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Table of contents for the manual
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Page 1
PLA Y IT SAFE! OPERA TIONAL, MAINTENANCE, AND INST ALLA TION MANUAL FOR RJ-88SC RJ-100SC RJ-250SC RJ-250VL Includes HT (Hydraulic T ailgate) Units and SL (StreamLine, Liquid Removal) Units RAM-JET SELF-CONT AINED COMP ACT OR CONT AINER VERNON, AL • F A YETTE, AL YERINGTON, NV • CLEARFIELD, P A Marathon Equipment Company • OMI Manual No. 0018,[...]
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Page 2
CONTENTS SECTION 1 - Operation Introduction ............................................................................. ..................... 1-1 Specifications ............................................................................................... 1-2 Pre-Operation Instructions ............................................................[...]
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Page 3
1 OPERATION INTRODUCTION 1-1 THANK YOU FOR PURCHASING A MARATHON SELF-CONTAINED COMPACTOR/CONTAINER. 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 com[...]
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Page 4
1 OPERATION SPECIFICATIONS 1-2 SIDE VIEW “A”, Clear Top Opening “B” “C” “D” “E” Fire Port - Each Side Model 88SC 100SC 250SC 250VL “A”, Clear Top Opening 30 1/2 x 48 35 x 60 40.5 x 58 35 x 60 (L x W) “B” 70 76 1/8 68 76 1/2 “C” 42 49 5/8 52 1/2 51 1/2 “D” (max.) 96* 104* 104* 104* “E” (max.) 254 1/2* 276* 275[...]
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Page 5
1 OPERATION PRE-OPERATION INSTRUCTIONS 1-3 NEVER ENTER ANY PART OF THE COMPACTOR UNLESS THE DISCON - NECT 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 poin[...]
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Page 6
1 OPERATION OPERATOR STATION 1-4 OPERATOR STATION FOR 88SC, 100SC, 250SC, & 250 VL KEYED START SWITCH REVERSE EMERGENCY STOP 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 one time (compl[...]
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Page 7
1 OPERATION OPERATING INSTRUCTIONS FOR RJ-88SC, RJ-100SC, & RJ-250SC 1-5 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” in the Decal Placement section to determine how your compacto[...]
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Page 8
1 OPERATION OPERATING INSTRUCTIONS FOR RJ-250VL 1-6 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” in the Decal Placement section to determine how your compactor is set up. Insert the k[...]
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Page 9
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 [...]
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Page 10
WARNING DECAL REQUIREMENTS When your compactor leaves the factory, several WARNING DECALS are installed for protection. These labels 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. 1 OPERAT[...]
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Page 11
1 OPERATION DECAL PLACEMENT for RJ-88SC, RJ-100SC, RJ-250SC, or RJ-250VL 1-9 REMOTE POWER UNIT[...]
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Page 12
OPTIONAL LOADING CONFIGURATIONS 1 OPERATION 06-0040 ACCESS GATE & HOPPER EACH OUTSIDE WALL DOCK 06-0039 06-0039 06-0039, 06-0052 EACH INSIDE WALL DOGHOUSE THRU-THE-WALL SECURITY CHUTE 06-0039 06-0039 DECAL PLACEMENT for RJ-88SC, RJ-100SC, RJ-250SC, or RJ-250VL 1-10[...]
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Page 13
1 OPERATION ADDITIONAL DECALS and DECAL PLACEMENT for HYDRAULIC TAILGATE (HT) UNITS 1-11 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. Decal Number 06-0104 - CAUTION: STAND CLEAR OF TAILGATE WHEN LIFTED. [...]
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Page 14
LOCK-OUT & TAG-OUT INSTRUCTIONS 2-1 ELECTRICAL: The motor control panel contains high voltage components. Only authorized service person - nel should be allowed inside the panel. Authorized ser - vice personnel should be allowed inside the panel only after the compactor has been locked-out and tagged- out. FOREWORD: Before entering any part of [...]
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Page 15
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. Clean out or wash out debris from behind compactor ram. Lubricate the ram guidance tracks using the grease fittings on the compactor [...]
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Page 16
When the hydraulic cylinders used in the RJ-88SC, RJ-100SC, RJ-250SC, and RJ- 250VL are fully extended or retracted, they bypass internally. This makes it impossi - ble for the hydraulic system to reach relief pressure. Follow the recommendations below for proper pressure setting. Disconnect and lock out power using the procedure on page 2-1. Using[...]
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Page 17
2 MAINTENANCE PROCEDURES 2-4 RAM CONTROL TIMER ADJUSTMENT Determine the cycle time of your machine. This can be found in the “CHARTS” section of this manual under “TIMER SETTINGS”. Set the timers as shown in the chart. When the switches are properly set, the ram will fully extend, stop for one-half to one second, then fully retract, stop an[...]
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Page 18
MULTI-CYCLE TIMER ADJUSTMENT - OPTION Determine the cycle time of your machine. This can be found in the CHARTS section of this manual under TIMER SETTINGS. Next multiply the cycle time by the number of cycles the machine should run and subtract one fourth of the cycle time. This is the cumulative number of seconds for which to set the switches. EX[...]
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Page 19
STANDARD SYSTEM OPERATING CHARACTERISTICS, 5 hp & 10 hp The system uses special cylinders to move the ram and two timers to control the opera - tion of the ram. When the hydraulic cylinders used in the RJ-88SC, RJ-100SC, RJ- 250SC, and RJ-250VL are fully extended or retracted, they bypass internally. This makes it impossible for the hydraulic s[...]
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Page 20
2 MAINTENANCE TAILGATE SEAL REPLACEMENT 2-7 FRONT VIEW - DOOR SEAL ON DOOR NEW SEAL A PRY BAR A SECTION A-A 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) WHEN REMOVING THE OLD SEALS (TOP & BOTTOM), MARK THE PO[...]
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Page 21
2 MAINTENANCE CHARTS 2-8 TIMER SETTINGS RAM STOP REAR RAM STOP FORWARD MODEL NO. T1 T2 T1 T2 RJ-88SC 27 17 17 27 RJ-100SC 21 16 16 21 RJ-250SC 19 13 13 19 RJ-250VL 21 16 16 21 Includes HT units and SL units. FUSES AND CIRCUIT BREAKERS MOTOR FULL DUAL ELEMENT CIRCUIT SERVICE SIZE VAC LOAD FUSE BREAKER DISCONNECT AMP. MAX. SIZE MAX. SIZE AMP. 5 HP, 1[...]
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Page 22
2 MAINTENANCE MOTOR STARTERS AND HEATER ELEMENTS MOTOR VOLTAGE STARTER HEATER ELEMENT SIZE SIZE A-B JOSLYN CLARK 5 HP, 1 PH 208 2 W-61 2452 230 2 W-60 2451 5 HP, 3 PH 208 1 W-55 2447 230 1 W-55 2446 460 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 C[...]
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Page 23
2 MAINTENANCE PARTS LIST 2-10 PART # PART DESCRIPTION 88SC 100SC 250SC 250VL 88HT 250HT 02-0050 SUCTION FILTER X X X X X X 02-0157 DIRECTIONAL VALVE X X X X X X 02-0184 CHECK VALVE X X X X 02-0197 BREATHER X X X X 02-0198 SIGHT GAUGE X X 02-0204 CHECK VALVE X X 02-0214 RELIEF VALVE X X X X X X 02-0215 SIGHT GAUGE X X X X 02-0244 HUB COUPLING X X X [...]
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Page 24
2 MAINTENANCE MOTOR CONTROL PANEL - TYPICAL 2-11 * Motor Starter brand and size determined by model number and voltage. *[...]
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Page 25
2 MAINTENANCE POWER UNIT - STANDARD 5 HP 2-12 DETAIL B DETAIL A DETAIL A DETAIL B DRAIN PLUG[...]
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Page 26
2 MAINTENANCE POWER UNIT - STANDARD 10 HP 2-13[...]
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Page 27
2 MAINTENANCE HYDRAULIC SCHEMATIC - TYPICAL 2-14 * SINGLE CYLINDER UNIT SHOWN. FOR DUAL CYLINDER UNITS, CONNECT IDENTICAL CYLINDER IN PARALLEL.[...]
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Page 28
2 MAINTENANCE TROUBLE-SHOOTING CHART 2-15 PROBLEM UNIT WILL NOT START UNIT WILL NOT CONTINUE RUNNING WHEN START BUTTON IS RELEASED MOTOR RUNS BUT RAM DOES NOT MOVE NORMALLY UNIT WILL NOT REVERSE CAUSE ( 1) No electrical power to unit ( 2) No electrical power to control circuit ( 3) No electrical power to motor ( 1) Motor starter is in-operative ( 2[...]
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Page 29
2 MAINTENANCE TROUBLE-SHOOTING CHART 2-16 PROBLEM PUMP MAKES NOISE-SOUNDS LIKE GRAVEL PUMP SHAFT SEAL LEAKING EXCESSIVE HEAT RAPID WEAR ERRATIC OPERATION OVERLOADS TRIP FREQUENTLY CAUSE ( 1 ) Partly clogged intake strainer or restricted intake pipe ( 2) Defective bearing ( 3) Air leak at pump intake pipe joints ( 1) Seal worn or damaged ( 1) Contin[...]
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Page 30
REVIEW THIS MANUAL BEFORE MAKING THE INSTALLATION. STUDY THE JOB - SITE 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 EXTRACT FROM AMERICAN NATIONAL STANDA[...]
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Page 31
If the appropriate accessories are ordered from Marathon Equipment Co., the com - pactor/container will be furnished with either a four-sided hopper or a three-sided hop - per with a hinged gate. THESE ACCESSORIES SHOULD NOT BE ALTERED AS THEY ARE MANUFACTURED IN ACCORDANCE WITH THOSE STANDARDS WHICH PRE - VAIL AT THE TIME OF MANUFACTURE. If the co[...]
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Page 32
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 com - pactor. This fused disconnect switch should be sized in accordance with the compactor (see Fuse and Circuit Breaker Chart). CAUTION: All equipment should be grounde[...]
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Page 33
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 build - ing), exercise care that these wires are reconnected as originally furnished. (Check local codes to be certain that Sealtite is acceptable.) CAUTION: Operator Statio[...]
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Page 34
3 INSTALLATION THROUGH-THE-WALL POWER UNIT INSTALLATION 3-5 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 No. Quantity Description 12 Hydraulic Hose, Hi-Pressure (sized to power unit*), 36” long 22 Pipe, Sch 80 (sized to power unit*), 36” lon[...]
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Page 35
4 HAULER INFORMATION HAULER INSTRUCTIONS - GENERAL 4-1 Before hauling to the landfill: Disconnect all hoses and electrical connections (if applicable) between the power unit and the compactor. Make sure they are laid in an area where they will not get damaged. Close and secure any hopper doors or gates. Make sure that the container door safety chai[...]
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Page 36
4 HAULER INFORMATION HAULER INSTRUCTIONS - DOOR/LATCH OPERATION 4-2 LATCH SIDE VIEW OF CONTAINER LATCH ASSEMBLY ACTUATED BY RATCHET CONTAINER DOOR RATCHET FOR OPENING AND CLOSING THE LATCH ASSEMBLY 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 CONTA[...]
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Page 37
4 HAULER INFORMATION HAULER INSTRUCTIONS - HYDRAULIC TAILGATE OPERATION (FOR OPTIONAL HT UNITS) 4-3 06-0105 WHEN LIFTED DANGER STAND CLEAR OF TAILGATE CAUTION STAND CLEAR OF TAILGATE WHEN LIFTED. TRUCK MUST BE ON FIRM, LEVEL SURFACE BEFORE LIFTING TAILGATE. FRONT AND REAR HOLD DOWNS MUST BE ENGAGED. TILT HOIST BEFORE LIFTING TAILGATE. * * * * CONTA[...]
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Page 38
4 HAULER INFORMATION LOCKING PIN RETRACTED MAINTENANCE BAR POSITION COLLAR POSITION COLLAR EXTENDED MAINTENANCE BAR DRAWING B DRAWING A LOCKING PIN EXPLODED VIEW DRAWING A 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[...]
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Page 39
4 HAULER INFORMATION HAULER INSTRUCTIONS - LIQUID REMOVAL (FOR OPTIONAL SL UNITS) 4-5 The Ram Jet 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[...]