KCP 113 User manual

USERUSER MANUALMANUAL
Serial No: 113
KCP Heavy Industries., Ltd

KCP Heavy Industries Warranty
1
1. Warranty
The equipment manufactured and sold by KCP Heavy Industries Co., Ltd. (hereinafter referred to as “our
company”) is designed and manufactured according to the construction equipment related law and under
strict quality control and inspection processes.
When the equipment goes out of order under the normal use and management following the maintenance
period and guidelines specified in the manual, we warrant it based on our company’s warranty regulation and
related laws (Construction Machinery Management Act and Framework Act on Consumers, etc.) as follows:
a. Coverage
The equipment must be managed and performed according to the maintenance period and guidelines
specified in the manual (inserted in the partbook).
Only for the equipment following the above mentioned requirements, when, within the warranty period
specified below, the component parts are out of order because of any defect in materials or manufacturing or
there is serious fault related to safety, we warrant it based on the consumer injury compensation rule.
b. Warranty Period
The warranty period counts from the release date. Between the warranty period and pumping hours, the
earlier expiring one is counted as the expiration date.
Classification
Warranty
period
Remarks
Boom
pump
Structure (turning base, outrigger,
boom, link)
Min. 1year
Max. 3years
One year warranty granted by KCP
after released the machinery.
Required the Periodic inspection per
yearly bases whether KCP direct or
authorized service person and the
company by KCP Heavy Industries
Co.,Ltd.
You may extend the warranty upto
three years only if the proof of proper
yearly periodic inspection summited
when KCP requires.
General parts(except for
consumables)
1 year
Within 1 year after leaving the factory
or pumping for 1000hours

KCP Heavy Industries Warranty
2
Line pump
Structure (turning base, outrigger)
Min. 1year
Max. 3years
One year warranty granted by KCP
after released the machinery.
Required the Periodic inspection per
yearly bases whether KCP direct or
authorized service person and the
company by KCP Heavy Industries
Co.,Ltd.
You may extend the warranty upto
three years only if the proof of proper
yearly periodic inspection summited
when KCP requires.
General parts(except for
consumables)
1 year
Within 1 year after leaving the factory
or pumping for 1000hours
Placing
boom
Structure (boom, link, base, master)
Min. 1year
Max. 3years
One year warranty granted by KCP
after released the machinery.
Required the Periodic inspection per
yearly bases whether KCP direct or
authorized service person and the
company by KCP Heavy Industries
Co.,Ltd.
You may extend the warranty upto
three years only if the proof of proper
yearly periodic inspection summited
when KCP requires.
General parts(except for
consumables)
1 year
Within 1 year after leaving the factory
or pumping for 1000hours
Trailer
pump
General parts(except for
consumables)
1 year
Within 1 year after leaving the factory
or pumping for 1000hours
c. Exclusions
1) When the warranty period expired
2) When there is secondary damage to customer due to equipment failure within the warranty period
▶all charges including transportation expenses, lodging expenses, suspension loss, taxes and the public
utilities’ charge
3) Even within the warranty period, we don’t warrant in following cases:

KCP Heavy Industries Warranty
3
a) The failure caused by not following the guidelines and maintenance period specified in the manual
b) Change of the consumable parts used for operation (except for the defect in manufacturing)
▶filters, hydraulic oil, lubricating oil, concrete pipe, concrete cylinder, ram, actuating oil seal and direct
and indirect concrete contactor of hopper
c) Sensory failures without any qualitative or functional problems
▶Slight noise, vibration, smell, problems in appearance and just feeling strange, etc.
d) Situations not because of equipment failure like careless use, fire, theft, immoderate operate, delay
repair, natural disaster and traffic accident, etc.
e) Breakdown due to getting service by one who didn’t get basic training at our company and not using
genuine parts
f) Breakdown due to the modification and remodeling to affect the performance and safety
▶For problems caused by the additional equipment and its components installed at customer's will
when the product is released, we shall assume no responsibility.
g) Breakdown due to not repairing the equipment at our service center
Northern Repair Center
Gyeongin Repair Center
(637-813) 336, Gwangjeong-ro, Haman-myeon,
Haman-gun, Gyeongsangnam-do, Korea
TEL: [phone]
FAX: [phone]
(445-943) 553, Toseong-ro, Yanggam-myeon,
Hwaseong-si, Gyeonggi-do, Korea
TEL: [phone]
FAX: [phone]
h) Breakdown due to not filling or changing oil timely and breakdown due to using other oil which is not
recommended by our company.
d. Warranty repair procedure
If you need to repair the equipment within the warranty period, contact the person in charge of warranty
service at our service center.
e. Manufacture’s authority
We have the authority to change specification of equipment and we do not have any responsibility to apply
the change of design.
f. Application of warranty
If there is an exegetical difference about this warranty, our company’s view will prevail.
KCP Heavy Industries Co., Ltd. is always trying to research and develop for excellent performance and quality improvement
and will take care of your equipment sincerely.

KCP Heavy Industries Co., Ltd. Table of Contents
1 - 1
1. GUIDE TO THE OPERATING INSTRUCTIONS ................................................... 1-1
1.1 FOREWORD ................................................................................................................1-2
1.2 ICONS AND SYMBOLS ...................................................................................................1-3
2. SAFETY REGULATIONS.............................................................................................2-1
2.1 BASIC PRINCIPLE ........................................................................................................2-2
2.1.1 Resale.................................................................................................................2-2
2.2 PROTECTIVE EQUIPMENT..............................................................................................2-3
2.3 DESIGNATED USE ........................................................................................................2-4
2.4 SAFETY REGULATION...................................................................................................2-4
2.4.1 General safety regulations...................................................................................2-4
2.4.2 Operating safety regulation .................................................................................2-5
2.4.3 Safety rules for spraying the concrete .................................................................2-5
3. GENERAL TECHNICAL DESCRIPTION ....................................................................3-1
3.1 SUMMARY ..................................................................................................................3-2
3.2 TECHNICAL DATA .......................................................................................................3-3
3.2.1 Noise emission measurement ............................................................................3-3
3.2.2 Machine rating plate ...........................................................................................3-3
3.3 DESCRIPTION OF THE FUNCTIONS .................................................................................3-3
3.3.1 Pump ..................................................................................................................3-3
3.3.2 S–tube ................................................................................................................3-4
3.4 ELECTRICAL CONTROL DEVICES ..................................................................................3-4
3.4.1 Control Panel .....................................................................................................3-5
3.4.2 Cable remote control ..........................................................................................3-6
3.4.3 EMERGENCY STOP button ...............................................................................3-7
3.5 HYDRAULIC CONTROL DEVICES ...................................................................................3-8
3.5.1 Output controller .................................................................................................3-9
3.5.2 Accumulator dump valve ..................................................................................3-10
3.5.3 Hydraulic cooler ................................................................................................3-11
3.5.4 Control valve.....................................................................................................3-11

KCP Heavy Industries Co., Ltd. Table of Contents
1 - 2
4. EQUIPMENT INSTALLATION .................................................................................. 4-1
4.1 SET-UP SITE................................................................................................................ 4-2
4.2 MOUNTING OF DELIVER LINE ....................................................................................... 4-3
5. OPERATION .......................................................................................................5-1
5.1 STARTING UP ............................................................................................................. 5-2
5.1.1 Test run ............................................................................................................. 5-2
5.1.2 Pump functions................................................................................................... 5-2
5.2 PUMP OPERATION ...................................................................................................... 5-4
5.3 PUMPING.................................................................................................................... 5-5
5.3.1 Blockages........................................................................................................... 5-6
5.3.2 Overheating........................................................................................................ 5-7
5.4 CLEANING ................................................................................................................ 5-10
5.5 HAND SIGNALS FOR DRIVING...................................................................................... 5-11
5.6 PRECAUTIONS FOR ENGINE START AND STOP.............................................................. 5-12
6. QUICK TROUBLESHOOTING GUIDE .................................................................... 6-1
6.1 PRESSURE SETTING PROCEDURES .............................................................................. 6-2
6.1.1 Main block 70-75bar and S-v/v 190-200bar pressure setting.............................. 6-2
6.1.2 Main pressure (main oil pump maximum pressure) setting................................. 6-3
6.1.3 Pressure setting of hopper 3-handvalve block.................................................... 6-4
6.1.4 Grease pump’s operating time setting ................................................................ 6-5
6.2 TROUBLE DIAGNOSIS AND SOLUTION............................................................................ 6-8
6.2.1 Check points before troubleshooting................................................................... 6-8
6.2.2 Electric problems................................................................................................ 6-9
6.2.2.1 When main panel is not powered................................................................. 6-9
6.2.2.2 E-stop lamp ON......................................................................................... 6-10
6.2.3 When radio remote is not operated................................................................... 6-11
6.2.4 Hydraulic problems........................................................................................... 6-12
6.2.4.1 Oil pumps failure ....................................................................................... 6-12
6.2.4.2 When pumping is not functioning............................................................... 6-14
6.2.4.3 Accumulator pressure is not accumulated................................................. 6-16
6.2.4.4 Outvolume control malfunction.................................................................. 6-18
6.3 CIRCUIT SYMBOL....................................................................................................... 6-19

KCP Heavy Industries Co., Ltd. Table of Contents
1 - 3
7. MAINTENANCE..........................................................................................................7-1
7.1 MAINTENANCE INTERVALS ...........................................................................................7-2
7.2 GENERAL TORQUE SPECIFICATION ..............................................................................7-3
7.2.1 Bite type fitting, Torque specification ..................................................................7-4
7.2.2 Bite type fitting, hydraulic steel line reassembling ...............................................7-5
7.3 FUNCTIONAL FLUIDS ...................................................................................................7-5
7.3.1 Hydraulic fluid .....................................................................................................7-5
7.3.2 Manual lubrication ..............................................................................................7-6
7.3.3 Automatic lubrication system ..............................................................................7-6
7.4 VISUAL CHECKS ..........................................................................................................7-7
7.4.1 General ..............................................................................................................7-7
7.4.2 Electrical system ...............................................................................................7-8
7.4.3 Hydraulic system ................................................................................................7-8
7.5 CHANGING THE HYDRAULIC FLUID ................................................................................7-8
7.5.1 Changing the fluid ..............................................................................................7-9
7.6 FUNCTION CHECKS ...................................................................................................7-10
7.6.1 Checking the accumulator ................................................................................7-11
7.7 FILTER CHANGE ........................................................................................................7-12
7.7.1 Checking Filters ...............................................................................................7-12
7.7.2 Preparation ......................................................................................................7-12
7.7.3 Main filter .........................................................................................................7-13
7.8 CHANGING DELIVERY PISTONS ...................................................................................7-14
7.8.1 Lock drive cylinder 1(passenger side) in the end position .................................7-14
7.8.2 Block drive cylinder 2(driver side) in the end position .......................................7-14
7.8.3 Rubber piston replacement ..............................................................................7-15
7.9 LUBRICATING HOPPER ..............................................................................................7-17
7.9.1 Lubrication intervals .........................................................................................7-17
7.10 S-TUBE ..................................................................................................................7-18
7.10.1 Removing the s tube shaft bearing (seal housing) ..........................................7-19
7.10.2 Seal housing seal set .....................................................................................7-21
7.10.3 Installation summary ......................................................................................7-23
7.10.4 Dismantle the S-tube seal housing .................................................................7-24
7.10.5 S-tube seal housing gasket set .......................................................................7-25
7.10.6 Installation summary ......................................................................................7-25
7.10.7 Removing the wear plate.................................................................................7-26

KCP Heavy Industries Co., Ltd. Table of Contents
1 - 4
7.10.8 Remove the S - tube ...................................................................................... 7-27
7.10.9 Fitting the wear plate ..................................................................................... 7-27
7.10.10 Replacing the wear ring ............................................................................... 7-29
7.10.11 Fitting the S tube seal housing ..................................................................... 7-29
7.10.12 Wear sleeve and thrust washer .................................................................... 7-30
7.10.13 Mounting the swing lever ............................................................................. 7-31
7.11 MEASURING THE WALL THICKNESS .......................................................................... 7-33
7.11.1 Straight pipes ................................................................................................. 7-34
7.11.2 Elbows ........................................................................................................... 7-34
7.11.3 S-tube ........................................................................................................... 7-35
7.11.4 Measuring ...................................................................................................... 7-36
7.11.5 Graph:Minimum wall thickness as a function of operating pressure................ 7-37

KCP Heavy Industries Co., Ltd. Guide to the Operating Instructions
1 - 1
1Guide to the Operating Instructions
In this section you will find notes and information that
will help you use these Operating Instructions. Do not
hesitate to contact us if you have any inquiries:
KCP Heavy Industries Co., Ltd.
465-3 Pasu-Ri, Hamahn-Myeon, Hamahn-Gun,
Kyeoungsangnam-Do, Korea
Tel: [phone]
Fax: [phone]
or the Branch or Agency that looks after you.
Name: ____________________________________
Address: __________________________________
__________________________________
Telephone: _________________________________
Fax: ______________________________________

KCP Heavy Industries Co., Ltd. Guide to the Operating Instructions
1 - 2
1.1 Foreword
These Operating Instructions are intended to familiarize the user with the machine and to
assist him in using the machine properly in various operations.
The Operating Instructions contain important information on how to operate the machine
safely, properly and efficiently. Observing these instructions helps to avoid danger, to
reduce repair costs and downtime, and to increase the reliability and service life of the
machine.
The Operating Instructions are to be supplemented by the respective rules and regulations
for accident prevention and environmental protection.
The Operating Instructions must always be available wherever the machine is in use.
These Operating Instructions must be read and applied by any person in charge of carrying
out work with and on the machine e.g.
- Operation, Including setting up, Troubleshooting in the course of work, Evacuation of
production waste, Care and disposal of fuels and consumables;
- Service (maintenance, inspection, repair), and/or
- Transport
In addition to the Operating Instructions and mandatory rules and regulations for accident
prevention and environmental protection in the country and place of use of the machine,
the generally recognized rules of technology for safe and proper working must also be
observed.
Should you have any questions following your study of the Operating Instructions, KCP
Heavy Industries Co., Ltd. the Branch or Agency serving you, will be happy to give you
more information.
You will make it much easier for us to answer any questions if you can give use the details
of the machine model and the machine number.
In the interests of constant improvement, modifications are made from time to time and it
could be possible that we were unable to take these into consideration when these
Operating Instructions were printed.
The contents of this publication may not be reproduced, even in extract, without our written
permission. All technical data, drawings, etc. are protected by copyright.

KCP Heavy Industries Co., Ltd. Guide to the Operating Instructions
1 - 3
1.2 Icons and symbols
The following icons and symbols are used in the Operating Instructions:
►Task symbol
Text following this symbol describes tasks that you are required to work through, generally
from top to bottom in the sequence shown.

Text following this symbol describes the result or effect of an action.
Refer also to the maintenance cards
The following special tools are required:
This icon identifies the special tools necessary to carry out the work. Normal tools,
i.e. commercially available tools or tools carried in the truck, are not specially listed.
Environmental protection _________________________________________________
Particular information regarding environmental protection The icon shown, the words
Environmental protection printed in bold, and a line will start and finish the paragraph.
_________________________________________________________________________
Note_____________________________________________________________________
Particular information regarding the economic use of the machine is introduced with
the icon illustrated, the word Note printed in bold, and a line will start and finish the
paragraph.
_________________________________________________________________________
Caution__________________________________________________________________
Particular information or rules or prohibitions intended to prevent damage area
introduced with the icon illustrated, the word caution printed in bold, and a line will
start and finish the paragraph.
_________________________________________________________________________

KCP Heavy Industries Co., Ltd. Guide to the Operating Instructions
1 - 4
Danger __________________________________________________________________
Particular information or rules or prohibitions intended to prevent injury or significant
damage are introduced with the icon illustrated, the word Danger printed in bold,
and a line will start and finish the paragraph.
_________________________________________________________________________
Danger of fire ____________________________________________________________
This symbol is used to identify tasks for which there is a particular danger of fire.
_________________________________________________________________________
Danger of explosion______________________________________________________
This symbol is used to identify tasks during which there is the danger of an explosion.
The explosion may also be caused by pressure being released suddenly.
_________________________________________________________________________
Falling items_____________________________________________________________
This symbol is used to identify tasks in which there is a danger of injury caused by
parts falling down.
_________________________________________________________________________
Danger of crushing_______________________________________________________
This symbol is used to identify tasks during which there is the danger of being crushed.
_________________________________________________________________________
Suspended load__________________________________________________________
This symbol is used to identify tasks in which suspended loads may fall down.
_________________________________________________________________________

KCP Heavy Industries Co., Ltd. Guide to the Operating Instructions
1 - 5
High voltage _____________________________________________________________
This symbol is used to identify tasks in which there is the danger of electrocution,
possibly with lethal consequences.
___________________________________________________________________________
Danger of burning ________________________________________________________
This symbol is used to identify tasks in which there is a danger of burning from
chemical substances, which are not specifically described.
___________________________________________________________________________
Danger of burning ________________________________________________________
This symbol is used to identify tasks in which there is a danger of burning from
battery acid.
_________________________________________________________________________
Danger of poisoning ______________________________________________________
This symbol is used to identify tasks in which there is a danger of poisoning by
inhalation of gases, ingestion of or contact with substances.
_________________________________________________________________________

KCP Heavy Industries Co., Ltd. Safety Regulations
2 - 1
2 Safety Regulations
This chapter summarizes the most important safety regulations.
This chapter is, therefore, particularly suitable for an initial basic
instruction of new operators. Naturally, the various rules are
also repeated once more at the appropriate points in the
Operating Instructions.
Note
_____________________________________________________________________
Special safety regulations may be necessary for some tasks.
These special safety regulations will only be found in the description of the particular
task.
We include here a listing of regulations and safety standards for your information:
- Distribution machines for concrete and mortar
- Safety of machinery
- Electrical equipment of industrial machines
_____________________________________________________________________

KCP Heavy Industries Co., Ltd. Safety Regulations
2 - 2
2.1 Basic principle
The machine/plant must only be used in technically perfect condition in accordance with its
designed use and the instructions set out in the Operating Instructions. Any disorders
involving functioning, especially those affecting the safety of the machine/plant, should,
therefore, be reported and corrected immediately.
To ensure safety make sure:
- No safety equipment is removed, rendered inoperable or modified
(EMERGENCY STOP, hopper grate etc.).
- Safety equipment removed for the purposes of maintenance work is re-fitted
immediately the work is completed.
To ensure a safe working environment, every time you begin work, check the safety of
operation.
Any defects found or suspected will be repaired immediately. If necessary, inform the
project
2.1.1 Resale
The following should be noted if you resell the machine:
Inform the new operator of all the papers (Operating Instructions, Maintenance Instructions,
diagrams, Machine Cards, test certificates etc.) you received with your machine.
If necessary, you may have to order the papers from us, giving the machine number.
The machine may not be resold without the papers under any circumstances.
Reporting a resale or acquisition to KCP Heavy Industries Co., Ltd. ensures that you will be
sent any information relating to modifications or innovations relevant to safety, and you will
also be eligible for technical consulting from our works.
Instruct the new operator and his operating personnel in the operation of the machine, just
as we instructed you, and have them confirm that they have received instruction from you.
Should you so require, we will gladly carry out the instruction of the new operator and the
new operating personnel on your behalf.

KCP Heavy Industries Co., Ltd. Safety Regulations
2 - 3
2.2Protective equipment
The following protective equipment is prescribed, with no exceptions, throughout the
working area in order to restrict the risks to the life and limb of the persons:
Hard hat
A hard hat protects your head against, for instance, falling concrete
or parts of the delivery line in the event of a hose bursting.
Ear defenders
Ear defenders protect you against the noise generated by the
machine when you are standing close to it.
Protective goggles
Protective goggles protect your eyes against injuries from concrete
splashes or other particles.
Safety harness
When working at height, use the climbing aids and working plat-
forms provided for reasons of safety or wear a safety harness. The
relevant national regulations must be complied with.
Protective gloves
Protective gloves protect your hand against aggressive or chemical
substances, as well as against mechanical effects (e.g. impact) and
cutting injuries.
Safety boots
Safety boots protect your feet against falling objects and against
penetration by projecting nails.

KCP Heavy Industries Co., Ltd. Safety Regulations
2 - 4
2.3 Designated use
The machine is designed exclusively for the delivery of concretes up to a bulk density of
2,400 kg/m3. Its operation must be restricted to pumping operations on construction sites.
The maximum concrete pressure must not exceed that specified on the rating plate or in
the checkbook.
You must also observe the specified Operating Instructions and comply with the conditions
and intervals for maintenance and inspection to operate the machine within the limits of its
designated use.
2.4 Safety regulation
2.4.1 General Safety Regulations
1) The operator of this equipment is required to have education and experience regarding
the operating instruction and relevant regulations for safe operation.
2) Replacing parts, operators are requested to use certified parts approved by KCP Heavy
Industries Co.,Ltd.
3) When it is necessary to uninstall or/and servicing hydraulic pipe, pre-existing pneumatic
pressure needs to be discharged before removing from the hydraulic fluid tank in order to
prevent the excessive leakage and accidents
4) It is strictly prohibited to access or climb the machinery other than equipment operator.
5) Safety-related components and parts should not be replaced nor eliminated.
6) Immediate repairing required when the machinery does not work properly just the way it
was operating before.
7) Electric and hydraulic systems and manual operation must be stated safely.
You must always be aware about this may cause a malfunction because Electric and
Hydraulic are controlled by remote controller
8) Construction site conditions ensuring visibility of work should be guaranteed if not extra
person must help for cooperation as assistant to visualize the site.
9) Lock status of outrigger must in place before driving or moving the vehicle.
10) Always, must be worn with a helmet, safety glasses and other personal protective
equipment anywhere, anytime at the construction site