Dover Marathon RAMJET Signature J-250SC Operation, Maintenance And Installation Manual Download

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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

Summary of Contents for Marathon RAMJET Signature J-250SC

Page 1: ... 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 ...

Page 2: ...d 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 Concrete Pad Requirements 37 ...

Page 3: ...n 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 instructio...

Page 4: ...inches 30 1 2 x 48 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 Determined by the size and capacity of the container A ...

Page 5: ...zed 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 Tag Out instructions in the Maintenance section FEDERAL REGULATION PROHIBITS THE USE OF THIS EQUIPMENT BY ANYONE UNDER 18 YEARS OF AGE STAY CLEAR OF ALL INTERNAL PARTS OF THE SELF CONTAINED COMPACTOR CONTAINER DURING OPERATION FAILURE TO DO...

Page 6: ...sert 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 R...

Page 7: ...hen you have finished using the compactor remove the key from the key switch For more information on the Multi Cycle Counter see page 25 DO NOT ENTER DANGER 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 re...

Page 8: ...ey 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 unti...

Page 9: ...ckwise 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 ...

Page 10: ...ef Description Quantity 05 0325 RIVETS 1 8 X 1 2 ALUM to go with 06 0364 4 06 0038 1 WARNING DO NOT REMOVE ACCESS COVER 2 06 0039 2 DANGER DO NOT ENTER 3 06 0067 3 D N REMOVE CONT TIL REAR 2 06 0072 4 QUICK CLEAN TANK 1 06 0093 5 FIRE HOSE PORT 2 06 0094 6 NOTICE WIPE OFF SEAL AFTER 2 06 0121 7 NOTICE FEDERAL REGULATION NO 18 y o 2 06 0124 8 CYCON 2 06 0249 9 DANGER HAZARDOUS VOLTAGE 2 06 0364 10 ...

Page 11: ...11 1 OPERATION DECALS PLACEMENT INSTALLED ON BOTH SIDES OF COMPACTOR IN SAME LOCATION ALSO INSTALLED ON REMOTE POWER PACK Match reference numbers to chart on previous page See next page for decal images ...

Page 12: ...12 1 OPERATION DECAL IMAGES 06 0104 06 0124 06 0364 06 0094 06 3231 06 0105 06 0052 06 0093 06 1836 06 0057 06 3123 06 0067 06 0038 06 0249 06 0057 06 0002 06 0121 06 0072 ...

Page 13: ...g Configurations Match reference numbers to Decals on page 10 when ordering replacement decals ACCESS GATE HOPPER 2 2 17 2 14 16 14 2 14 14 DOCK Located on each inside wall Located on each outside wall DOGHOUSE THRU THE WALL SECURITY CHUTE ...

Page 14: ...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 19 BOTH SIDES 18 19 REAR VIEW SIDE VIEW ...

Page 15: ...15 This Page Intentionally Left Blank ...

Page 16: ...nnect 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 tag out is effective If the lock out and tag out is effective re...

Page 17: ...ould 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 Repl...

Page 18: ...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 ...

Page 19: ...at 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 m...

Page 20: ...e 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 A New Seal Seal retainer Pry slightly upward so new seal can be inserted Pry Bar New Seal Use a plastic or rubber hammer to tamp the seal reta...

Page 21: ...CIRCUIT BREAKER MAX SIZE SERVICE DISCONNECT AMPS 5 HP 1 PH 208 22 0 50 80 60 230 20 8 45 70 60 5 HP 3 PH 208 13 8 30 40 30 230 13 4 25 40 30 460 6 7 15 20 30 575 5 4 10 15 30 10 HP 1 PH 208 43 0 100 125 100 230 39 0 90 125 100 10 HP 3 PH 208 27 5 50 80 60 230 25 6 50 70 60 460 12 8 25 35 30 575 11 4 20 30 30 ...

Page 22: ...0 1 W 46 2438 575 1 W 44 2435 10 HP 1 PH 208 3 W 66 N A 230 3 W 65 N A 10 HP 3 PH 208 2 W 63 2454 230 2 W 62 2454 460 1 W 55 2446 575 1 W 53 2445 WIRE SIZE THW Copper 75 C 165 F MOTOR SIZE VOLTAGE UP TO 100 UP TO 200 UP TO 300 5 HP 1 PH 208 8 6 4 230 8 6 4 5 HP 3 PH 208 10 6 4 230 10 8 6 460 12 12 10 575 12 12 12 10 HP 1 PH 208 4 1 1 0 230 4 2 1 0 10 HP 3 PH 208 6 4 2 230 8 4 3 460 12 10 8 575 12 ...

Page 23: ...partment 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 Ou...

Page 24: ... 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 ...

Page 25: ...SC 19 13 13 19 RJ 250 Ultra 19 13 13 19 Ram Stop Rear or Ram Stop Forward Selection STEPS DIRECTIONS 1 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 Arr...

Page 26: ...26 2 MAINTENANCE POWER UNIT STANDARD 5 HP MECO Match the reference numbers to the chart on the next page ...

Page 27: ...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 0...

Page 28: ...28 2 MAINTENANCE POWER UNIT DRY 10 HP MECO ...

Page 29: ...L 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 MATCH REFERENCE NUMBER...

Page 30: ...30 2 MAINTENANCE POWER UNIT DRY 10 HP NON MECO 1 2 3 4 6 5 8 13 12 14 15 9 16 17 7 18 10 11 19 20 TOP VIEW SIDE VIEW ISOMETRIC VIEW EXPLODED VIEW ...

Page 31: ...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 MATCH REFERENCE NUM...

Page 32: ...32 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 19 21 2 MAINTENANCE POWER UNIT SUBMERGED 10 HP NON MECO TOP VIEW SIDE VIEW ISOMETRIC VIEW EXPLODED VIEW SIDE VIEW with LID ...

Page 33: ...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 ...

Page 34: ...r 2 Quick Disconnect Female 3 Quick Disconnect Male 4 Valve 4 Way 5 Relief Valve 6 Check Valve 7 Pump 8 Suction Filter 9 Hub Coupling Not on Closed Coupled Units 10 Motor SINGLE CYCLINDER UNIT SHOWN FOR DUAL CYLINDER UNITS CONNECT IDENTICAL CYLINDER IN PARALLEL ...

Page 35: ...se 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 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 C...

Page 36: ...o 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 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...

Page 37: ...inimum 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...

Page 38: ...ttom 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 ...

Page 39: ...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 dec...

Page 40: ...l 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 sw...

Page 41: ...zed 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 List of Material 1 2 for hose lengths of 20 0 or less Consult factor for longer lengths CYLINDER ITEM 2 ITEM 4 EACH SIDE ITEM 5 ITEM 1 IT...

Page 42: ...e 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 sh...

Page 43: ... THE CONTAINER FLOOR AUTO RELATCH IN POSITION TO OPEN DOOR ROTATE THE AUTO RELATCH UP TO THE POSITION SHOWN AND OPEN THE LATCH AND DOOR AUTO RELATCH IN POSITION TO GRAB AND HOLD DOOR DURING DOOR CLOSING 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 LA...

Page 44: ...lumbing 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 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...

Page 45: ...or 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 EXTENDED MAINTENCE BAR RETRACTED MAINTENC...

Page 46: ...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 5 ANGELS PROVIDE PATH FOR LIQUID REMOVAL REAR DRAIN GRATING DIRECTS LIQUID OUT TO DRAINS TYPICAL DRAIN VALVE LOCATION AT LOW CORNER OF MAHINE 3 NPT FEMALE THREAD 4 DRAIN OUTLET AT EACH C...

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Summary of Contents for Marathon RAMJET Signature J-250SC

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