McLaughlin New Way K-PAC KP03 User Manual Download

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KP03 Mini Apartment Compactor

TABLE OF CONTENTS

iii

7/2021 K-PAC

™

Compactors, a product of McLaughlin Family Companies

SERVICE

PLC PROGRAMMING PROCEDURE  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  59
TIMER AND CYCLE SETTINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  62
MAIN RELIEF ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  67
PRESSURE SWITCH ADJUSTMENT  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  68

SCHEMATICS

CONTROL PANEL VOLTAGE OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

CONTROL TRANSFORMER WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

POWER PACK ELECTRICAL SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

208, 230, 460 VAC, 3HP, 3 PHASE, 60 HERTZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
ELECTRICAL SCHEMATIC SECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Section "A". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  71
Section "B". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  71
Section "C". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  72
Section "D". . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  72

HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

3HP, 3 PHASE, 60-HERTZ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

PARTS

OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Panel Cover Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  76
Panel Cover Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  77
Inside Panel Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  78
Inside Panel Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  79

POWER PACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

VARIABLES (Remove from book before publishing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Summary of Contents for New Way K-PAC KP03

Page 1: ...2 K PAC Compactors a product of McLaughlin Family Companies All Rights Reserved USER MANUAL Item No 144433 Rev A INCLUDES THE FOLLOWING INFORMATION Operation Installation Service Parts KP03 Mini Apart...

Page 2: ...RMATION 13 SAFETY ALERT SYMBOL 13 SAFETY ALERTS 14 SAFETY DECAL REQUIREMENTS 15 COMPACTOR SAFETY DECALS 15 SAFETY DECAL LOCATIONS 16 SAFETY DECAL IDENTIFICATION 17 CONTAINER SAFETY DECALS 17 SAFETY DE...

Page 3: ...ROL 41 OPERATING INSTRUCTIONS FOR STANDARD COMPACTORS 42 AUTO MODE 42 MANUAL MODE 42 CONTAINER FULL LIGHTS 42 ELECTRIC EYE OPTION 43 DISCONNECT AND EMPTY CONTAINER CONTAINER FULL LIGHTS 45 PREPARE COM...

Page 4: ...PHASE 60 HERTZ 70 ELECTRICAL SCHEMATIC SECTIONS 71 Section A 71 Section B 71 Section C 72 Section D 72 HYDRAULIC SCHEMATIC 73 3HP 3 PHASE 60 HERTZ 73 PARTS OVERVIEW 75 CONTROL PANEL 76 Panel Cover Il...

Page 6: ...fety Installation Operation Start Up Maintenance Service Schematics and Parts ABOUT K PAC K PAC Equipment a division of New Way has established itself as a leader in innovation and dependability in th...

Page 7: ...short newaytrucks com ARKANSAS To get started contact your local regional sales manager SCOTT RUPIPER 712 634 0064 srupiper newaytrucks com CALIFORNIA To get started contact your local regional sales...

Page 8: ...N 46371 OFC 800 833 2591 Serving these counties Boone Cook DeKalb BuPage Grundy Kane Kankakee Kendall Lake LaSalle Lee Livingston McHenry Will Winnebago INDIANA To get started contact your local regio...

Page 9: ...800 833 2591 MINNESOTA To get started contact your local regional sales manager SCOTT RUPIPER 712 634 0064 srupiper newaytrucks com MISSISSIPPI To get started contact your local regional sales manage...

Page 10: ...sales manager MIKE CASSOTTA 712 634 6386 mcassotta newwaytrucks com NORTH DAKOTA To get started contact your local regional sales manager SCOTT RUPIPER 712 634 0064 srupiper newaytrucks com OHIO To g...

Page 11: ...ence Lewis Lincoln Loudon Macon Marion Marshall Maury McMinn Meigs Montomery Moore Monroe Morgan Overton Perry Pickett Polk Putnam Rhea Roane Robertson Rugherford Scott Secquatchie Sevier Smith Stewar...

Page 12: ...al sales manager MIKE CASSOTTA 712 634 6386 mcassotta newwaytrucks com MunicipalEquipment OFC 800 248 7590 WISCONSIN To get started contact your local regional sales manager JOSH ISER 712 634 6384 jis...

Page 14: ...tment compactor A unique 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...

Page 15: ...pressure with its energy saving 3HP motor than most competitors 5HP motor models SPECIFICATIONS KP03 SPECIFICATIONS Charge Chamber Capacity a Manufacturer s Rating 1 3 yd3 b WASTEC Rating 25 yd3 Clea...

Page 16: ...11 Copyright 7 2021 K PAC Compactors a product of McLaughlin Family Companies All Rights Reserved DIMENSIONS CHUTE HOPPER FULL ENCLOSED HOPPER 21 0 31 0 41 0 30 0 24 19 34 0 74 0 43 5 35 5 68 0 21 0...

Page 18: ...these materials Failure to do so can result in serious injury or death SAFETY ALERT SYMBOL Elimination of the hazards listed in this manual should not be construed as providing guarantees that the eq...

Page 19: ...al 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 qu...

Page 20: ...equipment COMPACTOR SAFETY DECALS Depending on the Compactor configuration and optional equipment the actual location of the decals and or placards may vary slightly from the examples shown Specificat...

Page 22: ...02848 502859 502844 502853 No Part Number Qty Description 1 123550 2 K PAC LOGO Small 2 502842 1 DANGER Do not stand under the raised container 3 101439 1 CAUTION Stand clear when container is being l...

Page 23: ...ni Apartment Compactor SAFETY 18 Copyright 7 2021 K PAC Compactors a product of McLaughlin Family Companies All Rights Reserved SAFETY DECAL LOCATIONS SAFETY DECAL IDENTIFICATION 123550 502842 101437...

Page 24: ...ls shall be located outside the area and beyond the reach of the compactor 5 106403 2 WARNING Do not operate malfunctioning equipment 6 134892 2 SAFETY INSTRUCTIONS Before entering or climbing on comp...

Page 25: ...GENCY switch UP to activate the compactor controls 2 Insert key in ON OFF key switch and turn to ON 3 On the MANUAL AUTO switch select AUTO 4 Press the START button to arm the compactor system It will...

Page 26: ...0 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 DEFINITI...

Page 27: ...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...

Page 28: ...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 atte...

Page 30: ...nergy 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 requi...

Page 31: ...trols Off 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 L...

Page 32: ...erride 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 cylinders Disable the Powe...

Page 33: ...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 tha...

Page 34: ...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...

Page 35: ...oring The compactor Figure 6 2 should be anchored to concrete pad using 3 4 diameter anchor bolts The use of ITW Red Head Trubolt Wedge Anchors or equivalent anchor bolts is recommended To allow for m...

Page 36: ...red as required by the customer Figure 8 8 Hydraulic Hose Connections Hydraulic hoses are connected to and shipped with the Power Pack The standard length for the hoses is 12 feet unless a different l...

Page 37: ...meet or exceed any local code See the inside of the control panel door on the Power Unit for the electrical schematic Electrical schematics are also included in the SCHEMATICS section of this manual F...

Page 38: ...tor 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 11 1 on the cover of...

Page 39: ...ower 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 t...

Page 40: ...C Compactors a product of McLaughlin Family Companies All Rights Reserved Figure 13 0 0 1 B T 4 B L L E B A L E E S 3 0 1 D N G 7 2 1 L O 7 2 1 M 4 B L L E B A L E E S 2 0 1 U F A 2 0 1 U F 7 0 1 U F...

Page 42: ...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 th...

Page 43: ...mode 10 Quickly turn the FWD OFF REV Switch Figure 15 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 rot...

Page 44: ...hould 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 un...

Page 45: ...KP03 Mini Apartment Compactor START UP AND TESTING 40 Copyright 7 2021 K PAC Compactors a product of McLaughlin Family Companies All Rights Reserved This Page Intentionally Left Blank...

Page 46: ...urn 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 con...

Page 47: ...ter 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 complet...

Page 48: ...ycle the ram until the chamber is cleared To test this option block the electric eye with paper or cardboard by inserting it in front of the eye outside of the chamber There should be a delay time bef...

Page 50: ...OR TO SEPERATE CONTAINER Use the manual mode for operation procedures to prepare compactor for the safe removal of container Push DOWN on the EMERGENCY Switch Figure 16 1 to disable controls Pull UP o...

Page 51: ...NER FROM COMPACTOR Figure 19 After LOCKOUT TAGOUT has been applied the container can be separated from the compactor chamber Unlatch the container from the compactor by rotating the handle Figure 19 1...

Page 52: ...R TO BE DUMPED Figure 20 After separating the container from the compactor chamber secure the container to be emptied by a front loader Pull the side door Figure 20 1 down to close the container openi...

Page 53: ...forks Figure 21 3 into the sleeves of the container Move the front loader forward until the container slides all the way on the forks Raise the front loader arms Figure 21 4 to lift the container Rol...

Page 54: ...up Figure 22 1 Latch Figure 22 2 the side door in the open position On both top covers lock the latch Figure 22 3 to secure them in the closed position Roll the container to align with the compactor...

Page 55: ...tch Figure 16 3 and turn clockwise to ON position Rotate the MANUAL AUTO Switch Figure 16 2 to select the MANUAL position Operate Compactor controls to confirm the compactor is operating properly Sele...

Page 56: ...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 af...

Page 57: ...amage 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 op...

Page 58: ...ck 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 b...

Page 59: ...y fluid leakage f The couplings are damaged g The hose is damaged or kinked h The reinforcement is visible through the jacket DO NOT EXCEED the maximum recommended working pressure of the hose DO NOT...

Page 60: ...a tion monthly or every 200 hours A cover is provided to access the grease fittings Remove the cap screw Figure 24 1 on the top of the cover After removing the cap screw lift and raise the cover Figur...

Page 61: ...remium 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...

Page 62: ...inite 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...

Page 64: ...en To navigate to the Main Menu to change timer and cycle set tings press the ESC button Figure 26 2 once This will take you to the Main Menu Figure 26 STOP MENU During normal operation the top menu l...

Page 65: ...igure 28 START MENU When the top menu line reads Start Figure 29 1 this indicates that the program is not run ning To start the program navigate to the Start menu line by using the navigation buttons...

Page 66: ...3 After selecting press the OK button to navigate to the Program menu Figure 31 PROGRAM MENU The Program menu provides two menu options To identify the Program Name use the navigation buttons Figure 3...

Page 67: ...U 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 35 1 to scroll through the menus Select the OK...

Page 68: ...CT MENU The Retract menu Figure 37 1 sets the time the ram cylinders will retract The default setting is 6 04 seconds Figure 37 2 After the desired time is obtained press the OK button Figure 37 3 aga...

Page 69: ...fault setting is set at five Figure 39 2 which means that after a total of five signals are received from the 80 LITE MENU the 80 light will be triggered to come On The 80 CNT must be set lower than t...

Page 70: ...is sent to the 100 CNT It s default setting is 6 05 seconds Figure 42 2 For example if the pressure switch is tripped for more than 6 05 seconds while the unit is in the auto mode and the ram is exte...

Page 71: ...ights Reserved P DELAY MENU The P DELAY Figure 44 1 is the time in which the compactor will delay the auto cycle if triggered by the photo eye The default setting is 4 sec onds Figure 44 2 This featur...

Page 72: ...ctivate 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 t...

Page 73: ...itch setting Figure 47 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 Figur...

Page 74: ...e 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...

Page 75: ...PTION OPTION TRANSFORMER L I1 I2 I3 I4 I7 I8 M Q1 1 Q1 2 Q2 1 Q2 2 Q3 1 Q3 2 Q4 1 Q4 2 R R 109 109 109 109 115 115B 115C 107 117 119 125 127 107 107C 130 132 107 107C 107 115A 119A 123A 127A 109 OPTIO...

Page 76: ...DISCONNECT SET OVERLOADS PER MOTOR NAMEPLATE VOLTAGE KEY SWITCH OPTION OPTION TRANSFORMER OPTION 107A 107C L I1 I2 I3 I4 I7 I8 M Q1 1 Q1 2 Q2 1 Q2 2 Q3 1 Q3 2 Q4 1 Q4 2 R R 109 109 109 109 115 115B 1...

Page 77: ...7C V V L N R 502408 A 131 109 133 135 107A 137 PHOTO EYE BRN YEL BLU WHT 502408 BLK 107 107C 130 132 107 107C 107 LOW OIL PHOTO EYE OPTION OPTION OPTION VISUAL ALARM AUDIBLE ALARM DRIVER LIGHT 24 VDC...

Page 78: ...ini Apartment Compactor SCHEMATICS 73 Copyright 7 2021 K PAC Compactors a product of McLaughlin Family Companies All Rights Reserved HYDRAULIC SCHEMATIC 3HP 3 PHASE 60 HERTZ 13 13 12 9 11 3 4 1 6 7 5...

Page 79: ...RESERVOIR 18 GAL 2 502111 1 STRAINER 3 501849 1 ELECTRIC MOTOR 10 HP 3 PHASE 60 HERTZ 4 503159 1 COUPLER PUMP 4 503160 1 SPIDER JAW COUPLING 4 503161 1 COUPLER MOTOR 5 503141 1 PUMP GEAR 12 GPM 6 5031...

Page 80: ...he part is Not Serviced Separately Qty Figure 49 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 s...

Page 81: ...00301 500305 502212 Item Part Number Qty Description Note 1 NSS 1 INDICATOR LAMP 100 FULL RED 502376 1 HEAD ONLY PILOT LIGHT RED 502377 1 COMPLETE LIGHT BODY RED N1 2 NSS 1 INDICATOR LAMP 80 FULL ORAN...

Page 82: ...123551 1 SINGLE CONTACT BLOCK NO 5 NSS 1 SELECTOR SWITCH MANUAL AUTO 503135 1 HEAD ONLY SELECTOR SWITCH STAY PUT NSS 1 CONTACT BLOCKS DOUBLE NO NC N2 127244 1 BODY FIXING COLLAR 123551 1 SINGLE CONTA...

Page 83: ...Apartment Compactor PARTS 78 Copyright 7 2021 K PAC Compactors a product of McLaughlin Family Companies All Rights Reserved CONTROL PANEL Inside Panel Illustration Reference 500301 500305 502212 6 4 3...

Page 84: ...ide Panel Parts List Item Part Number Qty Description Note 1 502345 1 PROGRAMMABLE RELAY SMART 2 502373 1 EXPANSION I 0 MODULE 3 511003 1 MODULE MOTOR STARTER POWER BASE 4 502266 1 MODULE OVERLOAD 5 5...

Page 85: ...pyright 7 2021 K PAC Compactors a product of McLaughlin Family Companies All Rights Reserved POWER PACK Assembly Illustration Reference 501261 L L U F 0 0 L 1 L U F 0 8 V E R F F O D W N F O F F O O T...

Page 86: ...erved POWER PACK Assembly Parts List Item Part Number Qty Description Note 1 500580 1 COVER MOTOR AND PUMP 2 500769 1 BACK PLATE 3 500768 1 COVER CONTROL PANEL 4 502212 1 CONTROL PANEL ASSY 208 VAC 10...

Page 87: ...ompactor PARTS 82 Copyright 7 2021 K PAC Compactors a product of McLaughlin Family Companies All Rights Reserved POWER PACK Hydraulic Reservoir Illustration Reference 501261 3 1 13 14 15 18 17 16 10 1...

Page 88: ...1 FILLER STRAINER AND BREATHER ASSY 6 40 MICRON N2 6 NSS 1 BASKET STAINLESS 7 NSS 2 GASKET CORK 8 NSS 1 FLANGE 9 NSS 1 CAP BREATHER 503153 1 LEVEL TEMP GAUGE ASSY N3 10 NSS 1 LEVEL TEMP GAUGE 11 NSS...

Page 89: ...ARTS 84 Copyright 7 2021 K PAC Compactors a product of McLaughlin Family Companies All Rights Reserved POWER PACK Pump Hydraulics Illustration Reference 501261 19 14 4 3 2 10 18 1 8 9 5 6 7 21 25 24 2...

Page 90: ...03147 1 GAUGE PRESSURE 9 503143 1 TUBE ASSY PRESSURE 10 503149 1 VALVE ASSY 11 100100 1 ADAPTER JIC TO O RING 16MJ 16MO 0N 12 110968 1 ADAPTER JIC SWIVEL TO PIPE 16FX 16FP 0N 13 503142 1 PIPE SUCTION...

Page 91: ...i Apartment Compactor PARTS 86 Copyright 7 2021 K PAC Compactors a product of McLaughlin Family Companies All Rights Reserved POWER PACK Motor and Pump Illustration Reference 501261 1 2 3 4 5 6 7 8 9...

Page 92: ...iption Note 1 113241 4 BOLT HHCS 375 16 X 1 5 GR5 ZN 2 104661 4 WASHER LOCK SPLIT 375 ZN 3 501849 1 MOTOR ELECTRIC 3 PHASE 10 HP 4 503161 1 COUPLER MOTOR 5 503160 1 SPIDER COUPLER 6 503159 1 COUPLER P...

Page 94: ...ed VARIABLES Remove from book before publishing VARIABLE NAME DEFINITION Company Name Short K PAC Copyright McLaughlin Family Companies Title KP03 Mini Apartment Compactor Company Name Short 2 New Way...

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