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