Marathon V-4830, V-4830HD, V-6030, V-6030HD, V-6042LP Installation Manual
...
PLAY IT SAFE!
OPERATION, MAINTENANCE
AND INSTALLATION MANUAL
FOR
VERTICAL RECYCLER BALER
INCLUDING THESE MODELS:
V-4830 V-4830HD V-6030LP
V-6030 V-6030HD V-6042LP
V-7230HD
A
DOVER
INDUSTRIES COMPANY
Marathon Equipment Co. OMI Manual No. 0003, Rev. 01/01
VERNON, AL - YERINGTON, NV - CLEARFIELD, PA
LEEDS, AL - FAYETTE, AL
SECTION 1 - Operation
Introduction ................................................................. 1-1
Pre-Operating Instructions ....................................... 1-2
Controls
For HD and V-6030LP Units ................................1-3
For V-6030 and V-4830 Units ..............................1-4
For V6042LP Units .............................................. 1-5
Control Description ...................................................... 1-6
Operating Instructions
Making A Bale - HD and LP Units ....................... 1-7
Making a Bale - V-6030 and V-4830 ................... 1-8
Bale Tie Off - V-6030HD, V-4830HD, V-7230HD 1-9
Diagram .......................................................... 1-10
Bale Tie Off - V-6030LP ...................................... 1-11
Diagram .......................................................... 1-12
Bale Tie Off - V-6042LP ...................................... 1-13
Diagram .......................................................... 1-14
Bale Tie Off - V-4830 and V-6030 ...................... 1-15
Diagram .......................................................... 1-16
Tie Slot Cleaning-Diagram ........................................ 1-17
Decals ......................................................................... 1-18
Decal Placement For Vertical Balers ...........................1-20
SECTION 2 - Maintenance
Lock-Out & Tag-Out Instructions ............................ 2-1
Supporting of Platen ................................................... 2-2
Periodic Maintenance ................................................. 2-3
Procedures
Pressure Setting .................................................. 2-4
Interlock Testing .................................................. 2-4
Cylinder Removal ................................................ 2-5
Cylinder Rebuilding ............................................ 2-6
Limit Switch Adjustment ...................................... 2-6
Warranty and Service on Motors ......................... 2-6
Feed Gate Latch Adjustment ...............................2-7
Principles of Operation ............................................... 2-8
Baler Specifications..................................................... 2-10
Timer Adjustment ....................................................... 2-11
Charts ......................................................................... 2-12
Parts List .....................................................................2-13
Panel Box
For HD and LP Units ........................................... 2-14
For V-6030 and V-4830 Units ............................. 2-15
CONTENTS
CONTENTS
SECTION 2 - Maintenance (continued)
Power Unit
For 4830, 6030, 4830HD, 6030HD, & 7230HD ... 2-16
For 6030LP ......................................................... 2-17
For 6042LP ......................................................... 2-18
Hydraulic Schematic
For Vertical Balers - Typical ................................ 2-19
For V6042LP ....................................................... 2-20
Trouble-Shooting Chart ...............................................2-21
SECTION 3 - Installation
Off-Loading and Up-Ending Of Baler ......................... 3-1
General Installation .................................................... 3-2
Electrical Installation .................................................. 3-3
Start-Up Instructions .................................................. 3-4
Copyright Marathon Equipment Company, January 2001.
1 OPERATION
INTRODUCTION
THANK YOU FOR PURCHASING A MARATHON VERTICAL BALER.
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 baler, each person involved in the operation, maintenance and installation of the baler should read and
thoroughly understand the instructions in this manual and follow all warnings.
The employer(s) involved in the operation, maintenance and installation of the baler
should read and understand the most current version of the following applicable standards:
ANSI Standard No. Z245.5, “Safety Requirements For Baling Equipment”
(A copy of this standard may be obtained from Marathon Equipment
Company, Field Service Department, at 1-800-633-8974).
OSHA 29 CFR, Part 1910.147, “The control of hazardous energy (lockout/tagout)”
IF YOU SHOULD NEED FURTHER ASSISTANCE, PLEASE CONTACT YOUR
DISTRIBUTOR. YOU WILL NEED TO PROVIDE THE BALER SERIAL
NUMBER, INSTALLATION DATE, AND ELECTRICAL SCHEMATIC NUMBER
TO YOUR DISTRIBUTOR.
IF YOU HAVE ANY SAFETY CONCERNS WITH THE EQUIPMENT, OR
NEED FURTHER INFORMATION, PLEASE CONTACT US AT:
Marathon Equipment Company
P.O. Box 1798
Vernon, Al 35592-1798
Attn: Field Service Department
1-800-633-8974
1-1
ALL SERVICE OR REPAIR PROCEDURES DESCRIBED IN THIS
MANUAL SHOULD BE PERFORMED BY AUTHORIZED, FULLY
TRAINED PERSONNEL.
Any service or repairs that go beyond the scope of this manual
should be performed by factory authorized personnel only.
1 OPERATION
PRE-OPERATING INSTRUCTIONS
NEVER ENTER ANY PART OF THE BALER UNLESS THE DISCONNECT
SWITCH HAS BEEN TURNED OFF AND PADLOCKED. Before starting the
baler, be sure no one is inside. Be certain that everyone is clear of all points of
operation and pinch point areas before starting. See Lock-Out & Tag-Out
instructions in the Maintenance section.
THE EMPLOYER SHOULD ALLOW ONLY AUTHORIZED AND TRAINED PERSONNEL TO OPERATE
THIS BALER. This baler is equipped with a key oper-
ated locking system. The key(s) should be in the possession of only authorized personnel. Turn off and
remove key after use.
Pay close attention to the RED WARNING LIGHT on the control panel. If the light
is illuminated when the feed gate is raised, there is a malfunction of the magnetic interlock system. IN THIS EVENT, DISCONTINUE USE OF THE BALER AND
LOCK-OUT & TAG-OUT THE BALER PER THE INSTRUCTIONS IN THE
MAINTENANCE SECTION, PAGE 2-1. Perform necessary repairs before continuing operation of the baler.
ONLY AUTHORIZED PERSONNEL
SHOULD BE ALLOWED INSIDE THE
PANEL BOX. The panel box contains
high voltage components. See Lock-Out
& Tag-Out instructions in the
Maintenance section.
BE CERTAIN TURNBUCKLE AND LATCH IS FULLY LOCKED IN PLACE ON BALE
CHAMBER DOOR BEFORE STARTING BALER.
STAND CLEAR WHILE
BALER IS IN OPERATION.
WARNING: DO NOT OPERATE BALER UNTIL OPERATING INSTRUCTIONS ARE
THOROUGHLY UNDERSTOOD.
1-2
Federal regulation prohibits operation by persons under 18 years of age.
1 OPERATION
CONTROLS FOR V-4830HD, V-6030HD, V-6030LP, & V-7230HD
FRONT VIEW - VERTICAL BALER
MANUAL DOWN PUSHBUTTON
BALE MADE LIGHT
RED WARNING LIGHT
AUTOCYCLE BUTTON
KEYED ON-OFF SWITCH
EMERGENCY STOP BUTTON
MANUAL UP PUSHBUTTON
MOTOR OVERLOAD
RESET BUTTON
(ON DOOR)
DISCONNECT SWITCH
FEED GATE
CONTROL PANEL
PANEL BOX
TURNBUCKLE TO BALE
CHAMBER DOOR LATCH
BALE CHAMBER DOOR
WARNING
NOTICE
1-3
1 OPERATION
CONTROLS FOR V-6030 & V-4830
WARNING
STOP
MANUAL DOWN
MANUAL UP
AUTO CYCLE
OFF ON
RED WARNING LIGHT
KEYED ON-OFF SWITCH
AUTOCYCLE BUTTON
EMERGENCY STOP
BUTTON
MOTOR OVERLOAD
RESET BUTTON
(ON DOOR)
MANUAL UP BUTTON
MANUAL DOWN BUTTON
FEED GATE
TURNBUCKLE TO BALE
CHAMBER DOOR LATCH
BALE CHAMBER DOOR
CONTROL PANEL
PANEL BOX
NOTE: A fused disconnect is not provided on these models. The disconnect
must be provided, by the installer, per
the installation instructions in the
Installation section of this manual.
FRONT VIEW - VERTICAL BALER
1-4
1 OPERATION
CONTROLS FOR V-6042LP
1-5
FRONT VIEW - LOW PROFILE VER
TICAL BALER
RETRACT/EJECT SWITCH
SIDE-MOUNTED
POWER UNIT
MANUAL DOWN PUSHBUTTON
BALE MADE LIGHT
RED WARNING LIGHT
AUTOCYCLE BUTTON
KEYED ON-OFF SWITCH
EMERGENCY STOP BUTTON
MANUAL UP PUSHBUTTON
RESET BUTTON
(ON DOOR)
DISCONNECT
SWITCH
FEED GATE
CONTROL PANEL
PANEL BOX
TURNBUCKLE TO BALE
CHAMBER DOOR LATCH
BALE CHAMBER DOOR
ON-OFF (Keyed Selector Switch)
Turning this switch to the ON position activates the other controls on the control station.
The baler can not be operated unless the key is in the switch and the switch is in the ON
position. The purpose of this switch is to allow only authorized and trained personnel to
operate the baler. The key should be removed from the baler when not in use and should
stay in the possession of only responsible and trained personnel.
EMERGENCY STOP (Red Mushroom Head Pushbutton)
Depressing this button will stop the machine at any point in the cycle.
AUTOCYCLE (Green Pushbutton)
The AUTOCYCLE button can be used only when the feed gate and bale door are closed
and the keyswitch is in the ON position. Once depressed, the AUTOCYCLE button will
cause the platen to move to the fully down position and back to the fully raised position
(one complete cycle).
MANUAL UP (Black Pushbutton)
This button will only start the baler with the keyswitch in the ON position. Depressing the
button will raise the platen with the feed gate and bale door opened or closed. It is normally
used during bale ejection. It can also be used to interrupt the automatic cycle and raise the
platen should it become necessary. The MANUAL UP button is a “Hold To Run” control,
causing the baler to stop when it is released. WARNING: STAY CLEAR OF MOVING
PARTS WHEN USING THE MANUAL UP BUTTON WITH THE FEED GATE OPEN.
MANUAL DOWN (Black Pushbutton)
This button will only start the baler with the keyswitch in the ON position. Depressing the
button will lower the platen only if the feed gate and bale door are closed. It can be used to
interrupt the automatic cycle and lower the platen should it become necessary. The MANUAL DOWN button is a “Hold To Run” control, causing the baler to stop when it is released.
RED WARNING LIGHT
This light will warn the operator of a magnetic interlock switch malfunction. If the light is on
and the feed gate is in the up position, there is a problem. Discontinue use of the baler.
Turn off the baler and Lock-out and Tag-out per the instructions on page 2-1. Then call a
qualified service person. The light SHOULD BE ON when the feed gate is in the down position.
BALE MADE LIGHT (Not included on V-6030 and V-4830 models)
This light will come on if enough material has been compacted to make a complete bale.
RETRACT/EJECT (Spring-centered Switch) (USED ON THE V-6042LP ONL
Y)
This spring-centered switch will eject the bale by means of a hydraulic ejector when the
switch is held to the EJECT position. When the button is held to the RETRACT position, the
ejector will retract. The MANUAL UP button must be depressed and held at the same time
the RETRACT/EJECT switch is used.
1 OPERATION
CONTROL DESCRIPTION
1.
2.
3.
4.
5.
6.
7.
8.
1-6
1 OPERATION
T
O MAKE A BALE : HD & LP Units
1. Feed material into baler. If starting a new bale, place a large flat piece of mater-
ial flat on the baler floor. NOTE: Do not attempt to overfill the feed chamber by
forcing material into the chamber with the feed gate. This can cause gate release
malfunction and may damage baler.
2. Pull gate handle down to close feed gate. NOTE: Check red warning light
before closing feed gate. If gate is open and light is on, discontinue use of the
baler and call for service.
3. To start the baler, insert the key into the keyswitch and turn to the ON
position.
4. Press the AUTOCYCLE button. The platen will make a complete cycle down
and back up. When the platen is in the full up position, the feed gate will automatically open and the motor will automatically shutdown.
5. Repeat steps 1 through 4 until platen stops in down position and “BALE MADE”
light comes on.
NOTE: In normal operation, the feed gate will be open when you walk up to
place material into the baler. For added security, the feed gate can be manually
closed after the AUTOCYCLE(S). To open the gate, you will have to insert the
key into the keyswitch and run the baler through a complete AUTOCYCLE.
IN CASE OF EMERGENCY:
Push the large red button to
STOP
OPERATING INSTRUCTIONS - MAKING A BALE
WARNING: DO NOT OPERATE BALER UNTIL OPERATING INSTRUCTIONS ARE
UNDERSTOOD.
See pages 1-3 through 1-5 for control panel layout and location.
1-7
WARNING: Interlocks and safety devices were installed on this unit for
your protection. Never disable or bypass any interlock or safety
device. Failure to comply with this warning could result in serious injury or
death.
TO MAKE A BALE : V-6030 & V-4830
1. Feed material into baler. If starting a new bale, place a large flat piece of mater-
ial flat on the baler floor. NOTE: Do not attempt to overfill the feed chamber by
forcing material into the chamber with the feed gate. This can cause gate release
malfunction and may damage baler.
2. Pull gate handle down to close feed gate. NOTE: Check red warning light
before closing feed gate. If gate is open and light is on, discontinue use of the
baler and call for service.
3. To start the baler, insert the key into the keyswitch and turn to the ON
position.
4. Press the AUTOCYCLE button. The platen will make a complete cycle down
and back up. When the platen is in the full up position, the feed gate will automatically open and the motor will automatically shutdown.
5. Repeat steps 1 through 4 until the arrow on the platen dwells in direct line with
the arrow on the NOTICE decal on the feed gate, before returning to the up
position.
NOTE: In normal operation, the feed gate will be open when you walk up to
place material into the baler. For added security, the feed gate can be manually
closed after the AUTOCYCLE(S). To open the gate, you will have to insert the
key into the keyswitch and run the baler through a complete AUTOCYCLE.
WARNING: Interlocks and safety devices were installed on this unit for
your protection. Never disable or bypass any interlock or safety
device. Failure to comply with this warning could result in serious injury or
death.
IN CASE OF EMERGENCY:
Push the large red button to
STOP
OPERATING INSTRUCTIONS - MAKING A BALE
1 OPERATION
1-8
WARNING: DO NOT OPERATE BALER UNTIL OPERATING INSTRUCTIONS ARE
UNDERSTOOD.
See pages 1-3 through 1-5 for control panel layout and location.
When the BALE MADE light comes on, it is time to tie off the bale and eject the bale
from the baler. See page 1-3 for control panel layout and location. See the following
page for a diagram of the following steps.
FOR BALE TIE OFF & BALE EJECT (HD MODELS):
1. Depress the MANUAL UP button until the feed gate opens.
2. Insert a large, flat piece of material across the top of the bale.
3. Close feed gate and depress the AUTOCYCLE button. The platen
will stop in the down position and the BALE MADE light will be illuminated.
CAUTION: CLEAR ALL PERSONNEL FROM FRONT OF BALER
BEFORE PROCEEDING WITH STEPS 4 THROUGH 8.
4. Release the bale chamber door latch on the side of baler and open
the bale chamber door all the way. Feed gate is closed but will raise
when the chamber door is opened.
5. CAUTION: Wear safety glasses and leather gloves during the following operation:
Tie off bale by inserting bale ties through the platen, “loop end” first.
Always insert bale ties through the tie slots in the platen, first.
Feed wire through until it comes out of the slot in the baler floor.
Tie off each tie. Bale ties should be tightened only hand tight, allowing for bale expansion when released.
6. Standing at the side, make sure all personnel are clear of the front of
the baler. Depress the MANUAL UP button.
7. Hold the MANUAL UP button until bale ejects, then release the
button.
8. Remove bale.
9. Close and latch the bale chamber door. Close feed gate. Depress
AUTOCYCLE to cycle and reset ejector. Bale sequence is ready to
be repeated.
1 OPERATION
OPERATING INSTRUCTIONS BALE TIE OFF/BALE EJECT FOR V-6030HD, V-4830HD, V-7230HD
1-9
1 OPERATION
DIAGRAM BALE TIE OFF/BALE EJECT FOR V-6030HD, V-4830HD, V-7230HD
GATE CLOSED.
STEP 3.
PLATEN - BALE TIE
GUIDE, 6 PLACES.
SEE STEP 5.
BALE
MADE
LIGHT
DOOR
LATCH OPEN
BALE CHAMBER DOOR - OPEN.
SEE STEP 4.
FLOOR - BALE TIE
GUIDE, 6 PLACES.
SEE STEP 5.
FEED
FRONT VIEW OF BALER
SIDE VIEW
BALE TIE - TIGHTENED
HAND TIGHT
BALE DURING EJECTION
BALE
PALLET RECOMMENDED
FOR SUPPORTING BALE
SIDE VIEW
BALE CHAMBER
DOOR
SIDE VIEW
- BALE
BALE TIE - INSERT AND PUSH THROUGH
PLATEN GUIDES. TIES WILL CIRCLE THE
BALE AND COME OUT OF THE FLOOR
GUIDES. SEE STEP 5.
BALE
1-10
When the BALE MADE light comes on, it is time to tie off the bale and eject the bale
from the baler. See page 1-3 for control panel layout and location. See the following
page for a diagram of the following steps.
FOR BALE TIE OFF & BALE EJECT (V-6030LP):
1. Depress the MANUAL UP button until the feed gate opens.
2. Insert a large, flat piece of material across the top of the bale.
3. Close feed gate and depress the AUTOCYCLE button. The platen
will stop in the down position and the BALE MADE light will be illuminated.
CAUTION: CLEAR ALL PERSONNEL FROM FRONT OF BALER
BEFORE PROCEEDING WITH STEPS 4 THROUGH 8.
4. Release the bale chamber door latch on the side of baler and open
the bale chamber door all the way. Feed gate is closed but will raise
when the chamber door is opened.
5. CAUTION: Wear safety glasses and leather gloves during the following operation:
Facing the front of the bale, tie off bale by inserting bale ties (loop
end first) through the platen. Always insert bale ties through the
tie slots in the platen, first. Go to the rear of the baler and feed
the loop end of the bale ties down and through the aligned tie slots in
the floor. Finally, go to the front of the baler and tie each of the
ties. Bale ties should be tightened only hand tight, allowing for bale
expansion when released.
6. Before ejecting the bale, go to the rear of the baler and manually
engage the bale eject latch (WARNING: Never engage eject latch if
bale door is closed). To engage the latch, pull (rotate) the latch handle up all the way. Standing at the side, make sure all personnel are
clear of the front of the baler. Depress the MANUAL UP button.
7. Hold the MANUAL UP button until bale ejects, then release button.
8. Remove bale.
9. Close and latch bale chamber door. Close feed gate. Depress AUTOCYCLE to cycle and reset ejector. Bale sequence is ready to be
repeated.
1 OPERATION
OPERATING INSTRUCTIONS BALE TIE OFF/BALE EJECT FOR V-6030LP
1-11
1 OPERATION
DIAGRAM - BALE TIE OFF/BALE EJECT FOR V-6030LP
FEED
GATE
PLATEN - BALE TIE
GUIDE, 6 PLACES.
SEE STEP 5.
BALE
MADE
LIGHT
DOOR
LATCH OPEN
BALE CHAMBER DOOR OPEN.
SEE STEP 4.
FLOOR - BALE TIE
GUIDE, 6 PLACES.
SEE STEP 5.
FRONT VIEW OF BALER
SIDE VIEW
BALE TIE - TIGHTENED
BALE DURING EJECTION
- STEP 7.
BALE
PALLET RECOMMENDED FOR
SUPPORTING
BALE
SIDE VIEW
BALE CHAMBER
DOOR
SIDE VIEW -
BALE
BALE TIE - INSERT AND PUSH
THROUGH PLATEN GUIDE.
SEE STEP 5.
BALE
- CLOSED.
STEP 3.
HAND TIGHT
BALE EJECT LATCHENGAGED. STEP 6.
FEED TIES
THROUGH
FLOOR
GUIDES STEP 5.
1-12
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