Dover MARATHON V-6030 HD User manual

Marathon Equipment Co. OMI Manual No. 0003, Rev. 10/07
OPERATION, MAINTENANCE,
AND INSTALLATION
MANUAL
VERTICAL
BALERS
MODELS
V-6030 HD
V-7230 HD

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
Lock-Out and Tag-Out Instructions............................................................... 2-1
Supporting Platen (for cylinder removal) ......................................................2-2
Periodic Maintenance & Recommended Oil................................................. 2-3
Procedure -Cylinder Removal...................................................................... 2-4
Procedure - Pressure Setting....................................................................... 2-5
Electrical Charts............................................................................................ 2-6
Replacement Parts List................................................................................. 2-7
Panel Box Drawing & Parts Reference List.................................................. 2-8
Power Unit Drawing - A-Type........................................................................ 2-9
Power Unit Reference List - A-Type.............................................................. 2-10
Power Unit Drawing - T-Type........................................................................ 2-11
Power Unit Reference List - T-Type.............................................................. 2-12
Troubleshooting Guide.................................................................................. 2-13
Hydraulic Schematic..................................................................................... 2-15
Electrical Schematic - A-Type Power Unit.....................................................2-16
Electrical Schematic - T-Type Power Unit..................................................... 2-17
Layout & Description of Front Panel............................................................. 2-18
Description of LCD........................................................................................ 2-19
Run / Stop Program Directions..................................................................... 2-20
E-Prom Download......................................................................................... 2-21
Timer Settings............................................................................................... 2-22
Clear Fault & Start Program..........................................................................2-23
Fault List........................................................................................................2-24
Off Loading, and Up-Ending Machine........................................................... 3-1
Raising the Platen (Units Shipped w/Cylinder Lowered)...............................3-2
General Installation....................................................................................... 3-3
Electrical Installation......................................................................................3-4
Start-Up Instructions......................................................................................3-5
Index
© 2007 Marathon Equipment Company
OPERATION
MAINTENANCE
PLC MAINTENANCE
INSTALLATION
CONTENTS

OPERATION
INTRODUCTION
1-1
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.
The purpose of this manual is to provide the owner and operator(s) with the
necessary information to properly and safely install, operate, and maintain the baler. Also
included are sections regarding troubleshooting and service procedures. The manual is
not intended as a primary training source, but as a reference guide for authorized, trained
personnel. Each person involved in the operation, maintenance and installation should
read and thoroughly understand the instructions in this manual and follow all warnings.
Anyone involved in operation, maintenance, and installation of this baler should
read, and understand the most current versions of all applicable standards:
• ANSI Standard No. Z245.5 “Safety Requirements for Installation,
Maintenance, and Operation”
• ANSI Standard No. Z245.51 “Safety Requirements For Baling Equipment”
A copy of these standards may be obtained from:
ANSI
25 West 43rd Street
New York, NY 10036
• OSHA Title 29 CFR, Part 1910.147
"Control of Hazardous Energy (lockout, and tag out)"
Any service or repair instructions contained in this manual should be performed by
factory authorized personnel only.
If you should need assistance with your baler, please contact your distributor. When
contacting your distributor, you will need to provide baler serial number, installation date,
and electrical schematic number.
IF YOU HAVE ANY SAFETY CONCERNS WITH THE EQUIPMENT, OR
NEED FURTHER INFORMATION, PLEASE CONTACT OUR SERVICE
DEPARTMENT AT:
Marathon Equipment Company
P.O. Box 1798
Vernon, Al 35592-1798
Attn: Field Service Department
1-800-633-8974

OPERATION
PRE-OPERATING INSTRUCTIONS
1-2
WARNING: DO NOT OPERATE BALER UNTIL OPERATING INSTRUCTIONS ARE
THOROUGHLY UNDERSTOOD. WEAR SAFETY GLASSES, AND GLOVES WHEN
OPERATING THIS EQUIPMENT.
STAY CLEAR OF ALL INTERNAL, AND EXTERNAL
MOVING PARTS WHEN OPERATING BALER.
FAILURE TO DO SO COULD RESULT IN SERIOUS
PERSONAL INJURY OR DEATH!
NEVER ENTER ANY PART OF BALER UNLESS DISCONNECT SWITCH HAS
BEEN TURNED OFF, AND LOCKED, AND ALL STORED ENERGY SOURCES
HAVE BEEN REMOVED. See Lock-Out & Tag-Out Instructions in Maintenance
section of this manual. Before starting baler, be sure no one is inside. Be certain
that everyone is clear of all points of operation, and pinch point areas before starting.
CAUTION: BE CERTAIN TURNBUCKLE AND LATCH ARE FULLY LOCKED IN
PLACE ON BALE CHAMBER DOOR BEFORE STARTING BALER.
EMPLOYERS SHOULD ALLOW ONLY AUTHORIZED,
AND THOROUGHLY TRAINED PERSONNEL TO
OPERATE THIS BALER.
This baler is equipped with a key operated locking system.
Keys should be in possession of only authorized personnel.
Federal regulation prohibits operation by persons under 18
years of age. Turn off, and remove key after use.
The baler hydraulic system operates at high pressures, and at high temperatures. If
you suspect a leak, DO NOT CHECK WITH YOUR HANDS, and avoid contact with
piping, hoses, and cylinders.
ONLY AUTHORIZED PERSON-
NEL SHOULD BE ALLOWED
INSIDE PANEL BOX. The panel
box contains high voltage components.
See Lock-Out & Tag-Out instructions
in Maintenance section.

OPERATION
SPECIFICATIONS
1-3
MODEL # V-6030-HD V-7230-HD
Performance
Cycle Time:(empty) 58 seconds 58 seconds
Total Force: 62,200 lbs 62,200 lbs
Platen Face PSI: 37 PSI 32 PSI
Electrical
Control Voltage 120 VAC 120 VAC
Motor: 10 HP 10 HP
RPM: 1750 RPM 1750 RPM
Hydraulic
Pump: 10.5 GPM 10.5 GPM
Pressure:(3 Phase) 2200 PSI 2200 PSI
Pressure:(1 Phase) 1700 PSI 1700 PSI
Cylinder Bore: 6" 6”
Cylinder Rod: 3.5" 3.5”
Cylinder Stroke: 48" 48”
Reservoir Capacity: 22 GAL 22 GAL
Dimensional Data
Feed Opening Height: 25" 25”
Feed Opening Width: 60" 72”
Feed Height: 48 1/4" 50 1/2”
Bale Size
Width: 60" 72”
Depth: 30" 30”
Height: 48" 48”
Bale Door Clearance 58" 70”
Overall Height: 140” 142”
Overall Width: 89 1/4” 103”
Overall Depth: 41 1/2” 44 1/2"
Total Weight: 4,200 lbs 5,600 lbs
Bale Ties 14ga. X 14' 14ga. X 14'

11. At back of baler, ins ert chain ejector handles over the two platen hooks
protruding from the back of platen.
NOTE: On balers with Auto Eject, bale ejector is automatically engaged
when bale door is opened.
14.
11. En la parte trasera de la enfardadora, insertar las manijas del eyector de cadena
sogrelosdosganchosquesobresalenporlapartetraseradelaplatina.
NOTA: E n las enfardadoras con eyección automática, el eyector se activa
automátic amente c uando s e abre la c ompuer ta de la enfardadora .
06-3391
AL I ME NTACI ON
APAG CI CL O
AUTOM.
PAR ADA DE E MER GE NCI A
PLATINA
ELEVACION
MANUAL
BAJADA
MANUAL
OPERATION
CONTROL LAYOUT WITH OPERATING INSTRUCTIONS
1-4
BALE MADE
LIGHT
R
OFF
ON
460
**
*
*NON-FUSED DISCONNECT SWITCH (OPTIONAL)
**BALE MADE LIGHT (OPTIONAL)

OPERATION
CONTROLS DESCRIPTION
1-5
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.
(c) Turn OFF-ON-AUTO key switch to AUTO position and baler will start, platen will
traverse LOWER and return to the load position (one complete cycle).
3. PLATEN RAISE — PLATEN LOWER (Selector Switch)
Turn the switch to RAISE and hold to manually raise the platen. Turning the switch
to RAISE and holding will raise the platen, with the feed gate and bale door opened
or closed. This switch 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
RAISE switch is a “hold-to-run” control, meaning that the baler will stop when it is
released. WARNING: STAY CLEAR OF MOVING PARTS WHEN USING THE
MANUAL RAISE SWITCH WITH THE FEED GATE OPEN. Turn the switch to
LOWER and hold to manually lower the platen. The feed gate, and bale door
must be closed. It can be used to interrupt the auto cycle, and lower the platen
should it become necessary. The LOWER switch is a “hold-to-run” control also,
meaning that the baler will stop when it is released.
4. CYCLE READY LIGHT — (Red Light)
This light will warn the operator of an 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 power to the baler, and Lock-out/Tag-out per the instruc-
tions on page 2-1. Then contact a qualified service person. The light should be ON
when the feed gate is in the down position, indicating the baler is ready for
operation.
5. BALE MADE LIGHT — (Red Light) (Optional)
This light will come on if enough material has been compacted to make a complete
bale.
6. EXTERNAL RESET —(Pushbutton)
Allows the operator to reset overload protection without opening the panel box.

OPERATION
OPERATING INSTRUCTIONS - MAKING A BALE
1-6
IN CASE OF EMERGENCY:
PRESS the large RED
button to
“STOP”
WARNING: SAFETY INTERLOCKS AND DEVICES ARE INSTALLED ON THIS
MACHINE FOR YOUR PROTECTION. NEVER DISABLE OR BYPASS ANY
SAFETY DEVICE. FAILURE TO COMPLY WITH THIS WARNING COULD RESULT
IN SERIOUS INJURY OR DEATH.
HOW TO MAKE A BALE:
1. Open the bale chamber door by turning the turnbuckle on the chamber door latch.
2. Place a large flat piece of cardboard inside bale chamber on baler floor.
3. Close the bale chamber door, and secure it with the turnbuckle.
4. Load material into baler through feed opening.
NOTE: DO NOT OVERFILL BALER! Overfilling baler will result in serious damage
to the feed gate that may prohibit operation of the baler. When loading material
through the feed opening, keep material pushed away from the feed gate. This is
especially imperative when the bale chamber is full and bale is approaching ‘BALE
MADE’ status. Overfilling at this stage will damage baler and incur costly repair.
5. Pull the feed gate down by the handle to close the feed gate.
6. To start the baler, insert key into switch, and turn to the ON position.
7. Turn switch to AUTO position. The platen will go down and return up to the loading
position. As the platen returns fully to the up position, the feed gate will automatic-
ally open and the motor will stop.
8. Repeat steps 4 through 7 until the BALE MADE arrow decal on the feed gate is
aligned with the BALE MADE arrow decal on the platen.
8A. (Optional) If the baler is equipped with the optional BALE MADE light, it will
illuminate when the bale is made and ready to be tied and ejected.
NOTE: FOLLOW ALL SAFETY INSTRUCTIONS IN THIS MANUAL!
NOTE: DO NOT OVERFILL BALER!
PRESS

OPERATION
BALE TIE-OFF / BALE EJECT
1-7
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.
1. Turn PLATEN switch to RAISE and hold, until the feed gate opens.
2. Place a large flat piece of material across the top of the bale.
3. Close feed gate, Turn PLATEN switch to LOWER and hold until platen is
completely down.
4. Open the bale chamber door by turning the turnbuckle on the chamber door
latch.
5. Caution: Wear safety glasses and leather gloves during this operation.
6. Tie off bale by inserting bale ties through slots in platen, loop end first. Feed wire
all the way through the slots in the platen. Go behind baler and feed wire all the
way through the slots in the floor of baler. Tie each wire by first inserting the straight
end through the loop end and cinching the slack, then twist the straight end back around
itself several times to ensure it will hold.
6A. With Optional Front Tie-Off
Insert bale ties through slots in platen, loop end first. Continuing feeding wire through
until wire comes out the slots in bottom of baler. Tie each wire by first inserting the straight
end through the loop end and cinching the slack, then twist the straight end back around
itself several times to ensure it will hold.
7. Bale ties should be tightened only hand tight, allowing for bale expansion when
bale door is opened and pressure is released.
8. Place a pallet in front of the baler for the completed bale to land. Attach the 2
Ejector Chains to the Chain Eject Hooks located on the platen at the rear of the baler.
8A. Optional Auto-Eject
Bale eject mechanism automatically engages when opening chamber door.
9. Caution: Stand to the side of baler, all personnel must be clear of the front of the
baler. Turn PLATEN switch to RAISE and hold until bale ejects, then release.
10. Remove bale with pallet jack or forklift.
11. Close, and latch the bale chamber door. Close feed gate.
12. Turn to AUTO position, baler will start, ram will travel down and return up to the
load position and reset ejector.
13. Baling sequence is ready to be repeated.

OPERATION
DECAL PLACEMENT
1-8
Refer to the decal descriptions chart on the following page to match the reference
numbers 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” arrow on the feed gate (#2, decal 06-0651) MUST be
placed where the vertical center of the arrow is exactly 4 7/8” from the top of
the bale chamber door.
The “BALE MADE” arrow on the platen (#1, decal 06-0652) MUST be placed
where the vertical center of the arrow is exactly 2 3/8” from the top of the front
channel on the platen.