Home - K-PACUser Manual for K PAK models including: KP2SC, KP2SC20, KP2SC25, KP2SC30, KP2SC35, KP2SCL20, KP2SCL30, Self-Contained Compactor
KP2SC Self-Contained Compactor Copyright© 6/2021 K-PAC™ Compactors, a product of McLaughlin Family Companies i All Rights Reserved TABLE OF CONTENTS FOREWORD ...
KP2SC Self-Contained Compactor.
Item No. 503128 Rev. C USER MANUAL KP2SC Self-Contained Compactor INCLUDES INFORMATION FOR THE FOLLOWING MODELS: · KP2SC20 · KP2SC25 · KP2SC30 · KP2SC35 · KP2SCL20 · KP2SCL30 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor TABLE OF CONTENTS FOREWORD PURPOSE OF MANUAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SCOPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ABOUT K-PACTM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 CORPORATE HEADQUARTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 DEALER SUPPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 KP2SC SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 STANDARD POWER PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 CYCLE TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 STANDARD POWER PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SAFETY IMPORTANT SAFETY INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SAFETY ALERT SYMBOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SAFETY ALERTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SAFETY DECAL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 COMPACTOR SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SAFETY DECAL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Left Side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Chamber and Tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Right Side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SAFETY DECAL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 POWER PACK SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 SAFETY DECAL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Power Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 SAFETY DECAL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 LOCKOUT/TAGOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 LOCKOUT/TAGOUT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 REMOVE LOCKOUT/TAGOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 PROCEDURES FOR WORK IN CONFINED SPACES . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 HIGH VOLTAGE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 ARC FLASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 PROCEDURES FOR ELECTRICAL ARC FLASH AND SHOCK SAFETY . . . . . . . . . . . . . 21 MOST COMMON HAND SIGNALS USED IN THE FIELD . . . . . . . . . . . . . . . . . . . . . . . . . 22 INSTALLATION INSTALLATION REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 MAIN POWER DISCONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 INSTALLATION SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 ELECTRICAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 MAIN POWER DISCONNECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 WIRE COLORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 WIRING CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies i All Rights Reserved KP2SC Self-Contained Compactor TABLE OF CONTENTS OPERATION CONTROL PANEL and REMOTE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 OPERATING INSTRUCTIONS FOR STANDARD COMPACTORS . . . . . . . . . . . . . . . . . . 32 AUTO MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 MANUAL MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 CONTAINER FULL LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 START-UP AND TESTING INSTRUCTIONS POWER PACK START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 HYDRAULIC HOSE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 MANUAL MODE - RAM CYLINDER CYCLING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 AUTO MODE - RAM CYLINDER CYCLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 VALIDATE INTERLOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 MAINTENANCE MAINTENANCE INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 PREVENTIVE MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 INITIAL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 AFTER EMPTYING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 MONTHLY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 3-MONTH CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 MAINTENANCE INSTRUCTIONS FOR TAILGATE SEALS . . . . . . . . . . . . . . . . . . . . 38 FILTER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 YEARLY CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 HYDRAULIC HOSE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 RECOMMENDED HYDRAULIC FLUID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 GENERAL MAINTENANCE TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 FILTERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 RELIEF VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 SERVICE PLC PROGRAMMING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 TIMER AND CYCLE SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 MAIN RELIEF ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 PRESSURE SWITCH ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 CYLINDER PIVOT PIN INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 SCHEMATICS CONTROL PANEL VOLTAGE OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 CONTROL TRANSFORMER WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 POWER PACK ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 208, 230, 460 VAC, 10HP, 3 PHASE, 60 HERTZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 ELECTRICAL SCHEMATIC SECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Section "A" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Section "B" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Section "C" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Section "C" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 10HP, 3 PHASE, 60-HERTZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 ii Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor TABLE OF CONTENTS PARTS OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 CONTAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Door and Hinges Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Door and Hinges Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Door Latch Linkage Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Door Latch Linkage Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 CHAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Cover Plate, Rollers and Ram Blocks Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Cover Plate, Rollers and Ram Blocks Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Ram and Follower Assembly Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Ram and Follower Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Ram Cylinders and Mounting Illustration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Ram Cylinders and Mounting Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Ram Cylinder Hydraulics Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Ram Cylinder Hydraulics Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Panel Cover Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Panel Cover Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Inside Panel Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Inside Panel Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 POWER PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Assembly Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Assembly Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Hydraulic Reservoir Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Hydraulic Reservoir Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Pump Hydraulics Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Pump Hydraulics Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Motor and Pump Illustration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Motor and Pump Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies iii All Rights Reserved KP2SC Self-Contained Compactor TABLE OF CONTENTS This Page Intentionally Left Blank iv Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor FOREWORD PURPOSE OF MANUAL You have purchased a quality designed and manufactured K-PACTM compactor. Advanced features have been designed into the compactor for modern disposal operations. As with any investment, a return is expected and the return received from this investment will be in the form of maximum performance during many years of dependable service. In order to maintain quality performance of the new K-PACTM compactor, it is important that all of the information in the manual be reviewed and studied carefully before operation. It is suggested that owner/users read ANSI National Standards Z245.2-2013 for stationary compactors. Copies may be purchased from the American National Standards Institute, 11 W. 42nd Street, New York, NY, 10036, Phone: 212-642-4900. SCOPE This manual provides information for use by the owner/user. This manual contains a variety of information for General, Safety, Installation, Operation, Start-Up, Maintenance, Service, Schematics and Parts. ABOUT K-PACTM K-PACTM Equipment, a division of New Way® has established itself as a leader in innovation and dependability in the waste equipment industry. From engineering to production, K-PACTM is committed to providing top quality equipment and service. K-PACTM's neat, clean appearance, in both the rear and front loading model, blends attractively with its surroundings. In 2008 New Way® acquired K-PACTM Equipment, a leader in solid waste compaction equipment. New Way® now offers two lines of K-PACTM Industrial & Commercial Compactors: stationary compactors and self-contained compactors. There is a K-PACTM model to fit nearly every commercial and industrial application. From solid waste to heavy industrial waste compactors, K-PACTM compactors will crush nearly anything you throw their way. CORPORATE HEADQUARTERS Contact New Way® Trucks for K-PACTM factory direct sales and product support. New Way® TRUCKS P.O. Box 336 101 State Street Scranton, IA 51462 TELEPHONE Direct: 712-652-3396 Sales: 800-831-1858 Parts and Service: 844-652-3395 WEBSITE www.kpac-wastecompaction.com Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 1 All Rights Reserved FOREWORD KP2SC Self-Contained Compactor DEALER SUPPORT K-PACTM is committed to the design and manufacture of the best compactors, but it is our dealers that bring it all together for you. K-PACTM boasts a large, dedicated dealer network throughout the United States as well as internationally. We understand and appreciate the value that our dealers provide to us and to end users. Our dealers are our most important partner in helping you to install, support and maintain your compactor. The following is a list of K-PACTM dealers that can support your needs: CALIFORNIA EDCO Waste & Recycling Services Lemon Grove (San Diego), CA 91945 OFC: 619-287-5696, x4104 Gold Coast Ecology Simi Valley, CA 93063-6425 OFC: 805-501-5659 COLORADO Elliott Equipment Commerce City, CO 80022 OFC: 303-853-4840 ILLINOIS Elliott Equipment OFC: 563-391-4840 - Davenport OFC: 563-391-4840 - Grimes (Corporate) Rantoul Truck Center Rantoul, IL 61866 OFC: 217-893-4158 Toll Free: 877-898-9900 INDIANA Municipal Equipment Toll Free: 800-248-7590 IOWA Elliott Equipment OFC: 563-391-4840 - Davenport OFC: 563-391-4840 - Grimes (Corporate) KANSAS Elliott Equipment OFC: 816-761-4840 KENTUCKY Municipal Equipment OFC: 800-248-7590 MINNESOTA Olympic Sales Greg Krutsinger OFC: 701-281-8221 2 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor FOREWORD MISSOURI Elliott Equipment Grandview, MO 64030 OFC: 816-761-4840 NEBRASKA Elliott Equipment Lincoln, NE 68521 OFC: 402-474-4840 NEW YORK Long Island Sanitation, LLC 1670 New Highway Farmingdale, NY 11735 OFC: 631-531-9292 VIRGINA Municipal Equipment OFC: 800-248-7590 WASHINGTON GK Industrial Refuse Systems Auburn, WA 98002 OFC: 800-295-5543 WYOMING Elliott Equipment OFC: 563-391-4840 - Davenport OFC: 563-391-4840 - Grimes Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 3 All Rights Reserved FOREWORD KP2SC Self-Contained Compactor This Page Intentionally Left Blank 4 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor IDENTIFICATION PLATE GENERAL 2 1 3 Figure 1 An identification plate (Figure 1, 1) is located at the left-front corner of the chamber. The identification plate contains the compactor model number (Figure 1, 2). The model number for compactors covered by this manual will have the format KP2SC-XX-Yd. The first part of the model number, KP2SC, is the code which represents the model. Code KP2SC represents a self-contained compactor with a 2 cubic yard charge chamber and a side opening door. The code is followed by a dash number that represents the container capacity. Capacity sizes of 20, 25, 30 and 35 Cu Yd are available. A low profile charge chamber option is available for 20 and 30 Cu Yd capacities. A specific serial number (Figure 1, 3) is assigned to each compactor when it is manufactured. This serial number is important and should be used when requesting service or ordering parts. The serial number for compactors covered by this manual will have the format K1716-XX-XX. The first part of the serial number, K1716, represents the sales order number for the compactor. The next -XX represents the month the compactor was manufactured. The last -XX represents the year the compactor was manufactured. Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 5 All Rights Reserved GENERAL KP2SC Self-Contained Compactor FEATURES · Clear charge chamber opening of 41" x 68" is the largest in industry to prevent "bridging." · Full 14" ram penetration out performs competitive models. · 46.5" feed height eases ground level loading. · Guided and supported ram with easily replaceable guide shoes increases structural life and reduces maintenance costs. · "NoShok" system eliminates limit switches (80% of service calls) and improves hydraulic life. · .38" High Strength hopper floor is 52% thicker and 300% stronger than competitive guided ram compactors. · Wider ground rollers improve pavement life over competition. · Epoxy based paint with UV inhibitors exceed industry standards. · Adjustable door hinges and strongest structural design insure door rigidity to provide liquid integrity. · Full door seal of closed cell neoprene (as used in nuclear submarines) provides superior sealing and outlasts competitive seals. · Self-cleaning compactor sump (sub-floor) to prevent debris buildup behind ram. SPECIFICATIONS KP2SC SPECIFICATIONS · Ram Face · Clear Top Opening · Loading Height · Ram Penetration · Packing Force Normal · Packing Force Max. · Packing Pressure Normal · Packing Pressure Maximum · Hopper Floor · Compactor Sides · Ram Top · Ram Face 53"W x 46"H 41" x 68" 46.5" 14" 42,250 lbs. 45,700 lbs. 1,850 PSI 2,100 PSI .38 A36 Plate .25 Plate .38 Plate .25 Plate STANDARD POWER PACK · Power Pack · Hydraulic Pump · Reservoir · Cylinders 10 HP / 3 Phase 208/230/460 Volt 60 Hertz 12 GPM 20 Gallons 2 - 4" x 37" Diagonal CYCLE TIME · Time 34 Seconds 6 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor DIMENSIONS GENERAL F G H C B D A E MODEL KP2SC20 KP2SC25 KP2SC30 KP2SC35 KP2SC20-LP KP2SC30-LP Total Capacity - (Cu Yd) 20 A Chamber Height (Inches) 46.5 B Chamber Length (Inches) 71.5 C Body Length (Inches) 117 D Overall Height (Inches) 102 E Overall Length (Inches) 188 F Tailgate Width (Inches) 101.5 G Chamber Width (Inches) 68 H Chamber Opening (Inches) 41 Weight 9300 25 46.5 71.5 147 102 219 101.5 68 41 9835 30 46.5 71.5 177 102 249 101.5 68 41 10370 35 46.5 71.5 207 102 279 101.5 68 41 10900 20 46.5 71.5 135 90 207 101.5 68 41 9030 30 46.5 71.5 207 90 279 101.5 68 41 10100 STANDARD POWER PACK · Motor - 10HP 208 / 230 / 460 3-Phase 60 Cycle · Control Voltage - 115 VAC · Key operated Start/Stop/Reverse Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 7 All Rights Reserved GENERAL KP2SC Self-Contained Compactor This Page Intentionally Left Blank 8 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor SAFETY IMPORTANT SAFETY INFORMATION READ AND UNDERSTAND THIS ENTIRE MANUAL BEFORE OPERATING, REPAIRING OR ADJUSTING YOUR K-PACTM COMPACTOR. THOSE WHO USE AND MAINTAIN THIS EQUIPMENT MUST BE THOROUGHLY TRAINED AND FAMILIAR WITH THE PRODUCT. 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. Should operators of this equipment have a reading or learning disability, dyslexia, or other such condition, then they must be assigned a mentor/trainer to read and explain to them the entire contents of this manual as well as the safety guidelines, danger, caution, and warning decals on this unit. Such individuals should not be allowed to operate this equipment until they thoroughly understand all of these materials. Failure to do so can result in serious injury or death. SAFETY ALERT SYMBOL THIS SAFETY SYMBOL INDICATES IMPORTANT SAFETY MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL, CAREFULLY READ THE MESSAGE THAT FOLLOWS. BE ALERT TO THE POSSIBILITY OF PERSONAL INJURY OR DEATH. Elimination of the hazards listed in this manual should not be construed as providing guarantees that the equipment will meet or exceed all standards or regulations, or will be completely safe to all personnel. The operator should inspect and review the compactor after it is in his possession for adequacy in safety for the function for which it will be used. Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 9 All Rights Reserved SAFETY KP2SC Self-Contained Compactor SAFETY ALERTS Safety notices are one of the primary ways to call your attention to potential hazards. The following safety notices are used throughout this manual. DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE is used to address practices not related to personal injury. SAFETY INSTRUCTIONS is used to indicate general instructions relative to safe work practices. Read, understand and follow the safety guidelines and heed dangers and warnings listed below and contained in this manual as well as on the Compactor itself to promote reliable operation and prevent serious personal injury. The "signal words" of DANGER, WARNING AND CAUTION have specific meanings to alert you to the relative level of hazard. Take the safety warnings seriously. If you do not understand them or have questions about them, contact K-PACTM for assistance. 10 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor SAFETY SAFETY DECAL REQUIREMENTS When your compactor leaves the factory, SAFETY DECALS are installed for everyone's protection. The decals are subject to wear and abuse due to the nature of operation. These decals must be maintained. Additional decals may be purchased through your K-PACTM dealer or directly from the factory. Refer to decal placement illustrations later in this Safety section. COMPACTOR SAFETY DECALS The following safety decals are found on your compactor and warn of hazards related to the use of this equipment. Read and understand all safety decals before operating this equipment. Depending on the Compactor configuration and optional equipment, the actual location of the decals and/or placards may vary slightly from the examples shown. If any safety decals on the equipment are not clearly readable, contact your K-PACTM dealer. Specifications, appearance and part numbers for safety decals are subject to change without notice. No. Part Number Qty. Description 1 501940 2 123550 3 503085 4 101437 5 502852 6 101433 7 502850 8 134893 9 134892 10 502851 11 502848 12 502844 13 502853 14 502857 3 K-PAC LOGO, Large 1 K-PAC LOGO, Small 2 K-PAC LOGO, Proudly USA Made 3 DANGER, Do Not Enter 2 DANGER, Stay Clear At All Times When Container Is Off Ground 1 DANGER, Keep away from moving parts: Death or dismemberment may occur 2 DANGER, Be aware of power lines and overhead obstructions, Contact by the hoist or container could cause serious injury or death to the operator and bystanders 4 DANGER, Use LOCKOUT/TAGOUT Before Working On Equipment 4 SAFETY INSTRUCTIONS, Before entering or climbing on compactor to perform any work, read and follow OSHA Regulations concerning entry and working in "CONFINED SPACE" OSHA 1910.146 AND "LOCKOUT/TAGOUT" OSHA 1910.147 1 WARNING, Pinch Point, Stay Clear Of The Latch Area, Serious Personal Injury May Occur 2 WARNING, Escaping Fluid Under Pressure Can Penetrate The Skin Causing Serious Injury Or Death 2 CAUTION, Operators - All persons operating this compactor are to read the operators manual and understand the safety messages on this machine 1 CAUTION, Do not remove cover except for servicing 1 Wipe off seal after dumping Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 11 All Rights Reserved SAFETY DECAL LOCATIONS Left Side 11 SAFETY KP2SC Self-Contained Compactor 1 7 12 8 4 93 Chamber and Tailgate 8 9 6 4 8 13 9 2 5 1 12 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor Right Side SAFETY 1 7 14 5 10 11 12 3 948 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 13 All Rights Reserved SAFETY DECAL IDENTIFICATION SAFETY KP2SC Self-Contained Compactor 501940 123550 503085 101437 502852 101433 502850 134893 134892 502851 502848 502844 802853 502857 14 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor SAFETY POWER PACK SAFETY DECALS The following safety decals are found on your compactor and warn of hazards related to the use of this equipment. Read and understand all safety decals before operating this equipment. Depending on the Compactor configuration and optional equipment, the actual location of the decals and/or placards may vary slightly from the examples shown. If any safety decals on the equipment are not clearly readable, contact your K-PACTM dealer. Specifications, appearance and part numbers for safety decals are subject to change without notice. No. Part Number Qty. Description 1 502840 1 DANGER, High voltage 2 134933 1 DANGER, Do not open cover, Must be a QUALIFIED PERSON to open and access control panel 3 134932 2 DANGER, Arc flash and shock hazard, Appropriate PPE required 4 502847 1 WARNING, These controls shall be located outside the area and beyond the reach of the compactor 5 123550 2 K-PAC LOGO, Small SAFETY DECAL LOCATIONS Power Pack 3 4 3 1 5 5 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 15 All Rights Reserved Control Panel SAFETY KP2SC Self-Contained Compactor 100% FULL 80% FULL FW D/O FF/REV OFF ON M A N U A L/A U T O 100% FULL E-STOP 2 SAFETY DECAL IDENTIFICATION 502840 502847 134933 123550 134932 16 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor SAFETY LOCKOUT/TAGOUT Before performing any service and/or maintenance, OSHA regulation 1910.147 for LOCKOUT/TAGOUT must be read, understood and followed when performing any service and/or maintenance. Follow all company procedures for LOCKOUT/TAGOUT policy. Disable and de-energize all systems and apply energy control measures. Also consider stored energy. Before entering the compactor after LOCKOUT/TAGOUT, OSHA regulation 1910.146 for CONFINED SPACE must be read, understood and followed when performing any service and/or maintenance. LOCKOUT/TAGOUT PROCEDURE Per ANSI standard Z245.2-2013, the owner/employer shall have a hazardous energy control LOCKOUT/TAGOUT procedure to follow when performing service and maintenance on stationary compactors where the unexpected energization or start-up of equipment or release of stored energy could cause injury to employees. Because stationary compactors are offered with many customer request options and installations are unique for each compactor, the following LOCKOUT/TAGOUT procedure provided may not cover all hazards. A hazard assessment must be performed by the owner/ employer when they implement their hazardous energy control LOCKOUT/TAGOUT procedure to ensure all hazards are addressed. The following are instructions to LOCKOUT/TAGOUT the compactor to ensure that the stationary compactor is stopped, isolated from all potentially hazardous energy sources and locked out before employees perform any servicing or maintenance where the unexpected energization or start-up of the stationary compactor or release of stored energy. The following are instructions to LOCKOUT/TAGOUT the compactor to ensure that the stationary compactor is stopped, isolated from all potentially hazardous energy sources, stored energy released and LOCKOUT/TAGOUT applied to prevent the unexpected energization or start-up of the stationary compactor. · Notify all affected employees that servicing or maintenance is required on a stationary compactor and that the compactor must be shut down and locked out to perform the servicing or maintenance. · The authorized employee shall refer to the company procedure to perform a hazard assessment to identify the type and magnitude of the energy that the compactor utilizes, shall understand the hazards of the energy, and shall know the methods to control the energy. · Operate the compactor to place all components in a position so they are not subject to possible free fall and/or movement. Install additional blocking devices to prevent this potential when required. Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 17 All Rights Reserved SAFETY KP2SC Self-Contained Compactor When performing work on the ram after LOCKOUT/TAGOUT has been applied, the ram must be blocked/secured in place. 1 1 Figure 2 · Depress one of the E-STOP buttons (Figure 2, 1) to turn the Power Pack controls Off. 1 2 4 3 Figure 3 · Identify the Main Power Disconnect (Figure 3, 1) for the energy source. · Switch the lever (Figure 3, 2) to the OFF position to shut off the electrical power supply to the Power Pack. · Apply LOCKOUT/TAGOUT by affixing lock (Figure 3, 3) and tag (Figure 3, 4) to secure the lever in the OFF position. 18 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor SAFETY 1 2 3 2 2 Figure 4 · Stored or residual hydraulic pressure must be relieved after blocking devices are installed. Locate the direct acting directional control valve (Figure 4, 1) on the Power Pack. · Both solenoids (Figure 4, 2) on the directional valve have a manual override. · Insert an 1/8" or less diameter pin or screw driver (Figure 4, 3) into the end of both solenoid spools to relieve hydraulic pressure from both hydraulic lines for the ram cylinder. · Disable the Power Pack by turning the ON-OFF switch (Figure 5, 1) to OFF on the control panel. Remove the key and keep in your possession. 1 Figure 5 · After applying LOCKOUT/TAGOUT to system, verify the system has been isolated and disconnected from the energy source. · First check that no personnel are exposed. · Operate the controls to verify they have been disabled. The stationary compactor is now in LOCKOUT/TAGOUT. Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 19 All Rights Reserved SAFETY KP2SC Self-Contained Compactor REMOVE LOCKOUT/TAGOUT The removal of LOCKOUT/TAGOUT should be performed by the same authorized employee that it was applied by. Use the following steps to remove LOCKOUT/TAGOUT and restore the compactor back to service. · Check the stationary compactor and the immediate area around to ensure that nonessential items are removed from the area. · Check the compactor and surrounding area to verify that all components are intact. · Check the work area to ensure that all affected employees are safely positioned or removed from the area. · Verify that the controls are in neutral. · Remove the LOCKOUT/TAGOUT lock (Figure 3, 3) and tag (Figure 3, 4) that secured the lever on the Main Power Disconnect. · Switch the lever (Figure 3, 2) to the ON position to enable the electrical power supply to the Power Pack. · Insert the key into the ON-OFF switch (Figure 5, 1) on the control panel or remote. Enable the Power Pack by turning the ON-OFF switch to ON. The removal of some forms of blocking may require re-energizing of the stationary compactor before safe removal. · Reassess area to determine that the equipment is safe for operation. · Notify affected employees that the servicing or maintenance is completed and the compactor is ready for use. PROCEDURES FOR WORK IN CONFINED SPACES The owner/employer shall have a written procedure for work in confined spaces meeting the criteria of OSHA regulation 1910.146. The procedure shall utilize the LOCKOUT/TAGOUT procedure previously provided. Before entering or climbing on compactor to perform any work, read and follow OSHA regulations concerning entry and working in "CONFINED SPACE" OSHA 1910.146 and "LOCKOUT/TAGOUT" OSHA 1940.147. Follow OSHA regulations while performing any work to the compactor. Follow all safety instructions in your K-PACTM manual. Failure to do so can result in serious personal injury or death. HIGH VOLTAGE SAFETY High voltage electricity can be dangerous because of many variables. Precautions must be taken against the risk of death or injury. When any kind of electrical work is being undertaken, it is vital that a risk assessment encompassing all electrical hazards be taken. Energized electrical work shall only be performed by or under the direct supervision of a QUALIFIED PERSON. Guidance for electrical safety comes from several standards: · General Industry Safety Standards (OSHA 29 CFR 1910) · Standard for Electrical safety in the Workplace (NFPA 70E) · IEEE Guide for Performing Arc-Flash Hazard Calculations (IEEE 1584) OSHA 1910 Subpart "S" (1910.301 to 1910.399) specifies Electrical Safety-related work practices. The latest edition of NFPA 70E is also being used as a guideline for enforcing OSHA electrical safety rules. 20 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor SAFETY DEFINITIONS OSHA 1910.399 specifically defines a QUALIFIED PERSON as "One who has received training in and has demonstrated skills and knowledge in the construction and operation of electric equipment and installations and the hazards involved." The NFPA 70E® 2012 "Standard for Electrical Safety in the Workplace®" definition for a QUALIFIED PERSON is almost identical. All electrical work when installing and servicing must be performed by a QUALIFIED PERSON. QUALIFIED PERSON is one who has received training in and has demonstrated skills and knowledge in the construction and operation of electric equipment and installations and the hazards involved. ARC FLASH Arc flash is a phenomenon where a flashover of electric current leaves its intended path and travels through the air from one conductor to another, or to ground. The results are often violent and when a human is in close proximity to the arc flash, serious injury and even death can occur. Arc flash can be caused by many things. Three factors determine the severity of an arc flash injury: · Proximity of the worker to the hazard · Temperature · Time for circuit to break Because of the violent nature of an arc flash exposure when an employee is injured, the injury is serious - even resulting in death. It's not uncommon for an injured employee to never regain their past Quality of life. PROCEDURES FOR ELECTRICAL ARC FLASH AND SHOCK SAFETY Prior to intentionally coming into contact with energized electrical conductors or circuit parts of 50 volts or greater with the hands, feet or other body parts with tools, probes (energized electrical work), a shock and hazard analysis shall be performed to determine the safe work practices that are required to perform that work. Those safe work practices shall include the identification of the following, at a minimum: · Electrical shock and arc flash boundaries · Personal protective equipment to be worn · Need for electrically insulated measuring equipment and other tools · Other specialized work practices to be followed to perform that work safely · Requirements for the use of an Electrical Hot Work Permit All latches on the control panel must be secured at all times. Do not loosen latches or open cover unless you are QUALIFIED PERSON. Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 21 All Rights Reserved SAFETY KP2SC Self-Contained Compactor MOST COMMON HAND SIGNALS USED IN THE FIELD Below are the various hand and arm signals that can be used when visual communication is required and the participants remain relatively close together. When receiving hand signals, be sure to pay attention to the signalers facial expressions too. Recognize too that multiple hand signals can be combined in sequence in order to more accurately communicate the thought or action. 22 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor INSTALLATION INSTALLATION REQUIREMENTS GENERAL The installer of the stationary compactor shall do so in accordance with the appropriate sections of American national Standard ANSI Z245.2, applicable codes, local ordinances and the manufacturer's recommendations. The installer shall affix to such equipment the date of installation, installer's name and a statement attesting to compliance with ANSI Standards. MAIN POWER DISCONNECT Installation shall include a power disconnecting means that can be locked in the OFF position. Power disconnects and live electrical components shall have adequate work space in accordance with ANSI/ NFPA 70, National Electrical Code, Section 110, requirements for electrical installations. Power disconnects with more than 200 volt operating systems shall be labeled with "ARC FLASH" warning decals on the main disconnect panel face. INSTALLATION INSTRUCTIONS IT SHALL BE THE RESPONSIBILITY OF THE INSTALLER OF THE SELF CONTAINED COMPACTORS TO INSTALL COMPACTORS IN ACCORDANCE WITH CURRENT ANSI Z245.2 - 2013 SAFETY STANDARD AND OTHER APPLICABLE CODES. K-PACTM DOES NOT ASSUME RESPONSIBILITY FOR INSTALLATION PROCEDURES OF THIS EQUIPMENT. CONFORMANCE TO APPLICABLE LOCAL, STATE AND FEDERAL LAWS CONCERNING INSTALLATION RESTS WITH THE CUSTOMER. All involved personnel shall study this manual completely before proceeding. Study the installation carefully to be certain that all safety guards, and safety devices are provided and in the proper place to protect personnel and equipment during and after the installation. INSTALLATION SITE 1. Careful consideration should be given to the site selected for the K-PACTM Compactor. 2. Concrete Pad: Ample room should be provided for the collecting vehicle to maneuver, including room to avoid OVERHEAD ELECTRIC AND TELEPHONE LINES. The compactor should be placed on a reinforced concrete pad. Preferred dimensions of the concrete pad are 10'-0" wide and length of 5'-0" greater than the length of the self-contained compactor roll-off platform. It should be a minimum of 3,000 PSI concrete, steel reinforced, 6" thick. For good housekeeping practices, it is recommended that a drain beneath the platform be incorporated in the pad to allow for wash-down, etc. Concrete should be flush with the surrounding ground level. This is important for roll-off truck access. The pad must be level on outside 2 feet to allow contact of all four rollers. To provide accessibility, the concrete pad should be positioned to allow 2'-0" between the container and the building wall if installed parallel with the building. Allow a minimum of 45'-0" of clear space from container end of pad for container handling vehicle. Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 23 All Rights Reserved KP2SC Self-Contained Compactor INSTALLATION Container guide (optional) should be anchored with bolts grouted in with setting compound approximately 5" deep. Spacing between guides is determined by rail spacing of the containers. 3. Dock Installation: If appropriate options are ordered from K-PACTM, the compactor will be furnished with an open top 4-sided chamber (mounted or unmounted as ordered), or a closed chamber with safety hand and toe rails. If the compactor cannot be directly abutted to the dock, or if there is any difference in the height between dock and compactor, an appropriately sturdy transition section should be provided (by the customer) and securely affixed to both dock and compactor. Hand and toe rails should be extended as required to suit this transition. (ANSI Z245.2 - 2013 Standard). Transition must allow for pickup of compactor by roll-off truck and return without damage to transition. 4. Hopper Options: There are many hopper options available. Make sure that an appropriate hopper is installed for the application to ensure safe operation. The type of compacted material should be considered to protect operator and any nearby personnel from possible flying debris. 5. Guarding: Protection for personnel from contacting any moving parts or material loaded at the point of operation or other mechanical operations shall be provided by one of the following methods or by other means as effective as the following means: X Y Figure 6 The installation of a guard or loading hopper (Figure 6) with a minimum loading height above the working surface of 42 inches (Dimension "Y") and the sum of dimensions "X" and "Y" equaling 84 inches or greater, that shall prevent any person from contacting moving parts or material at the point of operation. Any guarding provided shall allow adequate clearances for entering and exiting for servicing and operation of the stationary compactor. 6. Interlocks: Access door(s) of loading chambers shall have an interlock system that prevents cycling motion while the access door(s) is/are open unless the provisions of guarding. When movement of a guard actuates an interlock, the arrangement shall be such that the guard is in place when the interlock is in the position that permits operation of the parts being guarded. 24 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor INSTALLATION 7. Emergency Stop: Multiple points of operation shall have an emergency stop readily accessible to each point of operation and material feed area. Where possible, the emergency stop should be located within 3 ft of each point of operation, material feed area or access door, if chute fed. 8. Power Pack: Must be located within 3' of the loading chamber for access in an emergency. If this is not possible, an auxiliary emergency stop control must be installed within this 3' range. Power pack to be anchored as required by the customer. The Power Pack must be located so the Control Panel with an Emergency Stop switch is readily accessible to the operator and within three (3) feet of charging chamber access door. If installation requires the Power Pack to be located in a more remote area, a second Emergency Stop should be provided by installing a remote control in the manner described above. Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 25 All Rights Reserved KP2SC Self-Contained Compactor INSTALLATION ELECTRICAL INSTALLATION All electrical work when installing and servicing must be performed by a QUALIFIED PERSON. QUALIFIED PERSON is one who has received training in and has demonstrated skills and knowledge in the construction and operation of electric equipment and installations and the hazards involved. All wiring should be in accordance with Local and National Electric Code regulations. Recommended fuses and wire sizes are listed on a chart below, but the ratings must always meet or exceed any local code. Motor Line Horsepower Voltage Dual Element Time Delay Fusetron - Amps Minimum Wire Size to Minimum Wire Size to 100' Copper 200' Copper 10 HP 208 45 3 Phase 230 45 8 Ga. 8 Ga. 6 Ga. 6 Ga. 460 25 10 Ga. 8 Ga. 1 Figure 7 There are three voltage options available, 208, 230 or 460 volts for the 10 Horsepower 3 Phase electric motor. The control panel is prewired to the voltage specified when the compactor was ordered. The voltage that the control panel is wired to is designated with an orange decal (Figure 7, 1) on the cover of the control panel. 26 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor INSTALLATION MAIN POWER DISCONNECT 1 2 Figure 8 A dedicated 50 Amp fuse disconnect circuit is required to provide power to the power pack. The main power disconnect must have the ability to be padlocked (Figure 8, 1) in the OFF position (Figure 8, 2) for OSHA LOCKOUT/TAGOUT. The main power disconnect and live electrical components shall have adequate work space in accordance with ANSI/NFPA 70, National Electrical Code, Section 110, Requirements for electrical installations. Power disconnects with more than 200 volt operating systems shall be labeled with "ARC FLASH" warning decals on the main disconnect panel face. Check and verify the voltage the control panel is wired to ensure the Main Power Disconnect is wired to match. Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 27 All Rights Reserved KP2SC Self-Contained Compactor INSTALLATION WIRE COLORS The US National Electrical Code only mandates white (or grey) for the neutral power conductor and bare copper, green, or green with yellow stripe for the protective ground. In principle any other colors except these may be used for the power conductors. The colors adopted as local practice are shown in table below. Black, red, and blue are used for 208/230 VAC three-phase; brown, orange and yellow are used for 460 VAC. Conductors larger than #6 AWG are only available in black and are color taped at the ends. Function Line, 3-phase Line, 3-phase Line, 3-phase Neutral Protective ground Label L1 L2 L3 N PG Color, 208/230 VAC black red blue white bare, green or green/yellow Color, 460 VAC brown orange yellow grey green 28 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor INSTALLATION WIRING CONNECTIONS 1 2 3 T104 FU102 FU102A FU107 SEE LABEL LB4 TB100 M127 GND103 4 PLC110 DIO128 SEE LABEL LB5 OL127 SEE LABEL LB4 1 2 3 Figure 9 A 3-Pole Power Terminal Block is located at the top right on the back panel inside the Control Panel. The Terminal Block provides a means of connecting the 3-phase line wires from the Main Power Disconnect. The three line wires are identified as L1, L2 and L3. The L1 wire is connected to the farthest left terminal (Figure 9, 1) on the Power Terminal Block. The L2 wire is connected to the middle terminal (Figure 9, 2) on the Power Terminal Block. The L3 wire is connected to farthest right terminal (Figure 9, 3) on the Power Terminal Block. A Ground Terminal Block is located on the left side of the Motor Starter and Overload in the control panel. The Motor Starter and Overload are located at the bottom right of the back panel in the Control Panel. The ground wire is connected to the top terminal (Figure 9, 4) of the Ground Terminal Block. Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 29 All Rights Reserved KP2SC Self-Contained Compactor INSTALLATION All latches on the control panel must be secured at all times. Do not loosen latches or open cover unless you are a QUALIFIED PERSON. QUALIFIED PERSON is one who has received training in and has demonstrated skills and knowledge in the construction and operation of electric equipment and installations and the hazards involved. 30 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor OPERATION CONTROL PANEL and REMOTE CONTROL 3 6 7 3 1 5 2 4 4 1 5 Figure 10 The control box enables the operator to control the Compactor functions and provides a central location for diagnosing any electrical issues. The following is a brief description for each switch starting from the left and moving right: NO. POSITION DESCRIPTION 1 EMERGENCY Switch The EMERGENCY Switch provides a means to control the Compactor. Push DOWN on the EMERGENCY Switch to disable all of the Compactor functions. Pull UP on the EMERGENCY Switch to enable the Compactor functions. 2 MANUAL/AUTO Switch Turn the switch counter-clockwise to select MANUAL mode. When in the Manual mode, the compactor ram cylinders are controlled by the FWD/OFF/REV Switch. Turn the switch clockwise to select AUTO mode. When in the AUTO mode, the compactor ram cylinders are controlled by the START switch. 3 OFF/ON Security Switch A key-locked OFF/ON Switch is provided to control who can operate the compactor. The lock requires a key to switch between the ON or OFF position. When in the OFF position, the compactor controls are securely disabled. When in the ON position, the compactor controls are enabled. 4 START Switch DEPRESS the START Switch to start the AUTO pack function. The default setting is three cycles. 5 FWD/OFF/REV Switch The switch is a momentary switch that is normally in the OFF position. Turn the switch counter-clockwise to FWD position to extend the ram into the container. Turn the switch clockwise to REV position to retract the ram from the container. 6 80% FULL Light Yellow Light indicates when the container is approximately 80% of full capacity. 7 100% FULL Light Red Light indicates when the container has reached capacity and is 100% of full capacity. Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 31 All Rights Reserved OPERATION KP2SC Self-Contained Compactor OPERATING INSTRUCTIONS FOR STANDARD COMPACTORS 1. Place material to be discarded into the charge chamber. 2. Pull UP on the EMERGENCY Switch (Figure 10, 1) to enable the Compactor controls. 3. Insert key in OFF/ON Security Switch (Figure 10, 3) and turn clockwise to ON position. 4. Determine pack mode and make selection on MANUAL/AUTO Switch (Figure 10, 2). AUTO MODE AUTO pack mode is programmed for 3 cycles from the factory. 1. Depress the START Button (Figure 10, 4) for 1 to 2 seconds, then release. 2. Upon start-up of pack cycle, the ram cylinders will extend until they are fully extended. 3. After the cylinders are fully extended, there should be a 1 second delay. 4. After the extend delay, the ram cylinders will begin retracting. The ram will completely retract and stop for a 1 second delay. 5. The pack cycle will start again and repeat until 3 cycles have been completed. The default pack cycle times from the factory are 20 seconds for extend and 14 seconds for retract. MANUAL MODE 1. The FWD/OFF/REV Switch (Figure 10, 5) is normally in the OFF position. 2. Turn the switch counter-clockwise to the FWD position to extend the ram cylinders into the container. 3. Turn the switch clockwise to the REV position to retract the ram cylinders. CONTAINER FULL LIGHTS There are two container full lights located at the top of the control panel cover. The yellow 80% FULL light (Figure 10, 6) indicates when the container is approximately 80% of full capacity. The red 100% FULL light (Figure 10, 7) indicates when the container is full and has reached 100% capacity. 32 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor START-UP AND TESTING INSTRUCTIONS POWER PACK START-UP Make sure that all access covers, chamber door or gates are closed and secured. Before proceeding with this test, make sure that persons are clear of the loading chamber and the container. Do not test this unit until you have read and understood the operating and maintenance instructions in this manual. 1. With the Main Power Disconnect switch OFF, visually inspect all hydraulic, mechanical and electrical connections on the Power Pack and Compactor. All connections must be tight. 2. Lubricate all oil and grease points on the compactor as instructed in the MAINTENANCE section of this manual. 2 1 Figure 11 3. Check the hydraulic fluid in the reservoir to be sure it is adequate. The oil must be to the 3/4 level or full on the sight gauge (Figure 11, 1). To add or replace, use an ISO Viscosity grade 15 of Northland Talamar Extreme® LTE premium anti-wear hydraulic fluid. Hydraulic fluid can be used from a alternative vendor, but the fluid must meet the properties identified in the table in the MAINTENANCE section. Also, any alternative hydraulic fluid must meet the performance specifications identified at the bottom of the table. 4. Remove the cover (Figure 11, 2) over the motor and pump to provide access to the motor and pump. 5. Turn the Main Power Disconnect switch to the ON position. BE ALERT for smoking, electrical arcing, or fuse failure. If any irregularity is observed, switch the Main Power Disconnect to the OFF position IMMEDIATELY. Find the source of trouble and make the necessary corrections. Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 33 All Rights Reserved KP2SC Self-Contained Compactor START-UP AND TESTING INSTRUCTIONS 3 5 4 2 1 Figure 12 6. Locate the fan cover (Figure 12, 1) for inspection of the motor fan to identify motor rotation. 7. Identify label (Figure 12, 2) on fan cover to determine the correct motor rotation. 8. Turn the key-locked OFF/ON Switch (Figure 12, 3) to the ON position to enable the compactor controls. 9. Turn the MANUAL /AUTO Switch (Figure 12, 4) to select the MANUAL mode. 10. Quickly turn the FWD/OFF/REV Switch (Figure 12, 5) to the FWD position and back to OFF and stop the motor. 11. Observe if the rotation of the motor fan through the fan cover to determine if the rotation is correct. If the pump runs backwards, STOP IMMEDIATELY! The pump will be damaged if it is run in reverse even for short periods of time. The direction of rotation must be in agreement with the marking on the motor. On 3-Phase motors, reversing any two incoming power lines will reverse the pump motor rotation. 12. If rotation is correct, jog the electric motor to prime the pump. If the pump makes excessive noise, shut the system down and check the suction line for leaks or an obstruction. 34 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor START-UP AND TESTING INSTRUCTIONS HYDRAULIC HOSE INSTALLATION 2 1 Figure 13 1. Hydraulic hoses are connected to and shipped with the Power Pack. The standard length for the hoses is 12 feet unless a different length was ordered. The hose for the ram cylinders extend function is connected to the tee fitting (Figure 13, 1) in the (A) port of the manifold. The hose for the ram cylinders retract function is connected to the adapter fitting (Figure 13, 2) in the (B) port of the manifold. 2 1 Figure 14 2. The hose connections are located at the left-front of the chamber on the compactor body. 3. The ram cylinders extend hose connected to port (A) on the Power Pack manifold has a quick disconnect coupler on the end of the hose. Connect the coupler to the nipple (Figure 14, 1) located at the bottom. 4. The ram cylinders retract hose connected to port (B) on the Power Pack manifold has a quick disconnect nipple on the end of the hose. Connect the nipple to the coupler (Figure 14, 2) located at the top. Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 35 All Rights Reserved KP2SC Self-Contained Compactor START-UP AND TESTING INSTRUCTIONS MANUAL MODE - RAM CYLINDER CYCLING 1. With the MANUAL mode selected, turn the FWD/OFF/REV Switch to the REV position to retract the ram cylinders until they are fully retracted. When retracting, monitor the hydraulic fluid level in the reservoir for the Power Pack so it is not over-filled. It may be necessary to remove fluid from reservoir. The hydraulic fluid level must be checked with the ram cylinders completely retracted to prevent over-filling. 2. With the MANUAL mode selected, turn the FWD/OFF/REV Switch to the FWD position to extend the ram cylinders until they are fully extended. 3. After completely extending the ram cylinders, turn the FWD/OFF/REV Switch to the REV position to retract the ram cylinders until they are fully retracted. 4. With the ram cylinders fully retracted, inspect and adjust the hydraulic fluid level in the reservoir. 5. Repeat previous steps several times to remove air from hydraulic system. AUTO MODE - RAM CYLINDER CYCLING 1. Turn the MANUAL /AUTO Switch to select the AUTO mode. 2. Depress the START Button for 1 to 2 seconds, then release. 3. Upon start-up of pack cycle, the ram cylinders will extend until they are fully extended. 4. After the cylinders are fully extended, there should be a 1 second delay. 5. After the extend delay, the ram cylinders will begin retracting. The ram will completely retract and stop for a 1 second delay. 6. The pack cycle will start again and repeat until 3 cycles have been completed. AUTO pack mode is programmed for 3 cycles from the factory. 7. After the completion of the packing cycle, the Power Pack should stop automatically and shut down. If it does not, press the EMERGENCY STOP button. Check the timers in power panel. They may be faulty or incorrectly adjusted. Refer to SERVICE section for procedure to set PLC. VALIDATE INTERLOCKS Depending on the application and the options ordered and provided, the compactor can be equipped with interlocks. All interlocks need to be verified that they are functioning properly. Make sure the interlocks are installed and functioning properly. With the factory electric interlock installed, opening of the chamber access door or gate will shut down the power pack. Doors or gate must be closed for power pack to operate. 36 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor MAINTENANCE MAINTENANCE INSTRUCTIONS It shall be the responsibility of the employer who operates the equipment to ensure the proper caring for, cleaning, inspecting, and maintaining of compaction equipment, in the case of employers who maintain their own equipment, the training of competent personnel for this purpose. It shall be the responsibility of the employer to establish and follow a program of periodic and regular inspections of compaction equipment, and to ensure that all parts, auxiliary equipment, and safeguards are in safe operating condition and adjusted in accordance with the manufacturer's recommended procedures. The employer shall maintain records of these inspections and of maintenance work performed. Before performing any service and/or maintenance, OSHA regulation 1910.147 for LOCKOUT/TAGOUT must be read, understood and followed when performing any service and/or maintenance. Follow all company procedures for LOCKOUT/TAGOUT policy. Disable or de-energize all systems and apply energy control measures. Also consider stored energy. Before entering the compactor after LOCKOUT/TAGOUT, OSHA regulation 1910.146 for CONFINED SPACE must be read, understood and followed when performing any service and/or maintenance. When access covers are removed from compactor to perform service or maintenance, they must be reinstalled and secured in position before removing LOCKOUT/TAGOUT. Escaping fluid under pressure can penetrate the skin causing serious injury. Avoid the hazard by relieving pressure before disconnecting hydraulic lines. Tighten all connections before applying pressure. Search for leaks with a piece of cardboard. Protect hands and body from high pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. Flammable spray can be generated by heating near pressurized hydraulic hoses, resulting in severe burns to yourself and bystanders. Do not heat by welding, or using a torch near hoses. Hose can be accidentally cut when heat goes beyond the immediate flame area. Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 37 All Rights Reserved KP2SC Self-Contained Compactor MAINTENANCE PREVENTIVE MAINTENANCE We recommend that the user of the K-PACTM compactors adopt a program of regularly scheduled maintenance procedures. This schedule should be followed to insure against premature failure of mechanical or hydraulic components. INITIAL CHECK · All nuts and bolts during the first week of use, and then monthly thereafter. · Hydraulic reservoir oil level should be at mid to upper range of sight glass with ram retracted. · Hydraulic lines for leaks. · Hydraulic hose condition. (Check for damage, kinks, etc.) · Access covers to be sure fasteners are in place. · Power Pack. Remove dust and dirt from outside of control box. Wipe off any dirt or grease, oil or moisture. AFTER EMPTYING · Wipe tailgate seal and mating surface clean: insure tailgate ratchet is tight. MONTHLY CHECK · Check external hoses for chafing, rubbing, or other deterioration and damage. · Check for any obvious unsafe conditions, such as electrical lines or operator obstructions, in compactor area. · Check oil level in hydraulic reservoir. · Wash unit out. 3-MONTH CHECK · Check functional operation of standard controls and options (stop button, timers, lights, etc.) · Open top cover and wash out behind ram. Clean out any accumulation of waste material. · Check hydraulic cylinder and internal hoses for leakage; hoses for chafing and wear. MAINTENANCE INSTRUCTIONS FOR TAILGATE SEALS · To prevent leakage, seal and mating surface should be wiped clean after unit has been emptied. · Periodically inspect seal for abrasions. · Check that seal is contacting the mating surface properly. If corrosion or damage has occurred on this surface, it may be necessary to sand off smooth. FILTER MAINTENANCE · Hydraulic filter should be cleaned after one (1) month of operation and then at regular intervals of not more than six (6) months. · Filter may be removed from unit by disconnecting pipe on suction side of pump, removing four bolts retaining cover plate, and lifting filter from reservoir. Filter may also be removed by tipping tank at angle and removing cleanout cover on end. With cover removed, filter can be accessed and removed. · Care should be exercised in cleaning filter to insure that the element is not torn. Clean with soft brush and standard industrial solvent. · Replace filter after cleaning; tighten union securely. Be sure to tighten pipe to pump before tightening 4 bolts on cover plate. Pump noise and "crackle" sound is most often caused by air entering pump suction line. Tightening the suction fittings will usually eliminate such problems. 38 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor MAINTENANCE YEARLY CHECK · Electrician to check all electrical connections, check motor resistance (recording successive readings helps to prevent future failure). Under heavy use, grease the motor. (DO NOT OVER-GREASE) · Hydraulic system - prior to winter season, drain and clean inside of reservoir by removing clean-out cover. Check and clean filter, replace cover and refill. Check for tightness. Refill reservoir with recommended hydraulic fluid. · Check structure of compactor for potential trouble areas and repair as needed. · Check hoses to insure that they do not become severely worn before being replaced. A broken hose will allow the reservoir to be pumped dry and ruin the pump. · Check condition of the ram UHMW slide blocks for wear. Replace if necessary. Keeping the slide blocks replaced when required will greatly extend the life of the compactor floor and sides. · Check condition of cylinder pivot pins and wear bushings. Replace as necessary. · Open top inspection cover plate and clean out any accumulation of waste material. Wash area and replace cover. If build-up is significant, then a more frequent clean-out is advised. Too much accumulation and build-up of waste material can cause hydraulic hose and fitting failure. HYDRAULIC HOSE MAINTENANCE · INSPECT the hose assembly before each use. · REPLACE the hose assembly immediately if: a. The jacket of the hose appears abnormal. b. You have reason to believe it may be abnormal. c. There is any fluid leakage. d. The couplings are damaged. e. The hose is damaged or kinked. f. The reinforcement is visible through the jacket. · DO NOT EXCEED the maximum recommended working pressure of the hose. · DO NOT KINK the hose assembly. · DO NOT BEND the hose assembly beyond its minimum recommended bend radius. · DO NOT EXPOSE to temperatures in excess of 225° Fahrenheit. · DO NOT USE AS A STRENGTH MEMBER for pulling or lifting equipment. If replacing hydraulic hose, use only hose that meets or exceeds 3,000 PSI working pressure Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 39 All Rights Reserved LUBRICATION 1 2 KP2SC Self-Contained Compactor MAINTENANCE 1 2 1 2 2 Figure 15 40 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor MAINTENANCE RECOMMENDED HYDRAULIC FLUID Northland Talamar Extreme® LTE premium anti-wear hydraulic fluid is currently used for all K-PACTM stationary compactors. An ISO Viscosity grade of 15 is used to function properly in a broad range of ambient-temperature operating environments. The Talamar Extreme® LTE provides improved oil fluidity and pumpability at low temperatures and stable operating viscosities in high temperature applications. The following table provides the properties for Northland Talamar Extreme® LTE premium anti-wear hydraulic fluid. Hydraulic fluid can be used from a alternative vendor, but the fluid must meet the properties identified in the table. Also, any alternative hydraulic fluid must meet the performance specifications identified at the bottom of the table. PROPERTIES ISO Viscosity Grade Gravity Deg. API Specific Gravity Pour Point °F Flash Point °F, min. Viscosity: cST @ 40°C Viscosity: cST @ 100°C Viscosity: SUS @ 100°F Viscosity: SUS @ 210°F Viscosity Index, min Brookfield Viscosity, cP, max. @ -20°C Rust Test Foam Test, max. Dielectric Strength, KV min. STANDARD ASTM D2422 ASTM D287 ASTM D1298 ASTM D97 ASTM D92 ASTM D445 ASTM D2161 ASTM S2270 ASTM D2983 ASTM D892 ASTM D892 SPECIFICATION 15 33.5 0.857 -55 375 18 4.6 95 42 185 410 pass 10/0 20/0 10/0 35 PERFORMANCE SPECIFICATIONS Denison HF-0, HF-2 Vickers / Eaton M-2950-S 35VQ25 ASTM D2882 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 41 All Rights Reserved KP2SC Self-Contained Compactor MAINTENANCE GENERAL MAINTENANCE TIPS OIL Even if high-grade oil was installed at start-up, oil does become contaminated in time. Watch for discoloration, foaming or change in viscosity. Ambient conditions as to heat or foreign materials will contribute to problems. Dust and chemicals can be drawn into system vents. FILTERS After the start-up of a new system, filter and strainers need very special attention. Chips from pipe threads, metal particles, and other foreign materials can be introduced during hook-up. Clean or replace filter elements after the first month of operation. RELIEF VALVES The relief valve is the greatest source of pump and system protection. Likewise, the relief valve is usually the first item to give a warning of other problems. This valve is designed to fail open, or "fail-safe". Relief valve malfunction is most often due to contaminants in the fluid. This is a good time to clean up the system; flush-out, change filter, open and clean any valve passages if necessary. PUMP Pump noise is a definite sign of trouble. Check shaft alignment and condition of coupler first. Cavitation is another cause of pump noise. Check for a restricted suction line, undersized pipes if altered, or dirty filter or strainer. Look for a suction line leak, air getting into the suction line by way of the plumbing or low oil supply will cause pump noise as well as erratic and noisy valves. Finally, a worn pump will also feel hotter than the surface of the reservoir. System pressures will drop and cycle rates will become slower. If pump is replaced, be sure to change filters and check out the entire system during down time. Also, check cleanliness of oil at this time. HEAT Heat will be developed by all mechanical devices. The amount of heat will depend upon the use, duty cycle, proper adjustment, age, etc. Hydraulic power packs usually can throw off any excess heat by way of the surfaces of the plumbing and reservoir. Hydraulic power packs should operate in the range of 140° maximum, 160° absolute maximum. If your new power pack operates too hot, be sure you are using the correct viscosity range and high-grade oil specification. Also important that the oil level is up in the reservoir. Check for any partially open by-pass valves. Check for worn directional valves or leaking cylinders. Internal-system leaks at high pressure are the greatest source of heat. 42 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor SERVICE PLC PROGRAMMING PROCEDURE HOME MENU - When the PLC is initially powered, the Home Menu (Figure 16, 1) is displayed on the PLC con- trol screen. Notice the flashing date and time screen. To navigate to the Main Menu to change timer and cycle set- 1 tings, press the ESC button (Figure 16, 2) once. This will take you to the Main Menu. 2 STOP MENU - During normal operation, the top menu line will read Stop (Figure 17, 1). This indicates that the program is running. To stop the program, use the navigation buttons (Figure 17, 2) to place the cursor on the Stop menu line and then press the OK button (Figure 17, 3). Figure 16 1 2 3 STOP PROMPT MENU - A menu will be displayed prompting if you want to stop the program. To stop the program, use the navigation buttons (Figure 18, 1) to place the cursor on the choice of Yes (Figure 18, 2). After selecting the Yes choice, press the OK button (Figure 18, 3). Figure 17 2 1 3 Figure 18 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 43 All Rights Reserved SERVICE START MENU - When the top menu line reads Start (Figure 19, 1), this indicates that the program is not running. To start the program, navigate to the Start menu line by using the navigation buttons (Figure 19, 2) to place the cursor on the Start menu line and then press the OK button (Figure 19, 3). KP2SC Self-Contained Compactor 1 2 3 START PROMPT MENU - A menu will be displayed prompting if you want to start the program. To start the program, use the navigation buttons (Figure 20, 1) to place the cursor on the choice of Yes (Figure 20, 2). After selecting the Yes choice, press the OK button (Figure 20, 3). MAIN MENU - Check the top menu line to verify Stop (Figure 21, 1) is displayed indicating the program is running. If the menu line displays Start, use the previous menus to start the program. Use the navigation buttons (Figure 21, 2) to select the Program menu line (Figure 21, 3). After selecting, press the OK button to navigate to the Program menu. Figure 19 2 1 3 Figure 20 1 3 2 Figure 21 Check the top menu line on the Main menu to verify Stop (Figure 21, 1) is displayed indicating the program is running. 44 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor SERVICE PROGRAM MENU - The Program menu provides two menu options. To identify the Program Name, use the navigation buttons (Figure 22, 1) to select Prog Name menu line (Figure 22, 2). Select the OK button (Figure 22, 3) to navigate to the Prog Name menu. PROG NAME MENU - The Prog Name will be displayed in a text box (Figure 23, 1). To return to the previous menu, select the ESC button (Figure 23, 2). 2 1 3 Figure 22 1 2 PROGRAM MENU (Continued) - The Set Parameter menu (Figure 24, 1) provides access to the timer and cycle settings. Use the navigation buttons (Figure 24, 2) to select the Set Parameter menu line. Select the OK (Figure 24, 3) button to navigate to the Set Parameter menu. Figure 23 1 2 3 Figure 24 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 45 All Rights Reserved SERVICE KP2SC Self-Contained Compactor SET PARAMETER MENU - The Set Parameter menu provides access to the timer and cycle settings. To navigate between the menu lines, use the UP and Down navigation buttons (Figure 25, 1) to scroll through the menus. Select the OK button (Figure 25, 2) to navigate to the selected menu. 3 1 2 Figure 25 TIMER AND CYCLE SETTINGS Scrolling is required to access all of the menu name menus. Menu name menus starting with a capital "B" followed by 3 numeric digits should not be selected for editing. Do not access menu name menus starting with a capital "B" followed by 3 numeric digits. These menus names are preset and used to adjust program parameters. Use the remaining 9 menu names to access the timer and cycle settings. The following menu names can be selected using the navigation buttons (Figure 25, 1) to select. MENU EXTEND RETRACT AUTO C 80% CNT 80% LITE 100% CNT 100% LIT P-EYE P-DELAY DESCRIPTION Controls the time the ram cylinders will extend. The default setting is 20 seconds. Controls the time the ram cylinders will retract. The default setting is 15 seconds. Controls the number of cycles that the unit will complete when you depress the start button or the photo-eye is tripped. The default setting is 3 cycles. Controls when the 80% light comes ON. The default setting is 5. Is the timer that controls the time the signal is received before it is sent to the 80% CNT. The default setting is 5 seconds. Controls when the 100% light comes ON. The default setting is 6. Is the timer that controls the time the signal is received before it is sent to the 100% CNT. The default setting is 6.05 seconds. The function will shut down the compactor if the photo-eye becomes blocked for more than a period time. The default setting is 5 minutes. Time the compactor will delay the auto-cycle if triggered by the optional photo-eye. 46 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor SERVICE EXTEND MENU - The Extend menu (Figure 26, 1) is the first menu to appear. The menu sets the time the ram cyl- inders will extend. To change the time, press the OK button (Figure 26, 2) and a cursor should appear on the 1 extend time box (Figure 26, 3). Use the Up and Down navigation buttons (Figure 26, 4) to increase or decrease the time. The left or right arrows will allow you to make finer adjustments in tenths and hundredths of a second. The default setting is 19 seconds. After the desired time is obtained, press the OK button again to accept settings. All of the following timers and counters are adjusted in the same manner as previously described. The order in which they are described will correspond with the use of the Down navigation button. RETRACT MENU - The Retract menu (Figure 27, 1) sets the time the ram cylinders will retract. The default setting is 15 seconds (Figure 27, 2). After the desired time is obtained, press the OK button (Figure 27, 3) 1 again to accept settings. 3 4 2 Figure 26 2 3 AUTO C MENU - Auto C (Figure 28, 1) function controls the number of cycles that the unit will complete after the start button is pressed or the photo eye is tripped. The 1 factory setting is 3 cycles (Figure 28, 2). Figure 27 2 Figure 28 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 47 All Rights Reserved SERVICE KP2SC Self-Contained Compactor 80% CNT MENU - The 80% CNT (Figure 29, 1) func- tion controls at what point the 80% light comes On. The default setting is set at five (Figure 29, 2), which means that after a total of five signals are received from the 80% 1 2 LITE MENU, the 80% light will be triggered to come On. The 80% CNT must be set lower than the 100% CNT, otherwise the 100% light will come On before the 80% light. 80% LITE MENU - The 80% LITE (Figure 30, 1) menu is the timer that controls the time required before a signal is sent to the 80% CNT. The default setting is five seconds (Figure 30, 2). For example if the pressure switch is 1 tripped for more than 5 seconds while the unit is in the auto mode and the ram is extending, it will send a signal to the 80% CNT counter. Figure 29 2 100% CNT MENU - The 100% CNT (Figure 31, 1) func- tion controls at what point the 100% light comes On. The default setting is set at six (Figure 31, 2), which means that after a total of six signals are received from the 100% 1 LIT MENU, the 100% light will be triggered to come On. To reset the 100% light after it has come On, depress the Emergency Stop. After depressing, pull Up again to resume normal operation. Figure 30 2 Figure 31 48 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor SERVICE 100% LIT MENU - The 100% LIT (Figure 32, 1) menu is the timer that controls the time required before a signal is sent to the 100% CNT. It's default setting is 6.05 seconds (Figure 32, 2). For example if the pressure switch is 1 2 tripped for more than 6.05 seconds while the unit is in the auto mode and the ram is extending, it will send a signal to the 100% CNT counter. Figure 32 It is important that the 100% LIT timer is set longer than the 80% LITE timer or else the 100% light will trigger before the 80% light. P-EYE MENU - The P-EYE function (Figure 33, 1) will shut down the compactor if the photo eye becomes blocked for more than a predetermined time. The default setting for the P-EYE function is 5 minutes 1 2 (Figure 33, 2). This function prevents the unit from run- ning indefinitely and overheating, also known as auto shut-down. If this timer is tripped, the Emergency Stop must be shut OFF and switched ON to reset and resume normal operation. P-DELAY MENU - The P-DELAY (Figure 34, 1) is the time in which the compactor will delay the auto cycle if triggered by the photo-eye. The default setting is 4 seconds (Figure 34, 2). This feature is used so that the 1 photo-eye must send a signal to the PLC for 4 seconds before it starts the auto-cycle. Figure 33 2 Figure 34 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 49 All Rights Reserved MAIN RELIEF ADJUSTMENT SERVICE KP2SC Self-Contained Compactor 1 Figure 35 1. Disconnect Power Pack hoses from compactor to eliminate the ram cylinders with built in by-pass. 2. Locate pressure gage installed on Power Pack. 3. Select the MANUAL mode on the MANUAL/AUTO Switch (Figure 16, 2) located on the control panel. 4. Turn the FWD/OFF/REV Switch counter-clockwise to the FWD position to activate the extend function. 5. Hydraulic pressure will build against the uncoupled Quick Couplers. 6. Observe the pressure reading on the pressure gage. Release the FWD/OFF/REV Switch and it will return to the OFF position. 7. If pressure was not 2,100 psi or pressure desired then continue on. 8. Loosen relief valve lock nut (Figure 35, 1) and turn relief clock-wise to raise or counter-clockwise to lower as required. Maximum pressure setting is 2,100 PSI and must not be exceeded. 9. Retighten relief valve lock nut. 10. Repeat steps 4 through 8. If the pressure reading was 2,100 psi, the main relief is properly set. 11. Reconnect the hoses to compactor and restart unit to check operation. 50 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor PRESSURE SWITCH ADJUSTMENT SERVICE 1 2 Figure 36 1. Refer to the MAIN RELIEF ADJUSTMENT procedure and lower the main relief setting to 1850 psi. 2. Locate the pressure switch (Figure 36, 1) installed below the control panel on the Power Pack. 3. Remove the locking screw (Figure 36, 2) from the switch to enable the switch to be adjusted. 4. Make 12 turns counter-clockwise to lower the switch setting. 1 Pressure Switch On Figure 37 5. Repeat the procedure for setting the main relief and monitor the screen on the PLC in the control panel to determine if the pressure switch signal was received. A message (Figure 37, 1) will be displayed on the PLC screen when the pressure switch signal is received. 6. If a pressure switch signal was not received, turn the pressure switch clock-wise a partial turn and repeat the procedure. 7. Repeat until the pressure switch signal is received. This indicates the pressure switch is properly set at 1,850 psi. 8. Insert and tighten the locking screw so the pressure switch maintains its adjustment. 9. Reset the main relief to its original setting of 2,100 psi. Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 51 All Rights Reserved CYLINDER PIVOT PIN INSPECTION SERVICE KP2SC Self-Contained Compactor 1 12 3 Figure 38 1. Remove access cover (Figure 38, 1) as shown. 2. Remove pin at each end of cylinder by removing bolt and pin (Figure 38, 2). Check condition of pin and bushing in cylinder (Figure 38, 3). If pin or bushing show significant wear, replace. 3. When re-installing pins, make sure retaining pin is tightened securely. 52 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor SCHEMATICS CONTROL PANEL VOLTAGE OPTIONS The Power Pack control panel is available in three different voltage options. The available voltage options are 208, 230 and 460 Volt AC. During manufacturing the control panel will be wired to the voltage specified on the sales order. The only control panel differences between voltages is the wiring of the Control Transformer. The transformer has multiple terminals that are used to set the appropriate voltage setup. CONTROL TRANSFORMER WIRING 208 VOLT AC - The 103 wire is attached to the H2 terminal (Figure 39, 1) on the Control Transformer. 230 VOLT AC - The 103 wire is attached to the H3 terminal (Figure 39, 2) on the Control Transformer. 460 VOLT AC - The 103 wire is attached to the H4 terminal (Figure 39, 3) on the Control Transformer. 1 2 3 1.5 amp 103 1 1.5 amp 104 H1 H2 H3 H4 3 amp 107B 115 VAC X1 X2 107C 1.5 amp 103 2 1.5 amp 104 H1 H2 H3 H4 3 amp 107B 115 VAC X1 X2 107C 1.5 amp 103 3 1.5 amp 104 H1 H2 H3 H4 Figure 39 3 amp 107B 115 VAC X1 X2 107C Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 53 All Rights Reserved KP2SC Self-Contained Compactor SCHEMATICS POWER PACK ELECTRICAL SCHEMATIC 208, 230, 460 VAC, 10HP, 3 PHASE, 60 HERTZ Section "A" Section "B" CUSTOMER SUPPLIED MAIN DISCONNECT 100 101 102 SET OVERLOADS PER MOTOR NAMEPLATE/VOLTAGE PUMP MOTOR M 1.5 amp 103 1.5 amp 104 KEY SWITCH (OPTION) (OPTION) (OPTION) 107 107C 107B 107A 3 amp 107B H1 H2 H3 H4 115 VAC X1 X2 TRANSFORMER 107C (OPTION) (OPTION) E-STOP 109B 109A 109 107A START PB (OPTION) E-STOP 115C 115B AUTO MANUAL (OPTION) PRESSURE SWITCH FORWARD OFF REVERSE FORWARD 121 OFF 123 REVERSE DOOR SW (OPTION) 107 L+ 113 I1 115 I2 117 I3 119 I4 121 I5 123 I6 125 I7 127 I8 M 107C Q1-1 109 Q1-2 115A Q2-1 109 Q2-2 119A Q3-1 109 Q3-2 123A Q4-1 109 Q4-2 127A RAM FWD SOLENOID RAM REV SOLENOID R 100% FULL LIGHT R [OPTION] HYD PUMP MOTOR 54 Section "C" 107 107C 107 LOW OIL (OPTION) 107 L1 107C N 130 I1 Q1-1 24VDC+ Q1-2 131 109 Q2-1 Q2-2 133 BRN YEL PHOTO 502408 EYE BLU BLK WHT PHOTO EYE 132 (OPTION) Q3-1 24VDC+ I2 Q3-2 135 I3 Q4-1 107A I4 Q4-2 137 502408 DRIVER LIGHT R 24 VDC POWER SUPPLY V- V+ 24VDC- 24VDC+ 107 L N 107C VISUAL ALARM A 80% FULL A LIGHT A (OPTION) 24VDC- AUDIBLE ALARM Section "D" WATLOW HEATER CARTRIDGE 502214 [OPTIONAL] 1 6 2 7 WATLOW CF 3 HEATER 8 CONTROLLER 4 502215 9 5 [OPTIONAL] 10 1.5 amp 107C 107A Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor SCHEMATICS ELECTRICAL SCHEMATIC SECTIONS Section "A" CUSTOMER SUPPLIED MAIN DISCONNECT 100 101 102 SET OVERLOADS PER MOTOR NAMEPLATE/VOLTAGE PUMP MOTOR M 1.5 amp 103 1.5 amp 104 KEY SWITCH (OPTION) (OPTION) (OPTION) 107 107C 107B 107A 3 amp 107B H1 H2 H3 H4 115 VAC X1 X2 TRANSFORMER 107C 107A Section "B" (OPTION) (OPTION) E-STOP 109B 109A 109 START PB (OPTION) E-STOP 115C 115B AUTO MANUAL (OPTION) PRESSURE SWITCH FORWARD OFF REVERSE FORWARD 121 OFF 123 REVERSE DOOR SW (OPTION) 107 L+ 113 I1 115 I2 117 I3 119 I4 121 I5 123 I6 125 I7 127 I8 M 107C Q1-1 109 Q1-2 115A Q2-1 109 Q2-2 119A Q3-1 109 Q3-2 123A Q4-1 109 Q4-2 127A RAM FWD SOLENOID RAM REV SOLENOID R 100% FULL LIGHT R [OPTION] HYD PUMP MOTOR 107 107C 107A 107 109 107C 107A Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 55 All Rights Reserved Section "C" KP2SC Self-Contained Compactor SCHEMATICS 109 107C 107A 107 107C 107A 107 107C 107 LOW OIL (OPTION) 107 L1 107C N 130 I1 Q1-1 24VDC+ Q1-2 131 109 Q2-1 Q2-2 133 BRN YEL PHOTO 502408 EYE BLU BLK WHT PHOTO EYE 132 (OPTION) Q3-1 24VDC+ I2 Q3-2 135 I3 Q4-1 107A I4 Q4-2 137 502408 DRIVER LIGHT R 24 VDC POWER SUPPLY V- V+ 24VDC- 24VDC+ 107 L N 107C VISUAL ALARM A 80% FULL A LIGHT A (OPTION) 24VDC- AUDIBLE ALARM Section "C" WATLOW HEATER CARTRIDGE 502214 [OPTIONAL] 1 6 2 7 WATLOW CF 3 HEATER CONTROLLER 8 4 502215 9 5 [OPTIONAL] 10 1.5 amp 107C 107A 107C 107A 56 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor SCHEMATICS HYDRAULIC SCHEMATIC 10HP, 3 PHASE, 60-HERTZ 13 13 12 11 3 4 1 9 8 10 5 2 6 7 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 57 All Rights Reserved KP2SC Self-Contained Compactor SCHEMATICS HYDRAULIC SCHEMATIC 10HP, 3 PHASE, 60-HERTZ Item 1 2 3 4 4 4 5 6 7 8 9 10 11 12 13 Part Number 500864 502111 501849 503159 503160 503161 503141 503148 503153 503140 503149 500849 503147 500719 500405 Qty Description 1 RESERVOIR, 18 GAL 1 STRAINER 1 ELECTRIC MOTOR, 10 HP, 3 PHASE, 60 HERTZ 1 COUPLER, PUMP 1 SPIDER, JAW COUPLING 1 COUPLER, MOTOR 1 PUMP, GEAR, 12 GPM 1 BREATHER, FILTER 1 SITE GLASS, 5" 1 MANIFOLD 1 DIRECTIONAL VALVE 1 RELIEF VALVE, 2,100 PSI 1 PRESSURE GAGE 1 PRESSURE SWITCH, 1,850 PSI 2 RAM CYLINDER, BY-PASSING Note 58 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor PARTS OVERVIEW Many features have been utilized in the Parts section. Facing pages have been used to ensure the illustration is displayed with the parts list. Descriptions are indented to indicate when the component is included with the assembly. Notes are used to provide additional information. The following is a summary of the layout used for the parts list: 1 2 3 4 6 7 5 Figure 40 Item (Figure 40, 1) is used to reference the callout and leader in the illustration of the facing page. Part Number (Figure 40, 2) identifies a component or assembly part. A part number is used when the part can be ordered as a replacement. A part that is not available to be ordered is identified with NSS indicating the part is Not Serviced Separately. Qty (Figure 40, 3) indicates the quantity required by its parent part number. In some situations the quantity required can vary. In these situations the quantity is not specified. The quantity is identified with AR indicating to use the quantity As Required. Description (Figure 40, 4) describes the component or assembly part. The description will include information relative to size, type or application. Bullets (Figure 40, 5) are used at the beginning of the Description to identify the indention level for the Part Number. All Part Numbers with descriptions indented an additional level are included when ordering the Part Number with the previous indention level. Note (Figure 40, 6) is used to indicate when additional information is available for a Part Number. A Note is identified by a N1, N2, etc. The capital letter N indicates that it is a Note followed by an unique identifier number. Notes are located at the bottom (Figure 40, 7) of the Parts Table using the identifier. Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 59 All Rights Reserved CONTAINER Door and Hinges Illustration PARTS KP2SC Self-Contained Compactor 4 5 8 9 7 10 11 6 1 3 60 12 14 15 13 2 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved Reference: 500906 KP2SC Self-Contained Compactor PARTS CONTAINER Door and Hinges Parts List Item 1 1 2 3 3 4 5 6 7 8 9 10 11 12 13 14 15 Part Number 100016 501384 502949 502948 502949 500711 500708 101042 500707 500569 100018 101407 100016 500537 100805 122196 100499 501927 Qty Description 1 DOOR WELDMENT, STANDARD 1 DOOR WELDMENT, LOW PROFILE 2 DOOR SEAL, HORIZONTAL, 80" 2 DOOR SEAL, VERTICAL, STANDARD, 93" 2 DOOR SEAL, VERTICAL, LOW PROFILE, 80" 2 DOOR HINGE 2 PIN, DOOR HINGE 2 COTTER PIN AR SHIM, SIDE AR SHIM, REAR 10 WASHER, FLAT 10 WASHER, SPLIT 10 BOLT, HHCS, .75-10 X 2.5, GR5 1 COVER, FIRE HOSE PORT 1 BOLT, JJCS, .5-13X1, GR5 1 WASHER, FLAT, .5, ZN 1 NUT, HEX, LOCK, REV, .5-13, ZN AR GLUE, ADHESIVE SEALANT N1 GLUE (501927) REQUIRED WHEN INSTALLING DOOR SEALS Note N1 N1 N1 N1 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 61 All Rights Reserved CONTAINER Door Latch Linkage Illustration PARTS KP2SC Self-Contained Compactor 8 1 5 4 2 7 6 3 10 11 9 Reference: 500906 62 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor PARTS CONTAINER Door Latch Linkage Parts List Item 1 2 3 4 5 6 7 8 9 10 11 Part Number 500572 100571 101018 111235 500573 500574 500575 500576 500717 NSS NSS Qty Description 2 LATCH, DOOR, KP2SC 2 BOLT, HHCS, 1-8X3, GR8 5 NUT, HEX, LOCK, TOP, 1-8, GR8, ZN 7 WASHER, FLAT, 1, USS, ZN 1 DOOR LINK, PLATE, KP2SC 1 PIVOT PLATE, KP2SC 1 CONNECTING LINK, PLATE, KP2SC 1 DOOR CATCH, PLATE, 1 TURNBUCKLE 2 · BOLT 2 · NUT Note Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 63 All Rights Reserved PARTS CHAMBER Cover Plate, Rollers and Ram Blocks Illustration KP2SC Self-Contained Compactor 11 10 9 8 7 2 3 45 1 13 12 6 Reference: 500906 64 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor PARTS CHAMBER Cover Plate, Rollers and Ram Blocks Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 Part Number 500581 500577 107154 109547 113661 120713 500051 500406 120094 120945 500430 500475 500476 Qty Description 4 FLOOR ROLLER WLDT, KP2SC 4 AXLE WLDT, KP2SC 4 GREASE ZERK, .125 NPT 4 BOLT, HHCS, .5-13X1.5, GR5, ZN 4 WASHER,SPLIT LOCK,.5, ZINC 4 ROLL PIN, SLOTTED, .375 X 2.5 8 SCREW, THD CUT, .375-16X.75, ZN 1 COVER, TOP, HEAD, KP2SC 2 BOLT, HHCS, .375-16X2, GR5, ZN 2 NUT, HEX, LOCK, TOP, .375-16, ZN 2 STOP, .625X1X2.5, KP2SC 4 NOSE ROLLER, KP2SC 4 AXLE, ROLLER, KP2SC Note Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 65 All Rights Reserved PARTS CHAMBER Ram and Follower Assembly Illustration KP2SC Self-Contained Compactor 4 5 2 1 3 Reference: 500906 66 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor PARTS CHAMBER Ram and Follower Assembly Parts List Item 1 2 3 4 5 Part Number 113018 122298 500886 500424 500451 Qty Description 16 WASHER, .50, ZINC PLATE 8 BOLT, HHCS, .5-13X2, GR8, ZN&YL 2 SLIDE BLOCK, UHMW 1 RAM PACK PANEL WLDT, KP2SC 1 SLIDE COVER WLDT, KP2SC Note Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 67 All Rights Reserved PARTS CHAMBER Ram Cylinders and Mounting Illustration KP2SC Self-Contained Compactor 3 2 4 5 1 Reference: 500906 68 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor PARTS CHAMBER Ram Cylinders and Mounting Parts List Item 1 2 3 4 5 Part Number 500405 500411 120944 113018 120946 Qty Description 2 RAM CYLINDER, 4X37, BY-PASS 4 PIN, WELDMENT, CYLINDER 4 BOLT, HHCS, .5-13X1.75, GR 5 4 WASHER, .5, ZINC PLATE 4 NUT, HEX, LOCK, TOP, .5-13, ZN Note Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 69 All Rights Reserved CHAMBER Ram Cylinder Hydraulics Illustration PARTS KP2SC Self-Contained Compactor 4 2 1 8 8 3 9 6 4 5 7 1 10 2 3 11 6 5 Reference: 500906 70 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor PARTS CHAMBER Ram Cylinder Hydraulics Parts List Item 1 2 3 4 5 6 7 8 9 10 11 Part Number 502952 502951 100108 102290 101081 101104 109926 502950 105811 109926 110912 Qty Description 2 HOSE ASSY, 45", H3008-08FX0N-08FX0N-45 2 HOSE ASSY, 29", H3008-08FX0N-08FX0N-29 2 ELBOW 90°, JIC TO O-RING, 8MJ-12MO-9N 2 ADAPTER, JIC TO O-RING, 8MJ-12MO-0N 4 BULKHEAD UNION W/ LOCKNUT, JIC, 8MJ-8BH-0N 4 SWIVEL RUN TEE, JIC, 8MJ-8FX-8MJ-RN 2 ADAPTER, JIC TO PIPE, 8MP-8FX-ON 2 HOSE ASSY, 66", H3008-08FXON-66-2 1 QUICK DISCONNECT FEMALE COUPLER, .5 NPT, 4250-4 1 QUICK DISCONNECT MALE NIPPLE, .5 NPT, 8010-4 2 CAP, JIC, 8FJ-C Note Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 71 All Rights Reserved CONTROL PANEL Panel Cover Illustration PARTS KP2SC Self-Contained Compactor 2 1 3 4 100% FULL 80% FULL FW D/O FF/REV OFF ON M A N U A L/A U T O 5 6 START E-STOP 7 Item 1 2 Part Number NSS 502376 502377 NSS 503833 502471 Reference: 500301 500305 502212 Qty Description 1 INDICATOR LAMP, 100% FULL, RED 1 · HEAD ONLY, PILOT LIGHT, RED 1 · COMPLETE LIGHT BODY, RED 1 INDICATOR LAMP, 80% FULL, ORANGE 1 · HEAD ONLY, PILOT LIGHT, ORANGE 1 · COMPLETE LIGHT BODY, ORANGE Note N1 N1 72 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor PARTS CONTROL PANEL Panel Cover Parts List Item 3 4 5 6 7 Part Number NSS 132785 NSS 127244 123551 NSS 503134 NSS 127244 123551 NSS 503135 NSS 127244 123551 123328 NSS 502469 NSS 127244 123551 NSS 503136 NSS 127244 123328 110834 Qty Description 1 3-POSITION SWITCH, FWD/OFF/REV 1 · HEAD ONLY, SELECTOR SWITCH, SPRING RETURN 1 · CONTACT BLOCKS - DOUBLE, NO 1 ·· BODY/FIXING COLLAR 2 ·· SINGLE CONTACT BLOCK, NO 1 SELECTOR SWITCH, OFF/ON, KEYED 1 · HEAD ONLY, KEYED SWITCH, STAY PUT 1 · CONTACT BLOCKS - SINGLE, NO 1 ·· BODY/FIXING COLLAR 1 ·· SINGLE CONTACT BLOCK, NO 1 SELECTOR SWITCH, MANUAL/AUTO 1 · HEAD ONLY, SELECTOR SWITCH, STAY PUT 1 · CONTACT BLOCKS - DOUBLE, NO/NC 1 ·· BODY/FIXING COLLAR 1 ·· SINGLE CONTACT BLOCK, NO 1 ·· SINGLE CONTACT BLOCK, NC 1 PUSH BUTTON, START, GREEN, FLUSH 1 · HEAD ONLY, PUSH BUTTON, GREEN 1 · CONTACT BLOCK - SINGLE, NO 1 ·· BODY/FIXING COLLAR 1 ·· SINGLE CONTACT BLOCK, NO 1 MUSHROOM-HEADED, E-STOP, PUSH BUTTON 1 · HEAD ONLY, EMERGENCY SWITCH, RED 1 · CONTACT BLOCKS - DOUBLE, NC 1 ·· BODY/FIXING COLLAR 2 ·· SINGLE CONTACT BLOCK, NC 1 · LEGEND, CIRCULAR YELLOW, EMERGENCY STOP Note N2 N2 N2 N2 N2 N1 INCLUDES FIXING COLLAR AND LIGHT BLOCK WITH INTEGRAL LED N2 INCLUDES BODY/FIXING COLLAR Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 73 All Rights Reserved CONTROL PANEL Inside Panel Illustration PARTS KP2SC Self-Contained Compactor 5 6 7 8 2 1 3 4 Reference: 500301 500305 502212 74 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor PARTS CONTROL PANEL Inside Panel Parts List Item 1 2 3 4 5 6 7 8 Part Number 502345 502373 511003 502266 503137 503138 503059 503139 Qty Description 1 PROGRAMMABLE RELAY (SMART) 1 EXPANSION I/0 MODULE 1 MODULE, MOTOR STARTER POWER BASE 1 MODULE, OVERLOAD 1 CONTROL TRANSFORMER, 150VA, 208/230/460 VAC 1 POWER DISTRIBUTION BLOCK 2 FUSE, 1-1/2 AMP, 600V 1 FUSE, MIDGET, 3 AMP, 250V Note Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 75 All Rights Reserved POWER PACK Assembly Illustration PARTS KP2SC Self-Contained Compactor 1 2 3 100% FULL 80% FULL FW D/O FF/REV OFF ON M A N U A L/A U T O START E-STOP 4 Reference: 501261 76 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor PARTS POWER PACK Assembly Parts List Item 1 2 3 4 4 4 Part Number 500580 500769 500768 502212 500301 500305 Qty Description 1 COVER, MOTOR AND PUMP 1 BACK PLATE 1 COVER, CONTROL PANEL 1 CONTROL PANEL ASSY, 208 VAC, 10 HP, THREE PHASE 1 CONTROL PANEL ASSY, 230 VAC, 10 HP, THREE PHASE 1 CONTROL PANEL ASSY, 460 VAC, 10 HP, THREE PHASE Note Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 77 All Rights Reserved POWER PACK Hydraulic Reservoir Illustration PARTS KP2SC Self-Contained Compactor 9 8 7 6 7 1 3 5 2 18 4 13 14 11 12 10 17 16 15 Reference: 501261 78 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor PARTS POWER PACK Hydraulic Reservoir Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Part Number 502345 503153 NSS NSS NSS NSS 503148 NSS NSS NSS NSS 503153 NSS NSS NSS 500921 124549 502111 108881 501260 102765 Qty Description 1 RESERVOIR, W/C 1 CLEAN-OUT COVER ASSY 1 · COVER, CLEAN-OUT 1 · BOLT, .625 UNC X 3 1 · GASKET, CLEAN-OUT COVER 1 · WASHER, FLAT, .625 1 FILLER, STRAINER AND BREATHER ASSY, 6", 40 MICRON 1 · BASKET, STAINLESS 2 · GASKET, CORK 1 · FLANGE 1 · CAP, BREATHER 1 LEVEL/TEMP GAUGE ASSY 1 · LEVEL/TEMP GAUGE 2 · HOLLOW BOLT, .5-13 UNC X 1.75" 2 · WASHER 1 NIPPLE, PIPE, 1" NPT X 12" 1 90° STREET ELBOW, PIPE, 1" NPT 1 SUCTION FILTER 1 PLUG, MAGNETIC, PIPE, 3/4" NPT 1 PLUG, PIPE, 1/2" NPT 1 PLUG, PIPE, 2" NPT Note N1 N2 N3 F4 N1 INCLUDES ITEMS 3, 4, 5 AND 6 N2 INCLUDES ITEMS 6, 7, 8 AND 9 N3 INCLUDES ITEMS 10, 11 AND 12 N4 MAX TIGHTENING TORQUE SUGGESTED 4 FT-LBS Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 79 All Rights Reserved POWER PACK Pump Hydraulics Illustration PARTS KP2SC Self-Contained Compactor 26 9 5 6 7 8 4 10 1 3 26 11 12 18 16 2 15 13 17 19 21 14 25 20 24 23 22 Reference: 501261 80 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor PARTS POWER PACK Pump Hydraulics Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Part Number 503141 503155 106401 500719 503144 503145 503146 503147 503143 503149 100100 110968 503142 101098 101113 107610 500849 503140 503154 503150 501850 NSS NSS NSS NSS NSS 112607 Qty Description Note 1 PUMP, GEAR 1 HOSE ASSY, 46", H3004-04FX0N-04FX0N-46 1 ADAPTER, JIC TO PIPE, 4MJ-4FP-0N 1 PRESSURE SWITCH 1 BRANCH TEE, JIC TO O-RING, 10MJ-10MJ-12MO-TN 1 ADAPTER, JIC SWIVEL TO PIPE, 10FX-6MP-0N 1 ADAPTER, 90° SWIVEL ELBOW, PIPE TO PIPE, 4FP-6FX-9N 1 GAUGE, PRESSURE 1 TUBE ASSY, PRESSURE 1 VALVE ASSY 1 ADAPTER, JIC TO O-RING, 16MJ-16MO-0N 1 ADAPTER, JIC SWIVEL TO PIPE, 16FX-16FP-0N 1 PIPE, SUCTION, 12 IN 1 ADAPTER, JIC TO O-RING, 8MJ-8MO-0N 1 ADAPTER, 90° ELBOW, JIC TO O-RING, 8MJ-8MO-9N 1 PLUG, O-RING, 6MO-P-HH 1 VALVE, RELIEF, 3,000 PSI 1 MANIFOLD, VALVE 1 RUN TEE, JIC TO O-RING, 8MJ-8MO-4MJ-RN 1 PIPE, RETURN, 12" 1 SUCTION FLANGE ASSY, 1" PIPE N1 1 · BOLT, HEX HEAD, .312-18 UNC X 1, ZN 1 · BASE PLATE 1 · GASKET, CORK 1 · SEAL, RUBBER 2 · TOP PLATE 6 SCREW, SOCKET HEAD, .25-20 X 2 N1 INCLUDES ITEMS 21, 22, 23, 24 AND 25 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 81 All Rights Reserved POWER PACK Motor and Pump Illustration PARTS KP2SC Self-Contained Compactor 1 2 3 4 5 6 7 8 9 10 11 12 Reference: 501261 82 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved KP2SC Self-Contained Compactor PARTS POWER PACK Motor and Pump Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 Part Number 113241 104661 501849 503161 503160 503159 503151 100498 121464 503141 100498 121464 Qty Description 4 BOLT, HHCS, .375-16 X 1.5, GR5, ZN 4 WASHER, LOCK-SPLIT, .375, ZN 1 MOTOR, ELECTRIC, 3 PHASE, 10 HP 1 COUPLER, MOTOR 1 SPIDER, COUPLER 1 COUPLER, PUMP 1 ADAPTER, MOTOR/PUMP, 10 HP 4 WASHER, LOCK, SPLIT, .5 4 BOLT, HHCS, .5-13 X 2, GR5, ZN 1 PUMP, GEAR 2 WASHER, LOCK, SPLIT, .5 2 BOLT, HHCS, .5-13X2, GR5, ZN Note Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies 83 All Rights Reserved PARTS KP2SC Self-Contained Compactor This Page Intentionally Left Blank 84 Copyright© 6/2021 K-PACTM Compactors, a product of McLaughlin Family Companies All Rights Reserved