TANK LIDS, REAR STEP AND WHEELS

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1 TANK LIDS, REAR STEP AND WHEELS M Rev.4/98 FOR MODELS - KP4F, KP6F, KP6R 4/98 Item Part Number Part Description Qty Tank Lid Weldment (KP4F -- Front Load) Tank Lid Weldment (KP6F -- Front Load) /8NC x 2 GD. 5 Cap Screw /8NC Self Locking Nut Rear Tank Lid Assembly (KP6R -- Rear Load) Extension Spring /16 DIA. x 1--1/2 Roll Pin (Steel) Lid Shaft Rear Step Handle Weldment Swivel Castor Wheel Rigid Castor Wheel /2NC x 1--1/2 Cap Screw /2 STD. Flat Washer /2 STD. Lock Washer /2NC Hex Nut 16 P1

2 P2 M Revised 8/94

3 LOADING CHAMBER & RAM ASSEMBLY FOR MODELS - KP4F, KP6F, KP6R 9/05 Item Part Number Part Description Qty Ram Weldment Pivot Shaft Spring /2 SAE Flat Washer /8NC Hex Nut /2 DIA. Eye Bolt /2NC Hex Nut /2NC x 2 GD. 5 Cap Screw /8 DIA. x 3/4 Roll Pin /2NC Self Locking Nut /2 DIA. U--Bolt Chamber Lid Weldment /8NC x 1--1/4 Cap Screw /8NF x 3/4 GD. 5 Cap Screw Selector Valve Assembly /8 STD. Lock Washer /8NC x 2--1/2 Cap Screw Retaining Plate /4 Thread Cutting Zerk Access Cover Hinge Adjustment Plate /16 DIA. x 1--1/2 Cotter Pin Spacer Adjustment Rod Adjustment Stud Latch Weldment Extension Spring /2NC x 2 GD. 5 Carriage Bolt Spacer Slip Tube /2 STD. Flat Washer /8 STD. Lock Washer 4 36 D Hinge Shaft 1 37 D /4NC x 1--1/2 GD.5 Cap Screw 2 38 D /4NC Self Locking Nut 2 39 D /16 Drive Zerk Rubber Pad Back--Up Plate /8NC Self Locking Nut Pipe Plug 1 D Used for Serial #1071 and On P3

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5 HYDRAULIC HOSES & FITTINGS FOR MODELS - KP4F, KP6F, KP6R 2/02 Item Part Number Part Description Qty. 1 3 x 16 Hydraulic Cylinder O--Ring 37_ Flare Adapter 4 3 Port Plug /8NPT STD. Zerk Pin /8NC x 2 Cap Screw /8NC Self Locking Nut R Hydraulic Hose 3/8 DIA. x 27 Long _ Male Bulkhead Tee /4 SAE Flat Washer 2 11 D Lock Nut _ Flare Male / Female 90_ Ell R Hydraulic Hose 3/8 DIA. x 21 Long /16 DIA. x 1--1/2 Cotter Pin Pin R Hydraulic Hose 3/8 DIA. x 28 Long /2NPTF x 3/4 JIC 37_ Flare /2NPTF Female Tee /2 Close Nipple /2NPT Male Coupler (Industrial) /2NPT x 4 Pipe Nipple /4JIC x 1/2NPT 90_ Fitting /2 x 90_ Street Ell /2 Female Dry Break Coupler (Aeroquip) Coupler O--Ring (Pioneer only) Coupler O--Ring (Aeroquip Industrial) 1 D This nut is provided with Item 9 Bulkhead Tee P5

6 P6 M Rev.6/99

7 POWER UNIT ASSEMBLY FOR MODELS - ALL 9/05 Item Part Number Part Description Qty. Item Part Number Part Description Qty Tank Weldment R 1/4 DIA. x 22 Hydraulic Hose /2NPT Pipe Plug /4NPT x 1/2 JIC Fitting /4NC Hex Nut Power Panel /4 STD. Lock Washer /2 x 90_ Electrical Adapter Sump Filter Conduit Connector 1 6 k /2NPT(F) 7/8 O -Ring 90_Elbow Wire Shield 1 7 k Pump Cartridge Heater & Thermostat 1 8 k /16NC x 3/4 GD. 5 Cap Screw /16 STD. Lock Washer /2NC Hex Nut 4 54 H /2 Liquitite Flex Metal Hose /2 STD. Lock Washer 4 12 k R 3/8 DIA. x 16 Hydraulic Hose 1 55 Electrical Wire /8 DIA. x 8 Tube Return Washer 2 14 k /16NC x 1 GD. 5 Cap Screw 2 57 h Two -Stage Pump 1 15 k Key 1 58 v hd /32 x 1/2 Woodruff Key /4NC x 3/4 GD5 Cap Screw 12 v /8 x 1/2 Woodruff Key 1 17 k /4NPT - 1/2NPT Reducer 1 59 hd /4NPT Close Nipple Tank Cover 1 60 hd /4NPT Street Elbow Filler Breather 1 20 Y /2NC x 1-3/4 GD. 5 Cap Screw 4 61 h /16NC x 5-1/2 GD.5 Bolt 2 h /8NC x 1-1/4 GD5 Cap Screw 4 62 hd /16 STD. Lock Washer 2 21 Y /2 STD. Lock Washer /2NC Hex Flange Serrated Nut 3 h /8 STD. Lock Washer /6 NC Retainer Nut 2 22 Y Mounting Bracket 1 65 hd R Hose 14-1/4 Long x 3/8 DIA. 1 h Mounting Bracket 1 66 h Coupler (Serial # 1083 & On) /2NC x 3 GD5 Cap Screw 4 h Coupler (Serial # ) /16 O -Ring to 9/16JIC Union 2 67 h Spider (Serial # 1083 & On) 1 25 k /2NPT Close Nipple 1 h Spider (Serial # ) Control Valve 1 68 h Coupler (Serial # 1083 & On) Adapter Fitting 2 h Coupler (Serial # ) R 1/2 DIA. x 144 Hydraulic Hose /4NPT Female Coupler Female Coupler Industrial -Retract Back Panel Male Coupler Industrial - Extend 1 71 v HP Hi -Lo Coupler 3/32 Keyway 31 k Coupler 1 D 32 Y Spider 1 v HP Hi -Lo Coupler 1/8 Keyway 1 33 Y Coupler 1 72 D HP Hi -Lo Pump 1 34 Y Key 1 73 D /16NC x 6 GD. 5 Cap Screw 2 h Key /16(M)O -Ring to 1/2JIC(M) 90_ 1 35 h Part used on 1HP Power Unit 36 Y Motor (3HP - Three Phase) 1 Y Part used on 3HP Power Unit h Motor (1HP - Single Phase) Wire Nut 4 k Part used on 3 HP Power Unit Ser. # /16NC x1 GD5 Cap Screw 12 D Used for 3 HP Serial No & On /16 STD. Flat Washer 4 H This is a bulk quantity item. You must specify length required when ordering Hood /16NC Hex Nut 12 v IMPORTANT: When ordering Item 58 Woodruff Key & Item 71 Pump Coupler note there are 2 different sizes Mounting Plate 1 available. Measure the keyway on your pump shaft to Lower Mounting Bar 1 determine size needed before ordering Plug 1 P7

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9 3 -PHASE POWER PANEL (SERIAL #3000 & ON) FOR MODELS - KP4F, KP6F, KP6R NOTE POWER PACK SERIAL NUMBERS LISTED 12/06 Item Part Number Part Description Qty Control Box (UL) Fuse 2--1/2 Amp Transformer Fuse Replacement Label #10 Hex Nut Relay Panel AC Contactor 10HP (CH) Auxiliary Contact Din Rail & Panel Adapter (3 Phase) Overload Relay ( AMP) Heater Pack (( AMP) Heater Pack ( AMP) Pressure Switch /2NPTS Lock Nut Pole Terminal Block (Size 4) Terminal Mounting Strip #8NC x 1/2 Cross Pan Head Thread Cutting Screw UL Control Panel Label 1 19 Electrical Schematic N.C. Contact Block N.O. Contact Block Legend Plate -- STOP Mushroom Operator, 2 Position -- STOP Mushroom Operator -- STOP Legend Plate -- START Green Operator -- START Keyed 2--Position Switch, Maintained Legend Plate -- ON/OFF Adapter 3/8 Cord--1/2 Pipe Liquitite Wire #14/3 Type SJ0 (Bulk) 12ft Scanner Block (2 Pieces) Power Block, AC (#PBA) Logic Module, Repeat Cycler /2JIC (M) -- 1/4NPT (F) 90_ Fitting 1 34 H Relay Socket 1 35 H Relay 1 36 H Timer Base 1 37 H Timer 8--Pin (Delay on Break) 1 38 H N.O. Early Close Contact Block 1 39 H Link Rail, 2 Terminal 1 40 H Pilot Light, 120V 1 41 H Legend Plate, Full 1 42 H Amber Lens, Pilot Light 1 H Part of Full Light Option P9

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11 3 -PHASE POWER PANEL FOR MODELS - KP4F, KP6F, KP6R NOTE POWER PACK SERIAL NUMBERS LISTED 9/05 Item Part Number Part Description Qty Control Box Relay Panel N.O. Contact Block (Serial # 1558 & On) Contact Block -- Key Start (Serial # ) N.C. Contact Block (Serial # 1558 & On) Contact Block -- Stop (Serial # ) Plastic Seal 1 6 Electrical Schematic Specify Serial No. & Voltage OPERATOR / KEY Contact OFF / ON Name Plate OPERATOR / START Button START Name Plate Mushroom Operator -- Stop (Serial # 1558 & On) Legend Plate -- Stop (Serial # 1558 & On) /2NPS Lock Nut /2(M)JIC to 1/4(F)NPT Straight Fitting Pressure Switch Terminal Mounting Strip (Serial # 1558 & On) Terminal Mounting Strip (Serial # ) End Clamp (Serial # ) 2 18 d Overload Relay ( ) (Serial # ) 1 D Overload Relay ( ) (Serial # ) End Barrier (Serial # ) Terminal Block (Serial # 1558 & On) Terminal Box Lug (Serial # ) /2 Amp Fuse (Serial # ) 1 K FNM 2--1/2 Amp Fuse 1 22 K Transformer AC Contactor (Serial # ) Switch Key (CH) (Serial # 1558 & On) Switch Key (E10) (Serial # ) Keyed 2--Position Switch (Serial # 1558 & On) Operator / Key Start (Serial # ) Legend Plate START (Serial # 1558 & On) Key Start Name Plate (Serial # ) 1 27 K Fuse Replacement Decal Ground Decal Elbow 1 d 208 Volt, 230 Volt D 460 Volt K For units with heater (Serial # ) K For all units (Serial # 1518 & On) P11

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13 SINGLE PHASE POWER PANEL (SERIAL # 3000 & ON) FOR MODELS - KP4F, KP6F, KP6R NOTE POWER PACK SERIAL NUMBERS LISTED 12/06 Item Part Number Part Description Qty Control Box Fuse Holder (UL Approved) Fuse 2--1/2 Amp Fuse Replacement Label #10 Hex Nut Relay Panel AC Contactor 10 HP (CH) Auxiliary Contact Din Rail & Panel Adapter (3 Phase) Overload Relay ( ANP) Heater Pack ( AMP) Heater Pack ( AMP) Pressure Switch Lock Nut 1/2NPTS Pole Terminal Block (Size 4) Terminal Mounting Strip #8NC x 1/2 Cross Pan Head Threaded Screw UL Control Panel Label 1 19 Electrical Schematic N.C. Contact Block N.O. Contact Block Legend Plate -- STOP Mushroom Operator -- STOP Operator, 2 Position Mushroom Legend Plate -- START Green Operator, START Keyed 2--Position Switch, Maintained Legend Plate -- ON/OFF Adapter 3/8 Cord--1/2 Pipe Liquitite Wire #14/3 Type SJO (Bulk) 12ft Scanner Block (2 Pieces) Power Block, AC (#PBA) Logic Module, Repeat Cycler /2JIC (M) -- 1/4NPT (F) 90_ Fitting 1 34 H Relay Socket 1 35 H Relay 1 36 H Timer Base 1 37 H Timer 8--Pin (Delay on Break) 1 38 H N.O. Early Close Contact Block 1 39 H Link Rail, 2 Terminal 1 40 H Pilot Light, 120V 1 41 H Legend Plate, Full 1 42 H Amber Lens, Pilot Light 1 H Part of Full Light Option P13

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15 SINGLE PHASE POWER PANEL FOR MODELS - KP4F, KP6F, KP6R NOTE POWER PACK SERIAL NUMBERS LISTED 9/05 Item Part Number Part Description Qty Control Box Relay Panel 1 3 kd AC Contactor (Serial # ) 1 d AC Contactor (Serial # ) Fuse Holder N.O. Contact Block (Serial # 1558 & On) Contact Block -- Stop (Serial # ) N.C. Contact Block (Serial # 1558 & On) Contact Block -- Stop (Serial # ) Plastic Seal 1 8 Electrical Schematic -- Specify Serial # and Voltage OPERATOR / KEY Contact OFF / ON Name Plate OPERATOR / START Button START Nameplate Mushroom OPERATOR / STOP (Serial # 1558 & On) RED OPERATOR / STOP Button (Serial # ) Legend Plate -- STOP (Serial # 1558 & On) STOP Nameplate (Serial # ) /2NPS Lock Nut /2(M)JIC to 1/4(F)NPT Straight Fitting 1 17 d Overload Relay (Serial # ) 1 k Overload Relay ( ) (Serial # ) 1 d Overload Relay ( ) (Serial # ) End Clamp (Serial # ) Terminal Mounting Strip (Seri. # 1558 & On) Terminal Mounting Strip (Serial # ) Terminal Block (Serial # 1558 & On) Terminal Box Lug (Serial # ) End Barrier (Serial # ) /2 Amp Fuse Pressure Switch Switch Key -- (CH) (Serial # 1558 & On) Switch Key -- (E--10) (Serial # ) Keyed 2--Position Switch (Serial # 1558 & On) Operator / Key Start (Serial # ) Legend Plate START (Serial # 1558 & On) Key Start Nameplate (Serial # ) Fuse Replacement Decal Ground Decal Ebow 1 k d D 110 Volt 220 Volt For 110 Volt and 220 Volt (Serial # 1518 & On) P15

16 SELECTOR VALVE ASSEMBLY M FOR MODELS Selector Valve 10/98 Item Part Number Part Description Qty. 1 O--Ring 2 2 Special Washer 2 3 Spring 1 4 Spool Stop 1 5 Spacer 1 6 Spring Cover /8NF x 2 Cap Screw /8 SAE Lock Washer /8NF x 3/4 GD. 5 Cap Screw 1 P16

17 CONTROL VALVE M FOR MODELS CONTROL VALVE 6/90 Item Part Number Part Description Qty Relief Valve Sequence Valve 1 P17

18 ENERGY HYDRAULIC CYLINDER ASSEMBLY M FOR MODELS X 16--1/8 Hydraulic Cylinder Assembly 10/98 Item Part Number Part Description Qty Seal Kit 1 1 Internal Retaining Ring 1 2 External Retaining Ring 1 3 Rod Wiper 1 4 Back--Up Washer 3 5 Back--Up Washer 1 6 O--Ring 2 7 O--Ring 1 8 O--Ring 1 9 Piston Ring 1 P18

19 PRINCE HYDRAULIC CYLINDER ASSEMBLY M x 16--1/8 Prince Hydraulic Cylinder Assembly 10/98 Retracted Extended /8 Stroke /8 Rod Diameter /2 Item Part Number Part Description Qty Piston Rod Assembly 1 2 k Butt and Tube Assembly Piston Lock Nut Gland 1 6 D O--Ring 2 7 D Back--Up Washer 2 8 D Back--Up Washer 1 9 D Bearing Ring 1 10 D O--Ring 1 11 D O--Ring 1 12 D Back--Up Washer 1 13 D Wiper 1 14 D Square Retaining Ring Port Plug Zerk Seal Kit ( D Items Included In Kit) k Part not available for repairs P19

20 M P20

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22 HOT NEUTRAL GROUND TO PANEL NC NO NO NO FUSE REPLACEMENT USE BUSS 250V,AGC 2-1/2 AMP OR EQUIVALENT L1 L2 L3 AC CONTACTOR T1 T2 T3 L1 L2 L OVERLOAD RELAY FACTORY OVERLOAD SETTING 16 AMPS UL LISTED CONTROL PANEL POWER FROM CUSTOMER DISCONNECT BOX PSA Connection Line Terminals: Load Terminals: Control Terminals Auxiliary Terminals: Terminal Block: Screw Size M4 M4 M3.5 M3.5 Torque Inch -Lb. Min. - Max USE COPPER WIRE 60 C WIRE INSULATION POWER PACK ELECTRICAL SCHEMATIC 1 HP SINGLE PHASE 110 VOLT (OIL HEATER OPTIONAL) BREAKER DISCONNECT CUSTOMER PROVIDED. L1 L2 L3 IM OL T1 T2 T3 MOTOR RED STOP RED 0 GRAY FUSE GROUND TO CONTROL BOX 1 WHITE 2 BLACK N.O. BLACK THERMO SWITCH ABOVE 70 F 2 OIL HEATER OPTIONAL CUSTOMER INSTALLED NOTE: Motor rotation must be clockwise. connect power leads to L1 & L3. check rotation of motor. If counter -clockwise rotation is observed, wires in motor housing connector box must be interchanged per motor housing. RED START RED ON/OFF BLUE RED 13 M1 14 BLUE 3 BLACK PSA N.C. BLUE 5 OL PURPLE M BLACK A1 96 A2 95 WHITE 2 1 STANDARD: BUSS 250V FNM 2--1/2 AMP OR EQUIV. M REV. 8/4/06 P22

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26 FRONT LOAD COMPACTOR DECAL PLACEMENT M Rev.10/96 FOR MODELS - KP4F, KP6F 12/06 Item Part Number Part Description Qty. 1 K K-PAC Decal 4 2 K DANGER - Electric Line Decal 1 3 K WARNING - Obstructions Decal 2 4 K CAUTION - Operators Decal 1 5 K WARNING - Do Not Stand Decal 1 6 K WARNING - Door Closed Decal 2 7 K WARNING - Opening Decal 1 8 K DANGER - Do Not Enter Decal Oil Level Decal WARNING - Do Not Operate Decal DANGER - High Voltage Decal 1 Item Part Number Part Description Qty VOLTS Decal VOLTS Decal VOLTS Decal VOLTS Decal VOLTS Decal 1 13 K WARNING - High Pressure Decal Rotation Arrow Decal Dexron III Oil Decal K -PAC Serial No. Plate #4x3/16GripNail 2 K Included in Decal Kit P26

27 REAR LOAD COMPACTOR DECAL PLACEMENT P27 M Rev.10/96 FOR MODELS - KP6R 12/06 Item Part Number Part Description Qty. 1 K K-PAC Decal 3 2 K DANGER - Electric Line Decal 2 3 K WARNING - Obstructions Decal 1 4 K CAUTION - Operators Decal 1 5 K WARNING - Do Not Stand Decal 2 6 K WARNING - Door Closed Decal 2 7 K WARNING - Opening Decal 1 8 K DANGER - Do Not Enter Decal Oil Level Decal WARNING - Do Not Operate Decal DANGER - High Voltage Decal 1 Item Part Number Part Description Qty VOLTS Decal VOLTS Decal VOLTS Decal VOLTS Decal VOLTS Decal 1 13 K WARNING - High Pressure Decal Rotation Arrow Decal Dexron III Oil DecalP K -PAC Serial No. Plate #4x3/16GripNail 2 K Included in Decal Kit

28 INSTRUCTION TO CONVERT 9003 (3 -PHASE) POWER UNIT VOLTAGE (CANNOT convert Single Phase to 3 -Phase) 1. What voltage to convert to? See Column I on the chart below. 2. What brand is the transformer? (Column I) Wiring is different because of different transformers. 3. Read conversion steps and chart below. Order parts as necessary. 4. Steps in making conversion. (All steps are very important) A. Change motor starter to transformer wire on transformer to agree with the chart below for voltage desired. (See Columns II and III) This step gives the proper voltage to controls and oil heater. B. Change overload relay per Column IV. This step is necessary for proper motor protection. NOTE: SAME RELAY IS USED FOR 208 VOLT and 230 VOLT (460 VOLT IS DIFFERENT). C. Set amperage of overload relay per Column V. This step is necessary for proper motor protections. If the correct amperage cannot be set, check that the overload relay is correct. D. Check wiring of control panel to motor at motor (high voltage vs. low voltage), and change to correspond if necessary. See nameplate on motor for correct wiring (208V and 230V are low voltage, 460V is high voltage). E. Change electrical schematic per chart to agree with voltage converted to. (See Column VIII) F. Change voltage decal on outside of control panel per chart. (See Column VI) 5. Re--check that all steps were taken and are correct before connecting to power. Check wire routing per electrical schematic. I. II. VII. III. IV. V. VI. TYPE VOLTAGE ACME WIRE FROM STARTER TO TRANSFORMER OVERLOAD RELAY K-PAC SIEMANS ALLIS # AMPERAGE SETTING L1 - - H1 COMMON MOTOR WIRES ELECTRICAL SCHEMATIC L2 - - H UA5000 -IK 11 See Motor S 230 L2 - - H UA5000 -IK 10 Plate S 460 L2 - - H UA5000 -IG S P B Revised 8--92

29 INSTRUCTION TO CONVERT 9001 (SINGLE- PHASE) POWER UNIT VOLTAGE (CANNOT convert Single Phase to 3 -Phase) 1. What voltage to convert to? See Column I on the chart below. 2. Steps in making conversion. (All steps are very important) A. Change relay and contactor per chart below (Column III). NOTE: The 6 red wire may be necessary between the contactor and the overload. OBserve wire routing when disassembling, and rewire the same way. This step is necessary for proper motor protection. B. Rewire controls per proper electric schematic (Column VI). NOTE: 16 white wire from L3 to terminal strip #2 will be added or removed per schematic. C. Set overload relay to correct amperage (Column IV). This step is necessary for proper motor protection. D. Change leads from the control panel to the motor at the motor. (Column V) See plate on motor for instructions. E. Change wiring schematic in control panel. (Column VI) F. Change voltage on outside of control panel per chart. (Column II) I. II. III. IV. V. VI. VII. VOLTAGE OVERLOAD RELAY AMPERAGE MOTOR ELECTRICAL VOLTAGE WIRE DECAL K-PAC SIEMANS ALLIS # SETTING WIRES SCHEMATIC Serial # Serial #1518 & On TB4210-0AA8 3UA52002B 3TB4110-0AA8 3UA5000 -IK 3TB4210-0AA8 3UA5200 -IK 3TB4210-0AA8 3UA5200 -IK See Motor Plate See Motor Plate See Motor Plate See Motor Plate S S S S 16 White 6 Red 6 Red 6 Red 6 Red 3. Double check that all steps were taken and are correct before connecting to power. Check wire routing per proper electrical schematic. 4. Note wiring schematic HS and HS need to have clear seal for installation A Revised P29

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CONTAINER GUIDE WELDMENTS

CONTAINER GUIDE WELDMENTS FOR MODELS - ALL FRONT LOAD CONTAINERS 4/98 1 9110--39--0 L.H. Container Guide Weldment 1 2 9110--38--0 R.H. Container Guide Weldment 1 3 9110--56--1 Instruction Sheet (Not Shown)