Dover MARATHON RamJet AST-220 Operation, Service And Installation Manual
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Dover MARATHON RamJet AST-220 Operation, Service And Installation Manual

Dover MARATHON RamJet AST-220 Operation, Service And Installation Manual

Stationary auger compactor
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®
RamJet
Stationary Auger Compactor
AST-220, AST-320, AST-440
OPERATION, SERVICE, AND INSTALLATION
ISSUED JULY 2021
____________________
CUSTOMER NAME:
____________________
SERIAL NUMBER:
COMPACTION & RECYCLING SOLUTIONS
0016-2-RJAST-0721
© 2021 Marathon Equipment Company
.

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  • Page 1 ® RamJet Stationary Auger Compactor AST-220, AST-320, AST-440 OPERATION, SERVICE, AND INSTALLATION ISSUED JULY 2021 ____________________ CUSTOMER NAME: ____________________ SERIAL NUMBER: COMPACTION & RECYCLING SOLUTIONS 0016-2-RJAST-0721 © 2021 Marathon Equipment Company...

  • Page 2: Important Safety Notice

    WARNING IF INCORRECTLY USED, THIS EQUIPMENT CAN CAUSE SEVERE INJURY. THOSE WHO USE AND MAINTAIN THE EQUIPMENT SHOULD BE TRAINED IN ITS PROPER USE, WARNED OF ITS DANGERS, AND SHOULD READ AND FULLY UNDERSTAND THIS ENTIRE MANUAL BEFORE ATTEMPTING TO SET UP, OPERATE, ADJUST OR SERVICE THE EQUIPMENT. KEEP THIS MANUAL FOR FUTURE REFERENCE IMPORTANT SAFETY NOTICE Proper service and repair are important to the safe, reliable operation of the Marathon Equipment...

  • Page 3: Table Of Contents

    ® RamJet Stationary Auger Compactor TABLE OF CONTENTS General Information Introduction ......................................4 Preface ......................................5 Hazard Symbols and Definitions ......................................5 Lock-Out/Tag-Out Instructions ......................................6 Service/Parts Assistance ......................................8 Guards and Access Covers ......................................8 Grease Lubrication Recommendation ......................................8 Recommended Oils for Gearbox ......................................8 Warning Decals on the Unit ......................................9 Decal Care ......................................9...
  • Page 4 ® RamJet Stationary Auger Compactor TABLE OF CONTENTS Index ..................................63 Issued July 2021 Printed in U.S.A. Table of Contents Copyright 2021, Marathon Equipment Company...
  • Page 5 ® RamJet Stationary Auger Compactor ® RamJet Stationary Auger Compactor AST-220, AST-320, AST 440 OPERATION, SERVICE, AND INSTALLATION ISSUED JULY 2021 0016-2-RJAST-0721 Printed in U.S.A. Issued July 2021 Copyright 2021, Marathon Equipment Company...
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  • Page 7: General Information

    ® RamJet Stationary Auger Compactor General Information SECTION 1 GENERAL INFORMATION Printed in U.S.A. Issued July 2021 Copyright 2021, Marathon Equipment Company General Information...

  • Page 8: Introduction

    ® RamJet Stationary Auger Compactor General Information INTRODUCTION ® ® Thank you for purchasing a Marathon RamJet Stationary Auger Compactor! This product is designed to give you reliable service and superior performance for years to come. The purpose of this manual is to provide the owner and/or operators with the necessary information to properly install, operate, and maintain the machine.

  • Page 9: Preface

    ® RamJet Stationary Auger Compactor General Information PREFACE The following sections are a guide for maintenance and service of the Marathon Equipment Company unit. The sections cover preventive maintenance, adjustment, and troubleshooting hints. Before performing maintenance, check the work area carefully to find all the hazards present and make sure all necessary safeguards or safety devices are used to protect all persons and equipment involved.

  • Page 10: Lock-Out/Tag-Out Instructions

    ® RamJet Stationary Auger Compactor General Information LOCK-OUT & TAG-OUT INSTRUCTIONS DANGER 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 ® RamJet Stationary Auger Compactor General Information LOCK-OUT & TAG-OUT INSTRUCTIONS (CONTINUED) RESTORING SERVICE When the servicing or maintenance is completed and the auger is ready to return to normal operating condition, the following steps shall be taken: 1. Check the compactor and the immediate area around the compactor to ensure that nonessential items have been removed and that the compactor components, guards and covers are operationally intact.

  • Page 12: Service/Parts Assistance

    ® RamJet Stationary Auger Compactor General Information SERVICE/PARTS ASSISTANCE Assistance in troubleshooting, repair and service is available by contacting the authorized Marathon Equipment Company Dealer in your area. Parts are available at your Marathon Equipment Company Dealer or through Marathon Equipment Company.

  • Page 13: Warning Decals On The Unit

    ® RamJet Stationary Auger Compactor General Information WARNING DECALS ON THE UNIT WARNING DO NOT operate without all guards and access covers in place. Make sure you can read all warning and instruction decals. Clean decals if you cannot read the words. See below for directions on cleaning decals.
  • Page 14 ® RamJet Stationary Auger Compactor General Information DECAL CARE - CONTINUED Issued July 2021 Printed in U.S.A. General Information Copyright 2021, Marathon Equipment Company...

  • Page 15: Electrical Symbols

    ® RamJet Stationary Auger Compactor General Information ELECTRICAL SYMBOLS Printed in U.S.A. Issued July 2021 Copyright 2021, Marathon Equipment Company General Information...
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  • Page 17: Installation

    ® RamJet Stationary Auger Compactor Installation SECTION 2 INSTALLATION Printed in U.S.A. Issued July 2021 Copyright 2021, Marathon Equipment Company Installation...

  • Page 18: Contact Information

    ® RamJet Stationary Auger Compactor Installation CONTACT INFORMATION Technical Service and Warranty: 877-258-1105 Parts: 800-528-5308 For parts visit our e-commerce market place at www.mecomerchant.com. If you do not have a user name and password, contact our Parts Department and they will assist with your registration. Normal Business Hours: Monday-Friday 8:00am - 5:00pm...

  • Page 19: Concrete Pad Requirements

    ® RamJet Stationary Auger Compactor Installation CONCRETE PAD REQUIREMENTS These installation instructions are not intended as a substitute for training and experience in proper use and safety procedures in operating this equipment. Marathon Equipment Co. does not assume responsibility for the installation procedures of this equipment. Conformance to applicable local, state, and federal laws concerning installation rests with the customer.

  • Page 20: Steel Installation Procedures

    ® RamJet Stationary Auger Compactor Installation STEEL INSTALLATION PROCEDURES Dock Installation If the appropriate accessories are ordered from Marathon Equipment Co., the compactor will be furnished with either a four-sided hopper or a three-sided hopper with a hinged gate. THESE ACCESSORIES SHOULD NOT BE ALTERED AS THEY ARE MANUFACTURED IN ACCORDANCE WITH THOSE STANDARDS WHICH PREVAIL AT THE TIME OF MANUFACTURE.

  • Page 21: Electrical Installation

    ® RamJet Stationary Auger Compactor Installation ELECTRICAL INSTALLATION The Panel Box contains high voltage components. Only authorized service personnel should be allowed inside. See Lock-Out & Tag-Out Instructions in the Service Section. A lockable fused disconnect switch (customer furnished) must be installed and be within sight of the compactor's electrical panel box location, not to exceed 50'0"...
  • Page 22 ® RamJet Stationary Auger Compactor Installation ELECTRICAL INSTALLATION (CONTINUED) Push-button Control Panel If a remote push-button station is furnished, it will be factory wired using Sealtite. If it is necessary to disconnect it from the wires (to install the push-button station inside a building), exercise care that these wires are reconnected as originally furnished.

  • Page 23: Section 3 Operation

    ® RamJet Stationary Auger Compactor Operation SECTION 3 OPERATION Printed in U.S.A. Issued July 2021 Copyright 2021, Marathon Equipment Company Operation...

  • Page 24: Contact Information

    ® RamJet Stationary Auger Compactor Operation CONTACT INFORMATION Technical Service and Warranty: 877-258-1105 Parts: 800-528-5308 For parts visit our e-commerce market place at www.mecomerchant.com. If you do not have a user name and password, contact our Parts Department and they will assist with your registration. Normal Business Hours: Monday-Friday 8:00am - 5:00pm...

  • Page 25: Compactor Pre-Operation Instructions

    ® RamJet Stationary Auger Compactor Operation PRE-OPERATION INSTRUCTIONS Employers should allow only authorized and thoroughly trained personnel to operate this compactor. This compactor is equipped with a key operated locking system. Keys should be in possession of only authorized personnel. Turn off and remove the key after use. DANGER ONLY TRAINED AND AUTHORIZED PERSONNEL SHOULD BE ALLOWED INSIDE PANEL BOX.

  • Page 26: Standard Control Panel

    ® RamJet Stationary Auger Compactor Operation STANDARD CONTROL PANEL CONTROL DESCRIPTION 1. KEYED SWITCH - This switch requires a key for operation. Insert the key and turn counterclockwise to the ON position. The compactor will cycle one time then stop. After use, turn the key clockwise to the OFF position and remove the key.

  • Page 27: Operating Instructions - Photoelectric Cycle Controls

    ® RamJet Stationary Auger Compactor Operation OPERATING INSTRUCTIONS - MODELS WITH PHOTOELECTRIC CYCLE CONTROL WARNING Use ONLY Marathon reinforced receiver containers with Marathon Stationary Auger Compactors. Use of a non-OEM receiver container with a Marathon Stationary Auger Compactor could result in container damage, property damage, and/ or personal injury –...

  • Page 28: Optional Controls

    ® RamJet Stationary Auger Compactor Operation OPTIONAL CONTROLS 1. 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 the "Hold-To-Run" button is released, the unit will stop instantly.

  • Page 29: Section 4 Service

    ® RamJet Stationary Auger Compactor Service SECTION 4 SERVICE Printed in U.S.A. Issued July 2021 Copyright 2021, Marathon Equipment Company Service...

  • Page 30: Contact Information

    ® RamJet Stationary Auger Compactor Service CONTACT INFORMATION Technical Service and Warranty: 877-258-1105 Parts: 800-528-5308 For parts visit our e-commerce market place at www.mecomerchant.com. If you do not have a user name and password, contact our Parts Department and they will assist with your registration. Normal Business Hours: Monday-Friday 8:00am - 5:00pm...

  • Page 31: Periodic Maintenance

    ® RamJet Stationary Auger Compactor Service PERIODIC MAINTENANCE WARNING Never enter any part of the compactor until the unit has been locked-out and tagged-out. 2 00 hours of Operation On compactors with legs, remove access cover(s) and clean debris from behind the compactor auger. While back cover is removed from back of unit, clean excess grease out of the grease drip pan.

  • Page 32: Maintenance Schedule Form

    ® RamJet Stationary Auger Compactor Service MAINTENANCE SCHEDULE FORM Make copies of below table to record your maintenance on equipment. MAINTENANCE SCHEDULE MONTHLY CHECK FOR CLEA GREASE CHECK/ CHECK CHECK CHECK INSPEC INSPEC CHECK UNSAFE N-UP BEARING GEARBO AUGER T HARD CORDS AND CONDITIONS CHAIN...
  • Page 33 ® RamJet Stationary Auger Compactor Service MAINTENANCE SCHEDULE FORM (CONTINUED) MAINTENANCE SCHEDULE QUARTERLY ANNUALLY CHECK FUNCTIONAL OPERATION OF LUBRICATE ELECTRIC MOTOR REPLACE GEARBOX OIL CONTROLS BEARINGS Sept Printed in U.S.A. Issued July 2021 Copyright 2021, Marathon Equipment Company Service...

  • Page 34: Bearing Lubrication

    ® RamJet Stationary Auger Compactor Service BEARING LUBRICATION For units equipped with Auto-Lube systems: 1. Fill the grease reservoir per the auto-lube manufacturer’s recommendation. The auto-lube system will automatically grease the bearings. 2. Depress the “Auto-Lube” button until grease fresh comes out of the drip hose. 3.
  • Page 35 ® RamJet Stationary Auger Compactor Service BEARING LUBRICATION (CONTINUED) 2. The AST-440 has a grease fitting on both sides of the unit located just above the gearbox. 3. Add grease to the grease fitting until fresh grease comes out of the drip hose. Printed in U.S.A.
  • Page 36 ® RamJet Stationary Auger Compactor Service BEARING LUBRICATION (CONTINUED) 4. Clean off grease fitting. 5. Clean out excess grease from drip pan. Issued July 2021 Printed in U.S.A. Service Copyright 2021, Marathon Equipment Company...

  • Page 37: Chain Tension And Adjustment

    ® RamJet Stationary Auger Compactor Service CHAIN TENSION AND ADJUSTMENT WARNING Never enter any part of the compactor until the unit has been Locked-out and Tagged-out. WARNING Add Warning Safety Alert text. WARNING Never service/adjust the chain until the unit has been locked-out and tagged out. Chain/Sprocket Layout 1.
  • Page 38 ® RamJet Stationary Auger Compactor Service CHAIN TENSION AND ADJUSTMENT (CONTINUED) How to adjust chain tension: 1. Loosen (4) gear box mounting plate bolts. 2. Loosen (2) jam nuts on the adjustment bolts. Issued July 2021 Printed in U.S.A. Service Copyright 2021, Marathon Equipment Company...
  • Page 39 ® RamJet Stationary Auger Compactor Service CHAIN TENSION AND ADJUSTMENT (CONTINUED) 3. Tighten (2) adjustment bolts until the proper tension is achieved. 4. Tighten (2) jam nuts on the adjustment bolts. Printed in U.S.A. Issued July 2021 Copyright 2021, Marathon Equipment Company Service...
  • Page 40 ® RamJet Stationary Auger Compactor Service CHAIN TENSION AND ADJUSTMENT (CONTINUED) 5. Tighten (4) gearbox mounting plate bolts. Issued July 2021 Printed in U.S.A. Service Copyright 2021, Marathon Equipment Company...

  • Page 41: Hard Surface Weld

    ® RamJet Stationary Auger Compactor Service HARD SURFACE WELD WARNING Never enter any part of the compactor until the unit has been Locked-out and Tagged-out. Inspection: 1. For stationary compactors - separate the compactor and container. For self-contained compactors – dump compaction container. 2.
  • Page 42 ® RamJet Stationary Auger Compactor Service Hard Surface Weld (Continued) Hard surface weld wire specification and recommended settings: GMAW-C (MIG) -wire Weartech WT-1 -wire diameter .045" -volts 26-28 -amps 240-260 -wire Lincore 60-0 -wire diameter .045" -volts 25-27 -amps 190-210 SMAW (STICK) -wire Weartech WT-1 -rod diameter .125"...

  • Page 43: Principles Of Operation

    ® RamJet Stationary Auger Compactor Service PRINCIPLES OF OPERATION Standard Operation Upon start up, a contact is made that energizes the motor starter, starting the electric motor and at the same time energizing T1 timer in the program. When T1 is energized, the auger will turn counterclockwise (forward) for the predetermined amount of time in T1.
  • Page 44 ® RamJet Stationary Auger Compactor Service AST-320 FUSES AND CIRCUIT BREAKERS Three Phase DUAL ELEMENT CIRCUIT SERVICE FULL LOAD MOTOR SIZE FUSE BREAKER DISCONNECT MAX. SIZE MAX. SIZE AMP. 51.0 48.0 20 HP 24.0 19.1 AST-320 WIRE SIZES Three Phase THW Copper 75°C (165°F) LENGTH MOTOR SIZE...
  • Page 45 ® RamJet Stationary Auger Compactor Service AST-440 FUSES AND CIRCUIT BREAKERS DUAL ELEMENT CIRCUIT SERVICE FULL LOAD MOTOR SIZE FUSE BREAKER DISCONNECT MAX. SIZE MAX. SIZE AMP. 208V 230V 2 X 20 HP 460V 575V AST-440 WIRE SIZES LENGTH MOTOR SIZE VOLTAGE TO 100' TO 200'...

  • Page 46: Plc Maintenance - Layout & Description

    ® RamJet Stationary Auger Compactor Service PLC MAINTENANCE - LAYOUT & DESCRIPTION REFERENCE DESCRIPTION RETRACTABLE MOUNTING FEET. SCREW TERMINAL BLOCK FOR THE POWER SUPPLY. LCD, 4 LINES, 18 CHARACTERS SCREW TERMINAL BLOCK FOR INPUTS SCREW TERMINAL BLOCK FOR 0-10 VOLT ANALOG INPUTS USABLE IN DISCRETE MODE ON SOME MODELS CONNECTOR FOR BACKUP MEMORY OR PC CONNECTION CABLE SHIFT KEY...

  • Page 47: Plc Maintenance - Forward/Reverse Timer Adjustment

    ® RamJet Stationary Auger Compactor Service PLC MAINTENANCE - FORWARD/REVERSE TIMER STEPS DIRECTIONS PRESS MENU/OK BUTTON PRESS ARROW DOWN BUTTON TO SELECT PARAMETER (SHOULD BE FLASHING) PRESS MENU/OK BUTTON PRESS ARROW UP BUTTON UNTIL TT1 = FORWARD TIMER (FLASHING) PRESS ARROW LEFT BUTTON UNTIL TIME SETTING (FLASHING) PRESS ARROW UP OR ARROW DOWN TO ADJUST TIME* PRESS MENU/OK BUTTON PRESS MENU/OK BUTTON TO CONFIRM CHANGES...

  • Page 48: Electric Schematic

    ® RamJet Stationary Auger Compactor Service ELECTRICAL SCHEMATIC Refer to the electrical schematic shipped with your compactor or contact Marathon Equipment Company’s Technical Service Department at 877-258-1105. Be sure to have compactor serial number ready when contacting service. Issued July 2021 Printed in U.S.A.

  • Page 49: Troubleshooting Chart

    ® RamJet Stationary Auger Compactor Service TROUBLESHOOTING CHART TROUBLESHOOTING CHART PROBLEM CAUSE SOLUTION UNIT WILL NOT START 1. No electrical power to unit 1a. Turn on main disconnect. 1b. Replace fuse or reset breakers. 2. No electrical power to 2a. Check primary and secondary sides of transformer. control circuit 2b.
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  • Page 51: Replacement Parts

    ® RamJet Stationary Auger Compactor Replacement Parts SECTION 5 REPLACEMENT PARTS Printed in U.S.A. Issued July 2021 Copyright 2021, Marathon Equipment Company Replacement Parts...

  • Page 52: Contact Information

    ® RamJet Stationary Auger Compactor Replacement Parts CONTACT INFORMATION Technical Service and Warranty: 877-258-1105 Parts: 800-528-5308 For parts visit our e-commerce market place at www.mecomerchant.com. If you do not have a user name and password, contact our Parts Department and they will assist with your registration. Normal Business Hours: Monday-Friday 8:00am - 5:00pm...

  • Page 53: Typical Panel Box Configuration

    ® RamJet Stationary Auger Compactor Replacement Parts TYPICAL PANEL BOX CONFIGURATION The diagram below represents a typical panel box configuration for the self-contained compactors. The panel box on your compactor may differ depending on the model and/or optional equipment/controls. Refer to the chart below to identify components.

  • Page 54: Decal Parts List

    ® RamJet Stationary Auger Compactor Replacement Parts DECAL PARTS LIST WARNING When your compactor leaves the factory, several WARNING DECALS are installed for your protection. These labels are subject to wear and abuse due to the nature of operation. The FOLLOWING DECALS MUST BE MAINTAINED. Additional decals may be purchased through your distributor or from Marathon Equipment Company by calling the parts department at 800-528-5308.

  • Page 55: Decal Placement

    ® RamJet Stationary Auger Compactor Replacement Parts DECAL PLACEMENT Printed in U.S.A. Issued July 2021 Copyright 2021, Marathon Equipment Company Replacement Parts...

  • Page 56: Decal Placement For Optional Loading Configurations

    ® RamJet Stationary Auger Compactor Replacement Parts DECAL PLACEMENT FOR OPTIONAL LOADING CONFIGURATIONS In addition to the standard decal placement, the following decals shown below need to be maintained on any optional loading configurations installed with your horizontal compactor. Match the reference numbers with the decals listed on the Decals chart.
  • Page 57 ® RamJet Stationary Auger Compactor Replacement Parts DECAL PLACEMENT FOR OPTIONAL LOADING CONFIGURATIONS (CONTINUED) Printed in U.S.A. Issued July 2021 Copyright 2021, Marathon Equipment Company Replacement Parts...

  • Page 58: Decal Images

    ® RamJet Stationary Auger Compactor Replacement Parts DECAL IMAGES 06-0038 06-0039 06-3044 06-0052 06-3978 06-0040 06-0249 06-3123 06-0133 06-3977 06-3333 06-1839 Issued July 2021 Printed in U.S.A. Replacement Parts Copyright 2021, Marathon Equipment Company...
  • Page 59 ® RamJet Stationary Auger Compactor Replacement Parts DECAL IMAGES 06-0002 06-2751 06-0121 06-0413 06-0097 Printed in U.S.A. Issued July 2021 Copyright 2021, Marathon Equipment Company Replacement Parts...
  • Page 60 ® RamJet Stationary Auger Compactor Replacement Parts DECAL IMAGES 06-3976 Issued July 2021 Printed in U.S.A. Replacement Parts Copyright 2021, Marathon Equipment Company...

  • Page 61: Spare Parts Lists

    ® RamJet Stationary Auger Compactor Replacement Parts SPARE PARTS LISTS Printed in U.S.A. Issued July 2021 Copyright 2021, Marathon Equipment Company Replacement Parts...
  • Page 62 ® RamJet Stationary Auger Compactor Replacement Parts SPARE PARTS LISTS (CONTINUED) Issued July 2021 Printed in U.S.A. Replacement Parts Copyright 2021, Marathon Equipment Company...
  • Page 63 ® RamJet Stationary Auger Compactor Replacement Parts SPARE PARTS LISTS (CONTINUED) Printed in U.S.A. Issued July 2021 Copyright 2021, Marathon Equipment Company Replacement Parts...
  • Page 64 ® RamJet Stationary Auger Compactor Replacement Parts SPARE PARTS LISTS (CONTINUED) Issued July 2021 Printed in U.S.A. Replacement Parts Copyright 2021, Marathon Equipment Company...
  • Page 65 ® RamJet Stationary Auger Compactor Replacement Parts SPARE PARTS LISTS (CONTINUED) Printed in U.S.A. Issued July 2021 Copyright 2021, Marathon Equipment Company Replacement Parts...
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  • Page 67 ® RamJet Stationary Auger Compactor INDEX If these methods do not work on a problem area, call a Marathon Equipment Company Dealer or Marathon anchoring Equipment Company Customer Support. introduction It is important that the decals are properly cleaned to make sure that they are readable and do not come off chute-fed installation the unit.
  • Page 68 ® RamJet Stationary Auger Compactor INDEX safety symbols and definitions service/parts assistance spare parts lists Spot clean the decal with Isopropyl Alcohol and a micro-fiber cloth (rag) Spray angle: 65° from vehicle’ s body Spray nozzle opening: 40° wide pattern standard control panel standard operation steel installation procedures...
  • Page 69 www.marathonequipment.com Customer Care: 800-633-8974 Parts Central: 800-528-5308 www.mecomerchant.com Technical Service and W arranty: 877-258-1105 Customer Support: Marathon Equipment Company P.O. Box 1798 Vernon, AL 35592-1798...

This manual is also suitable for:

Marathon ramjet ast-320Marathon ramjet ast-440

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