ACM 103 Central Switchbox Description

Speaker:
Richard Kim
Calvin Lee
Hanwoo-Academy
INTRODUCTION TO HANWOO PUMPS ELECTRICS

Hanwoo-truck mounted concrete pumps are equipped with a modern and reliable electrical
control system. The main features are :
- proportional control of the concrete pump,
- proportional control of all boom sections,
- integrated remote control of all important truck operations.

The concrete pump is driven hydraulically. The movement of the piston in the drive cylinders is operated by the
displacement of the hydraulic pump : A 3-way valve is changing the direction of the displacement(change over
valve). As long that valve is in neutral position, the hydraulic pump has no oil delivery and the concrete pump
stands still. In pumping position one solenoid of the magnet valve is powered. Change over is effected when
piston number one has reached rod end or bottom end side proximity limit switch. Change over means the
opposite solenoid of the change over valve will be powered and the pistons will change direction.

The concrete pump speed is controlled by a electric driven needle valve. Control oil is operating the pump
speed internally. The more that needle valve is closed (control pressure rises) the more oil is delivered from
the hydraulic pump to the drive cylinder and the pump speed rises.

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The cylinder of the delivery boom are also driven hydraulically. Proportional valves serve for smooth operation
of each boom section and the slewing system, on/off valves operate the support system. Due to the operating
angle of the master switches on the remote control unit the valve borings of the valves open more or less and
the speed of the boom sections rise proportionally.

All important vehicle functions are remote controlled by the HANWOO equipment :
The vehicle’s engine can be started or stopped by the remote control unit. The rpm of the engine can also be
controlled. To separate drive and pump operation, the gearbox is switched over mechanically or
electropneumatically.

The electric control system components are in limited areas.

All switchgears for boom and pump operations are situated in the central control box. The interface inside the
box is equipped with colored LED’s as a diagnosis instrument. The cable harness is connecting the control box
with all components outside. Separate from the box are valves, motors, the radio remote control and optional
the central lubrication system.

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Legend

Electric diagram : H2100023A, issued March 2003

LED: luminous diode

CS: central switchbox
3K2: the number before the letter is the page number, where in the electric diagram the part can
be found.
X10/16: X10 is the terminal inside the central switch box; 16 is the number of the inspected pin.

Terminal inside the switchbox:

green LED: output signal

yellow LED: input signal
red LED: disturbance

All parts without designated position, are inside the central switchbox. The electro hydraulic parts are
concentrated on the pump control block resp. on the boom control block.

4
AUXILIARY DRIVE
The auxiliary drive will be activated, when the machine is switched over from drive to pump operation.
1. Electric circuit : page 1
2. Parts concerned :
1S133 = gear neutral position switch
B5 = limit switch in the gearbox
1K27 = main relay
H7 = pilot lamp in the driver’s cab “power supply on”
H1 = pilot lamp at the central control box “power supply on”

3. Series fuse : 1F78, 1F100

The gear shifting lever in the driver’s cab is set to neutral position and the switch auxilliary drive is set in “pump on”
position. The vehicles power supply is activated by the ignition key.

Current flows from vehicle’s power supply via the gear neutral position switch (1S133-in the gear box) to the main
relay(1K27).

Connection from main relay to minuspole is via the gearbox-limit switch (B5-in the gearbox).

The main relay is switching on electric power to the HANWOO-equipment. The pilot lamps H7(green-in the driver’s
cab) and H1 (green-central control box) are on.

4. Remark :
The interface between HANWOO and the vehicle depends on the kind of used vehicle. For additional information
is as follows

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PUMP ON/OFF

Switching on the pump at running engine starts concrete delivery.

1. Electric circuit : page 3, page 4, and page 9

2. Parts concerned :

3S226 = switch “pump on”

S202 = switch “pump on” in the remote control unit
3K2 = relay “pump on/off”
2K238 = relay “change over”
4Y4 = solenoid of the changeover valve
4Y5 = solenoid of the changeover valve
H2 = pilot lamp in the central control box
H18 = pilot lamp in the remote control unit
3K239 = relay “pump off” disturbance
6A17 = emergency-off switching device

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 3. Series fuse : 2F81, 3F82

The switch “pump on/off” S202 (operating mode remote) or S226 (operating mode local) is activated.

The current flows from the switch to relay “pump on/off” (3K2). Relay 3K2 picks up, the contact “pump on”, is
closed and current flow from fuse 3F81 via contact 3K2 to the changeover valve with solenoid 4Y4 and 4Y5. In
the central control box the green LEDs at the label “changeover” are alternating on.

In between are relay contacts of 3K239 (pump off-disturbance) , 6A17 (emergency off) and 2K238
(changeover). 3K239 and 6A17 are closed during normal operation. Contact 2K238 is changing it’s position after
each stroke to supply both changeover solenoids with energy.

In position “pump on” the pilot lamp 3H2 (green-control panel) and H18 (remote control box) are illuminated.
As long the switch “pump on” is kept in pressed position, the green LED at the label “pump on” in control box is
on.
If switch “pump on” is pressed again, relay contact of 3K2 is moving again to basic position and the concrete
pump stops.

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CONCRETE PUMP LOCKING

The working concrete pump can be locked in case of different troubles or by command of the truckmixer driver.

1. Electric circuit : page 3, page 6

2. Parts concerned :
3S226 = switch at the control panel “pump locking”
3K239 = relay “pump off” disturbance
3K81 = relay “ pump locking”
6K69 = relay “ emergency off”
3K4 = relay “oil overheating”
6S39 = “emergency off” switches at operating positions
S39.1 = “emergency off” switches at operating positions
S39.2 = “emergency off” switches at operating positions

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3. Series fuse : 2F81, 6F76

The working concrete pump is locked through switch “pump locking” (3S226) at the control panel, oil
overheating occurs or one emergency button (6S39 or S39.1 or S39.2) is pressed.
Current flow to relay 3K239 when the pump is on. The connection to minuspole is established only when the
pump is locked via relay “pump locking” , relay “emergency off” or relay “oil overheating”.
The activation of relay “pump locking” (3K81) is done by mixer driver, pressing switch 3S226. Current flows then
from the switch to relay 3K81. Relay 3K239 gets plus potential via contact 3K81 and the pump is locked until
the operator presses the switch “pump on/off” two times.
Relay emergency off” (6K69) is on when an emergency button was pressed, and supplies 3K239 with plus
potential, the pump is locked.
Relay “oil overheating” (3K4) picks up, when the temperature of the hydraulic oil rises over 90C. Thus relay
3K239 is also supplied by pluspotential. As long the oil overheating system is on, the red pilot lamp at label 3H4
in control panel is on.
4. Remark :
As long the concrete pump is on but locked the pilot lamps “pump on/off” at the control panel and at the cable
remote control unit are flashing. Pump locking can be reset generally by pressing the switch “pump on/off” at
the remote control unit.
Condition for further pumping is that all troubles must be rectified before, otherwise the pump will be locked
again. About emergency off system see also chapter emergency off control

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CHANGE OVER

During pumping operation the stroke will change over

after the pistons have reached their end position.

1. Electric circuit : page 2, 4 and 9

1. Parts concerned :

2S65 = proximity switch “changeover” around the water box

2S65.1 = proximity switch “changeover” around the water box
2A23 = Push over hydraulic and reverse electronic device
2K238 = changeover relay
4Y4 = solenoids of the changeover valve
4Y5 = solenoids of the changeover valve
2Y7 = “push-over” valve at the control block

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3. Series fuses : 2F81 and 3F82.

Each delivery piston alternates the limit switch position when in pumping mode. Both limit positions are
indicated by a limit switch (proximity switches 2F65 and 2F65.1). One limit switch is screwed inside the drive
cylinder 1 on head end side. The second switch is screwed inside the drive cylinder 1 on rod end side.

Current flows from both limit switches alternatingly to pin 1 and 2 of the push over and reverse electronic
(2A23). The input signals are shown at the green LED 1 and 2 on the push over and reverse electronic.

The signals are running through the electronic device to the change over relay (2K238). The input signals to
that relay are shown from two green LEDs on the relay’s base.

Relay change over is responsible for alternating power supply to both solenoids of the change-over valve (as
long the concrete pump is on). Change over is indicated by a red LED on each plug of the change over
valve.

Simultaneously to each change over operation, the “push-over” valve is actuated approx. 0,3 sec. The signal
is indicated at the red LED 10 on the push over and reverse electronic device.

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4. Remark
Manual changeover from the switch on the remote control box is indicated by a red LED on each plug of the
changeover valve and also depending to the stroke at LED 7 or 8 from the push over and reverse electronic
(2A23).

On each proximity switch a yellow LED is actuated when a piece of any metal reaches a distance of approx. 2
mm to the switch in the drive cylinder 1 on rod end side and 2 mm to the switch in the drive cylinder 1 on head
end side.
In case of malfunction of the change over system, the delivery pistons stop during the stroke or are blocked in
end position.
When push- over function fails the time needed for change over will be extended.

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BACKPUMPING

At function “back pumping” the relation between the movement of the pistons and the transfer tube is changed.
The concrete pump is sucking then concrete from the pump to the hopper.

1. Electric circuit : page 2, 4 and 9

2. parts concerned :

S226 = switch “back pumping” in the control panel

S3 = switch “back pumping” in the remote control box
9K3 = relay “back pumping”
1Y3 = valve “back pumping” at pump control block

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3. Series fuse “ 4F123

In distant mode back pumping is actuated by the switch on the remote control unit. In local mode, back pumping is
effected by the switch on the central control box .

Current flows from switch “back pumping” (3S226 or S3) to the relay “back pumping” (9K3). The relay picks up and
the valve “back pumping” (4Y3) is actuated.

The green pilot lamp (labelled 9H3) in the central control box indicates the input from the back pumping switch.
The red LED at label “back pumping” (labelled Y3) in main relay board of the control box indicates the output signal
to the back pumping valve.

4. Remark :

Both switches “back pumping” are mechanically interlocked. The switch lever must be pulled for turning.

Mode “local” is for pump cleaning without the remote control box. The mode “local/remote” is changed by switch
3S44 at the central control box.

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OUTPUT CONTROL

Output of the concrete pump is electrically adjusted via the remote control.

1. Electric circuit : page 4 and 8

2. Parts concerned :

S54 = output control switch In the remote control

8K48 = relay “output control +”
8K49 = relay “output control -”
4M9 = motor needle valve at pump control block

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3. Series fuse : 4F119 (fine wire fuse 0.2A)

The switch S54 has operating positions. Activated in “plus direction” the output is rising, pressed to “minus
direction” the output is decreasing.

The current flows at “plus operation” from switch “output control” (S54) to relay “output +” (8K48), at “minus
operation” from the switch to relay “output -“ (8K49).
Both relays supply the motor needle valve (4M9) with a current of alternating polarity. Output rising is indicated
by a red LED at the label ”M9+” in main relay board of the central control box . Output decreasing is indicated
by a green LED at the label “M9-“ in main relay board of the central control box.

4. Remark :
In case of malfunction the output regulation can be done also mechanical (see operation and maintenance
manual section 3.6.5)

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OUTRIGGER OPERATION

The outrigger system prevents the pump from falling down when the delivery boom is extended.

1. Electric circuit : page 9 and 13

2. Parts concerned :

S219 = detented switch “outriggers on” in the remote control box

9K248 = relay to select boom operation/outrigger operation
13Y148 = hydraulic valve outriggers situated near to modular boom control block
6A17 = emergency off switching device

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3. Series fuse : 13F135
The pump support is to be selected by a switch. Speed and direction of the outrigger cylinders are selected
by hydraulic control levers.

Current flows in case of actuation from the switch “outrigger” (S219) to relay 9K248. If the relay is actuated
current flows via the emergency off device (6A17) to the valve “outrigger” (13Y148). Extension and retraction
of the outrigger is selected by hydraulic levers. Also the speed depends on the operation angle of these
levers.
“Outrigger system on” is indicated by a yellow pilot lamp at the label “9H74” in the control box. Power output
to the valve “outrigger” is indicated by a red LED at the label “S-LEG” in main relay board of the control box.

4. Remark :
As long the relay “outrigger on” is actuated, it is not possible to operate the boom sections.

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SLEWING OPERATION

The whole arm assembly can be moved right or left. The slewing is operated
hydraulically by 0cylinders or a slewing gear.

1. Electric circuit : page 10, 11, 12 and 13

2. Parts concerned :

S223.1 = micro switch boom control “ready for operation” in the master switch
S30 = master switch in the remote control box
R26 = speed preselector potentionmeter in the remote control box
10Y125 = proportional valve slewing at the modular boom control block
10K251 = relay boom control “ready for operation”
7S26 = limit switch slewing operation
7K46 = relay “slewing limit”
7K47 = relay “slewing limit”
7K43 = relay “ driver’s cab protection”
7K45 = relay “ driver’s cab protection”
7S40 = left switch “driver’s cab protection” at A-cylinder
7S41 = right switch “driver’s cab protection” at A-cylinder
5H12 = horn at the vehicle
13Y148 = hydraulic valve support legs or boom at the modular boom control block

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3. Series fuses : 6F76, 13F135

For slewing operation the master switch “slewing” (S30) in the remote control box is pressed to the right side
for slewing to the right and towards the left side for slewing to the left.

As long as the switch is pressed anyhow, the micro switch (S 223.1) is providing relay boom control “ready
for operation” (10K251) with current. That relay is responsible for power supply of the proportional valve “boom
operation” (13Y148). Input to central control box from the micro switch is indicated by a green LED at relay
(K251) . Output to the valve is indicated by a red LED at labelled “Y148” in main relay board of the control box

Due to angle and direction of the radio remote control master switch operation, a control signal is established
at the pin 2 and 3 of the slewing valve (10Y125). The slewing valve is no movement if current does not exceed
120mA. At a current between the approx. 120mA and approx. 650mA the movement is more and more
accelerated to the right. And at a previous value the movement is more and more accelerated to the left. The
speed depends on the distance from the maximum current value to the minimum current value.

Using the cable remote control the current value is created not by the master switch but by a separate
potentiometer (R26). The more this potentiometer is turned to the right, the more the boom speed is
accelerated. The direction depends again on the switching direction of the master switch.

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 At all pumps with a slewing gear motor the slewing is stopped by a limit switch. Current flows from the limit
switch “slewing” (7S26) to relay “slewing limit” (7K46) in right end position and to relay “slewing limit” (7K47) in
left end position. Both inputs from the limit switch are indicated by green LEDs at label “7K46 and 7K47” relay
in the main relay board of the control box.

Relay “driver’s cab protection” (7K43) left side is actuated by the left switch “driver’s cab protection” (7S40).
Indication for the input is the green LED at label “7K43” relay in the main relay board of the control box.

Relay “driver’s cab protection” (7K45) right side is actuated by the right switch “driver’s cab protection”
(7S41). Indication for the input is the green LED at label “7K45” relay in the main relay board of the control box.
Actuation of “driver’s cab protection” is always indicated by horn 5H12, output from control box is shown by red
LED at label “H12” in the main relay board of the control box.

4. Remark :
Using the cable remote control only the direction of movement is created by the master switches. The boom
speed depends on potentiometer R 26 on the cable remote control box. The more this potentiometer is turned
to the right the more the preselected arm movement is accelerated.

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A-SECTION MOVEMENT

A- section is the first of the boom assembly. It is controlled

Hydro proportionally.

1. Electric circuit : page 7, 10 and 13

2. Parts concerned :

13Y148 = hydraulic valve support legs or boom at the modular boom

control block
S15 = master switch A-section movement
S223.1 = micro switch boom control “ready for operation” at the
master switch
7K43 = relay “driver’s cab protection”
7K45 = relay “driver’s cab protection”
10Y126 = proportional valve A-section at the modular boom control block
10K251 = relay boom control “ready for operation”
7S40 = left switch “driver’s cab protection” at A-cylinder
7S41 = right switch “driver’s cab protection” at A-cylinder

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 3. Series fuse : 6F76 and 13F135
For A-section operation the master switch “A-section” (S15) in the remote control box is pressed forward for
moving the A-section down backward for moving it up.

As long as the switch is pressed anyhow, the micro switch (S 223.1) is providing relay boom control “ready for
operation” (10K251) with current. That relay is responsible for power supply of the proportional valve “boom
operation” (13Y148). Input to central control box from the micro switch is indicated by a green LED at relay
(K251) . Output to the valve is indicated by a red LED at labelled “Y148” in main relay board of the control box

Due to angle and direction of the radio remote control master switch operation, a control signal is established
at the pin 2 and 3 of the A-section valve (10Y126). The A-section valve is no movement if current does not
exceed 120mA. At a current between the approx. 120mA and approx. 650mA the movement is more and more
accelerated to upwards. And at a previous value the movement is more and more accelerated to downwards.
The speed depends on the distance from the maximum current value to the minimum current value.

Using the cable remote control the voltage value is created not by the master switch but by a separate reostat
(R26). The more this reostat is turned to the right, the more the boom speed is accelerated. The direction
depends again on the switching direction of the master switch

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 Relay “driver’s cab protection” (7K43) left side is actuated by the left switch “driver’s cab protection” (7S40).
Indication for the input is the green LED at label “7K43” relay in the main relay board of the control box.

Relay “driver’s cab protection” (7K45) right side is actuated by the right switch “driver’s cab protection” (7S41).
Indication for the input is the green LED at label “7K45” relay in the main relay board of the control box. Actuation
of “driver’s cab protection” is always indicated by horn 5H12, output from control box is shown by red LED at label
“H12” in the main relay board of the control box.

4. Remark :
The driver’s cab protection system is only installed on machines where a destruction of the driver’s cab by the
A-section could be possible. The switches are mounted on the right and left side of the A-cylinder and look like
small antennas.

For basic function of the proportional boom control see also remark of chapter SLEWING OPERATION.

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B-SECTION MOVEMENT

The B-section is the second of the whole boom assembly. It is controlled proportionally.

1. Electric circuit : page 10, 11, and 13

2. Parts concerned :

S16 = master switch for B-section movement

In the remote control box
11Y127 = proportional valve B-section at the modular boom
control block
S223.2 = micro switch boom control “ready for operation” at the master switch
10K251 = relay boom control “ready for operation”
13Y148 = hydraulic valve support legs or boom at the modular boom control block

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 3. Series fuses : 6F76 and 13F135

For B-section operation the master switch “B-section” (S16) in the remote control box is pressed to direction up
or direction down.

As long as the switch is pressed anyhow, the micro switch (S 223.2) is providing relay boom control “ready for
operation” (10K251) with current. That relay is responsible for power supply of the proportional valve “boom
operation” (13Y148). Input to central control box from the micro switch is indicated by a green LED at relay
(K251) . Output to the valve is indicated by a red LED at labelled “Y148” in main relay board of the control box

Due to angle and direction of the radio remote control master switch operation, a control signal is established at
the pin 2 and 3 of the B-section valve (11Y127). The B-section valve is no movement if current does not exceed
120mA. At a current between the approx. 120mA and approx. 650mA the movement is more and more
accelerated to upwards. And at a previous value the movement is more and more accelerated to downwards. The
speed depends on the distance from the maximum current value to the minimum current value.

4. Remark
For basic function of the proportional boom control see also remark of chapter SLEWING OPERATION.

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 C-SECTION MOVEMENT

The C-section is the third arm of the whole boom assembly. It is controlled proportional

1. Electric circuit : page 10, 11 and 13

2. Parts concerned :

S17 = master switch C-section-movement

In the remote control box
11Y128 = proportional valve C-section at the modular boom control block
10K251 = relay boom control “ready for operation”
S223.2 = micro switch boom control “ready for operation” at the
Master switch
13Y148 = hydraulic valve support legs or boom at the modular boom control block

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3. Series fuses : 6F76 and 13F135
For C-section operation the master switch “C-section” (S17) in the remote control box is pressed to the right
side for moving the A-section down and towards the left side for moving it up.

As long as the switch is pressed anyhow, the micro switch (S 223.2) is providing relay boom control “ready for
operation” (10K251) with current. That relay is responsible for power supply of the proportional valve “boom
operation” (13Y148). Input to central control box from the micro switch is indicated by a green LED at relay
(K251) . Output to the valve is indicated by a red LED at labelled “Y148” in main relay board of the control box

Due to angle and direction of the radio remote control master switch operation, a control signal is established at
the pin 2 and 3 of the C-section valve (11Y128). The C-section valve is no movement if current does not exceed
120mA. At a current between the approx. 120mA and approx. 650mA the movement is more and more
accelerated to upwards. And at a previous value the movement is more and more accelerated to downwards.
The speed depends on the distance from the maximum current value to the minimum current value.

4. Remark :
For basic functions of the proportional boom control see also remark of chapter SLEWING OPERATION.

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D-SECTION MOVEMENT

The D-section is the fourth arm of the whole boom assembly.

It is controlled proportionally.
At machines with 4 section booms it is last one.

1. Electric circuit : page 10, 12, and 13

2. Parts concerned :

S18 = master switch D-section In the remote control box

12Y129 = proportional valve D-section at the modular boom control block
S223.3 = micro switch boom control “ready for operation” at the master switch
10K251 = relay boom control “ready for operation”
13Y148 = hydraulic valve support legs or boom at the modular boom control block

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 3. Series fuses “ 6F76 and 13F135
For D-section operation the master switch “D-section” (S18) in the remote control box pressed to direction
up or direction down.

As long as the switch is pressed anyhow, the micro switch (S 223.3) is providing relay boom control “ready
for operation” (10K251) with current. That relay is responsible for power supply of the proportional valve
“boom operation” (13Y148). Input to central control box from the micro switch is indicated by a green LED at
relay (K251) . Output to the valve is indicated by a red LED at labelled “Y148” in main relay board of the
control box

Due to angle and direction of the radio remote control master switch operation, a control signal is
established at the pin 2 and 3 of the D-section valve (12Y129). The D-section valve is no movement if current
does not exceed 120mA. At a current between the approx. 120mA and approx. 650mA the movement is more
and more accelerated to upwards. And at a previous value the movement is more and more accelerated to
downwards. The speed depends on the distance from the maximum current value to the minimum current
value.

4. Remark :
For basic functions of the proportional boom control see also remark of chapter SLEWING OPERATION.

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ENGINE START / STOP REMOTE CONTROL

Start/stop remote control of the engine is possible. The function is optional.

1. Electric circuit : page 4, 9 and 14

2. Parts concerned :

S22 = switch engine start/stop in the remote control box

14K22 = relay engine start in the driver’s cab
14S67 = start button resp. ignition contact (part of the vehicle’s
chassis-manufacturer) in the driver’s cab
14K25 = starter protection relay
9K82 = relay engine stop
4Y60 = pneumatic valve engine stop in the vehicle’s chassis
(For mechanical engine)

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3. Series fuses : 6F76

The switch engine start is operating the relay engine start in the driver’s cab. Depending on the kind of vehicle
the relay belongs to the vehicle or is installed by HANWOO.

From start switch (S22) current flows to the start relay (14K22).

The start relay is actuating the starter protection relay (14K25). The relay is providing the engine starter with
current.

Engine start procedure is only possible when current supply to the starter is released by the starter protection
relay.

The release depends on :

- the engine is not already running,

- the last start trial is more than 7 sec. ago,

- the ignition key in the driver’s cab is in position on.

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Pressing switch S22 in stop position during running engine, current flows to the pneumatic valve “engine stop”
(4Y60) and the engine stops. Depending in the kind of vehicle, it could be necessary to reduce the engine’s
rpm on minimum level before engine stop procedure. Otherwise it is not possible to stop the engine. The input
to the control box is indicated by a green LED at the label “9K82” in the main relay board. Output signal to the
valve is indicated by a red LED at the label “Y60”.

4. Remark
The exact wiring of the interface between the HANWOO equipment and the vehicle’s manufacturer must occur
in accordance with driver’s cab, divided into the different types of vehicles used.

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RPM CONTROL OF THE ENGINE

Increasing and decreasing of the engine’s rpm via remote control

is possible.

1. Electric circuit : page 6 and 8

2. Parts concerned :

S21 = switch “RPM(gas +)/RPM(gas –)“ in the remote control box

6Y22 = pneumatic valve “RPM(gas +)”
6Y23 = pneumatic valve “RPM(gas –)“

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HORN

The horn serves for signal exchange between the operator and

the truckmixer driver but also as an alarm signal when the cab’s protection switch is actuated.

1. Electric circuit : page 5, 7 and 9

2. Parts concerned :

5S175 = switch “horn” at the control panel

5K24 = relay “horn”
S219 = switch “horn” in the remote control box
7K43 = relay “driver’s cab protection”
7K45 = relay “driver’s cab protection”

35
 1. Series fuse : 5F64
When the switch “horn” is pressed at the remote control box or at the control panel, the horn is actuated by
relay 5K24.

Current flows from the switch “horn”(5S175) or from the switch “horn” (S219) to relay “horn” (5K24). The relay
is providing the horn (5H12) with power. The input from the switch to main relay board of the control box is
indicated by a green LED at relay ”horn” (5K24). The output signal to the horn is indicated by a red LED at label
“horn or H12”.

As long one of the driver’s cab protection switches is on, the appropriate protection relays (7K43 or 7K45)
supply also relay “horn” (5K24) with current. The input signal from these switches to the control box are indicated
by two green LEDs at relay “boom slewing” (7K46 resp. 7K47).

2. Remark
The horn (5H12) is regular the vehicle’s one.
On some vehicles the horn is controlled by a minus signal (for example MAN). In these cases a second horn is
used or a signal changing relay is installed in the driver’s cab.

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COOLER FAN

When the hydraulic oil Temperatures rising above 55℃, a fan behind the oil cooler is switched on
automatically.
It can also be started manually.

1. Electric diagram(599-00021) : page 1 and 5

2. Parts concerned :
5B2 = thermo probe 55℃
5K40 = power relay cooler fan on
5S19 = switch “cooler fan on” at the control box
1M2 = cooler fan
5H19 = green pilot lamp “cooler fan on” at the control box

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 3. Series fuses : 1F94 and 5F64
The cooler fan is started at a temperature of 55℃ or by a switch at the control box.
Current flows directly to the power relay “cooler fan” (5K40). The connection to minus is established via switch
“cooler fan” (5S19) or thermo probe (5B2). Minus signal input to the control box is indicated by a green pilot
lamp of the indicator “cooler fan” (5H19). Outside at the control box a green pilot lamp at label “cooler fan” is on.

The power relay “cooler fan” supplies the cooler fan itself with current, indication in the power/toggle relay
board of the control box is the red LED label “cooler fan” (K40).

4. Remark
The current to the cooler fan flows directly from the battery line via terminal PB12 to the fan. The terminal
PB12 is a connector in the power/toggle relay board.

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EMERGENCY OFF CONTROL

The mobile pump is equipped with a proofed

emergency off
switching device. This device contains self monitoring circuits,
which are dropped out in case of emergency or an internal failure.

1. Electric circuit : page 3, 6 and 8

2. Parts concerned :
6A17 = emergency off switching device
6K69 = relay emergency off
6H28 = red pilot lamp “emergency off” at the control box
6S 39 = emergency off buttons at the control box
S39.1 = emergency off button at the left side
S39.2 = emergency off button at the right side
3K239 = relay “pump off” disturbance relay
H14 = red LED “emergency off” in the cable remote control box

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 3. Series fuses : 3F82, 6F76

When all emergency off buttons are released, the emergency off switching device is in operating position.

Under normal conditions the input to the emergency off switching device (6A17) A1 and A2 is provided with
power. It is indicated by the red LED at the emergency off switching device (6A17). The device itself is
equipped with two green LED indicators to show the situation “ready for service”. If at least one emergency
button (S 39…) is pressed down, the LED indicators on the emergency off device go out.

When no emergency button is pressed but the device realizes an internal failure only the green LED
indicators on the device itself go out but the red LED at the emergency off switching device (6A17) stays on.

The three n/o and n/c circuits of the emergency system are shown on the cover of the emergency off
switching device. Under operating conditions contacts 13-14, 23-24 and 33-34 are closed. The contact 41-42 is
open. In case of emergency the contacts are in the position labelled on the cover of the device

Due to open contact 13-14 in case of emergency, both plugs of the changeover valve are getting currentless,
the concrete pump stops running.

Due to open contact 23-24 the hydraulic support legs or boom selection valve “boom and legs operation” are
off. Pilot oil is running into the oil tank and neither boom nor outriggers can be operated.

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Due to open contact 33-34 the engine’s rpm are reduced to minimum level.

Due to closed contact 41-42 the relay “emergency off” (6K69) picks up and the concrete pump is stopped
additionally via relay “pump off” disturbance (3K239). The green light “pump on” at the control panel is flashing.
Current is also flowing through relay “emergency off” to the red LED “emergency off” (6H28) outside the control
box.

There is a second red LED “emergency off” (H14) at the cable remote control box.

4. Remark
The following reasons can lead into an emergency drop out:

- An emergency button was pressed.

- An emergency button has failed.
- The emergency off switching device has failed.
- One of the fuses 3F82, 6F76 has blown.
- Operation mode with radio remote control :
- Radio propagation/communication disturbance.
- The battery is discharged.
- A fine wire fuse in the transmitter resp. receiver is broken.

About locking the pump function see also chapter PUMP ON/OFF and CONCRETE PUMPING LOCKING.

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