 DANGER: HAZARDOUS VOLTAGE ...LOCK OUT & TAG OUT 06-0413 WARNING: CRUSH HAZARD! 06-1839...
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Page 10: Maintenance
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. -
Page 11: Periodic Maintenance
2 MAINTENANCE PERIODIC MAINTENANCE WARNING: NEVER ENTER ANY PART OF THE COMPACTOR UNTIL THE UNIT HAS BEEN LOCKED OUT AND TAGGED OUT. DAILY Check oil level in reservoir . Level should be 3/4 of the sight gauge with the ram retracted fully. - Page 12 2 MAINTENANCE PERIODIC MAINTENANCE ANNUALLY Change the hydraulic oil or filter it twice through a 3 micron filter . If the oil is filtered, a sample should be analyzed and additives mixed with the oil if required. Lubricate the electric motor bearings per the manufacturers suggestions. Check the cylinder pins for wear.
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Page 13: Limit Switch Adjustment
2 MAINTENANCE LIMIT SWITCH ADJUSTMENT WARNING: NEVER ENTER ANY PART OF THE COMPACTOR OR PERFORM ANY MAINTENANCE UNTIL THE UNIT HAS BEEN LOCKED OUT AND TAGGED OUT. Note: Adjustment on limit switches is to stop the ram 3/4” from the end of the cylinder stroke, Forward and Rearward. - Page 14 2 MAINTENANCE CHARTS - 20HP POWER UNIT FUSES AND CIRCUIT BREAKERS THREE PHASE MOTOR FULL DUAL ELEMENT CIRCUIT SERVICE SIZE LOAD FUSE BREAKER DISCONNECT AMP. MAX. SIZE MAX. SIZE AMP. 20 HP 59.4 WIRE SIZE MOTOR SIZE 100’ 200’ 300’ 20 HP Wire size based on 75 deg.
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Page 15: Charts
2 MAINTENANCE CHARTS - 30HP POWER UNIT FUSES AND CIRCUIT BREAKERS THREE PHASE MOTOR SIZE 30 HP FLA (MAIN MOTOR) 1 HP (FAN MOTOR) FUSE DUAL ELEMENT MAX. SIZE INVERSE TIME BREAKER SERVICE DISCONNECT AMP. WIRE SIZE 100’ 200’ 300’ Wire size based on 75 deg. -
Page 16: Panel Box Arrangement
2 MAINTENANCE PANEL BOX ARRANGEMENT - STANDARD... -
Page 17: Power Unit 20Hp/18Gpm
2 MAINTENANCE POWER UNIT - 20HP/18GPM REF # PART # DESCRIPTION 02-0051 SUCTION FILTER 02-0081 DIRECTIONAL CONTROL VALVE 02-0197 BREATHER 02-0015 SIGHT GAUGE 02-0219 CLEAN OUT COVER 02-0259 PUMP, 18GPM 02-0397 PUMP/MOTOR ADAPTER 02-0398 HUB COUPLING 02-3043 SUBPLATE 02-3113 RELIEF VALVE 03-0014 PRESSURE SWITCH, DUAL 03-0347... - Page 18 2 MAINTENANCE PRESSURE SETTINGS FOR 20HP/18GPM POWER UNITS The following adjustments will need to be made with the power unit running. See START-UP SEQUENCE and PRE OPERATING INSTRUCTIONS. Remove the forward limit switch. Loosen the lock nut on the relief cartridge at the manifold, and adjust the relief counter clockwise several turns.
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Page 19: Hydraulic Schematic 20Hp/18Gpm
2 MAINTENANCE HYDRAULIC SCHEMATIC - 20HP/18GPM 2-10... -
Page 20: Power Unit 20Hp/50Gpm
2 MAINTENANCE POWER UNIT 20HP/50GPM 2-11 B A LD O R REF # PART # DESCRIPTION REF# PART # DESCRIPTION 03-1071 MOTOR 20HP 02-1065 SUCTION FLANGE 02-1086 PUMP 50GPM 02-0219 CLEAN OUT COVER 02-0932 HUB COUPLING 02-0970 CHECK VALVE 02-0667 VALVE 02-0215 SIGHT GAUGE... - Page 21 2 MAINTENANCE PRESSURE SETTINGS FOR 20HP/50GPM POWER UNITS 2-12 The following adjustments will need to be made with the power unit running. See START-UP SEQUENCE and PRE OPERATING INSTRUCTIONS. Remove the forward limit switch. Loosen the lock nut on the relief cartridge at the manifold, and adjust the relief counter clockwise several turns.
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Page 22: Hydraulic Schematic 20Hp/50Gpm
2 MAINTENANCE HYDRAULIC SCHEMATIC - 20HP/50GPM 2-13... -
Page 23: Power Unit 30Hp/75Gpm
2 MAINTENANCE POWER UNIT - 30HP/75GPM 2-14 REF# PART # DESCRIPTION REF # PART # DESCRIPTION 02-3019 Pump, 75gpm 02-0620 Suction Flange, 2 1/2" 03-1179 Motor, 30hp 02-0621 Suction Flange, 3" 02-0664 Hub Coupling 02-0623 Suction Filter, 2 1/2" 02-3021 Valve 02-0668 Suction Filter, 3"... -
Page 24: Pressure Setting 30Hp/50Gpm
2 MAINTENANCE PRESSURE SETTINGS - 30HP/75GPM 2-15 The following adjustments will need to be made with the power unit running. See START-UP SEQUENCE and PRE OPERATING INSTRUCTIONS. Loosen the lock nuts on R1 and R2. Remove the caps from the top of the Pressure Switches. Remove the front limit switch. -
Page 25: Hydraulic Schematic 30Hp/50Gpm
2 MAINTENANCE HYDRAULIC SCHEMATIC - 30HP/75GPM 2-16... -
Page 26: Installation
3 INSTALLATION CONCRETE PAD REQUIREMENTS CAUTION: REVIEW THIS MANUAL BEFORE STARTING 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. - Page 27 3 INSTALLATION ANCHORING - (CONTINUED)
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Page 28: Steel Installation Procedures
3 INSTALLATION STEEL INSTALLATION PROCEDURES RATCHETS/CLAWS FOR CONTAINER CONNECTION (‘XW’ models only) The ratchets, claws, and ratchet pinning plates are shipped loose on ‘XW’ models. This is done to insure proper location of the pinning plates in the field. The pinning plates should be located vertically between the first and second side post on the compactor. - Page 29 3 INSTALLATION STEEL INSTALLATION PROCEDURES CONTAINER GUIDES If container guides (optional) are used with the comp actor and cont ainer, each guide should be anchored to the concrete pad using two (2) 3/4" X 6" (minimum) anchor bolts. These bolts should be concrete anchors or exp ansion type anchor bolt s. To allow for construction variations, it is best if these holes are drilled in the concrete af prelocating the container guides in their desired location.
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Page 30: Electrical & Hydraulic Installation
3 INSTALLATION ELECTRICAL & HYDRAULIC INSTALLATION The panel box cont ains high volt age components. Only authorized service personnel should be allowed inside. See Lock-Out & Tag-Out instructions in the maintenance section. For units without a lockable fused disconnect in the p anel box, a lockable fused disconnect switch (customer furnished) must be inst alled and be within sight of the compactor's electrical panel box location, not to exceed 50'0"... -
Page 31: Start Up Instructions
3 INSTALLATION ELECTRICAL & HYDRAULIC INSTALLATION PUSHBUTTON CONTROL STATION If a remote push button st ation is furnished, it will be factory wired using Sealtite. If it is necessary to disconnect it from the p anel box, (to install the pushbutton station inside a building), exercise care that these wires are reconnected as originally furnished.
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