Emc32tcf - Trouble Shootin33

ELECTRICAL SYSTEM
1
TABLE OF CONTENTS
Troubleshooting – Electrical System …………………………………………
3
Reading and Understanding of CAD Electrical Circuit Diagram ………

… 5
Wiring Harness Illustrations …………………………………………………..

10
Overview …………………………………………………………………………10
Introduction To DHI Electrics ……………………………………………….

10
Auxillary Drive …………………………………………………………………... 1

1
Pump On/off ……………………………………………………………………... 1

2
Concrete Pump Locking ……………………………………………………….

13
Changeover ……………………………………………………………………… 1
4
Backpumping ……………………………………………………………………. 1
6
Output Control ……………………………………………………………………1

6
Outrigger Operation ……………………………..…………………………….. 1

7
Slewing Operation ……………………………………………………………… 1

8
A-section Movement …………………………………………………………… 2

0
B-section Movement …………………………………………………………… 2

1
2
C-section Movement …………………………………………………………… 2
2
D-section Movement …………………………………………………………… 2

3
Engine Start/stop Remote Control …………………………………………...

24
RPM Control Of The Engine ………………………………………………...…

26
Horn ……………………………………………………………………………….. 2
6
Cooler Fan ………………………………………………………………..……… 2

7
Emergency Off Control …………………………………………………………

28
TROUBLESHOOTING – ELECTRICAL SYSTEM
Problem Cause Remedy

Pump is switched The specified minimum en Increase engine speed.
on, but will not st gine speed for pumping ope
art. rations of 900 rpm is not a
chieved.  rpm
Pumping rate too low. Increase pumping rate.
EMERGENCY SHUT-DOWN Unlock EMERGENCY

chain is activated (EMERG SHUT-DOWN chain.
E-
NCY SHUT-DOWN button
pressed)
3
The red indicator l The hydraulic fluid has over Allow the hydraulic fluid to
ight for “fluid over heated. cool and, if necessary, to
heating” is lit. p up or replace the water
in the water box.
The fan on the heat excha Check fan function and re
nger is defective. place the fan motor if nec
essary.
Temperature sensor B1 is d Replace temperature senso
efective. r. Hold temperature sensor
connection to ground to c
heck.
The connection cable to the Clean and fasten the conn
temperature sensor is loos ections on the temperature
e. sensor.
The fan connection is corro Clean the terminals on the
ded. fan motor and fasten the
connection cables properly.
Caution
Avoid contact with
ground.
The A-arm no lon Water in the driver’s cab cir Open and dry out the circ
ger moves doward cuit breaker (seat on the A uit breaker. Extend A arm
s(warning signal s cylinder) defective or unfavo upwards.
ounds) urable position of the boom.
Caution
No protective function
Problem Cause Remedy

The fan on the oil Thermal contact switch B2 Check terminal (and groun
cooler no longer defective (seat on the conn d contact). Replace therma
switches in autom ecting flange of the cooler) l contact switch (do not for
atically. get copper gasket). Switch
on cooler motor by the m
anual switch.
4
The engine speed Leak in the air system. Check air system for leaks
reduces spontanc . Use leak spray if necess
eously. ary, Tighten air unions on
the pneumatic throttle adju
stment valves.
EMERGENCY SHUT-DOWN Brief EMERGENCY SHUT-
pulses from the radio contr DOWN pulses from the ra
ol system. dio control system can be
caused by radio interferenc
e. If nesessary, move the t
ransmitter site. In some cir
cumstances on particular c
onstruction site it will be n
ecessary to work with the
cable remote control syste
m. Change channel if the
radio control system has c
hannel selection.
The radio transmit The batteries have inadequa Clean the contacts in the
ter has to be sha te contacts in the battery co battery comportment thorou
ken to activate it. mpartment. ghly and bend carefully.
The radio remote Fuses in the receiver or tra Check fuses.
control system no nsmitter have blown
longer operates p To replace transmitter fuse,
erfectly, some fun open transmitter casing wi
ctions are incorret. th 4 mm allen key.
To check the fuse in the r
eceiver, unscrew casing lid
, undo the front PCB and
flap down. The microfuse
s are mounted on the rear
PCB. The current ratings
are marked next to the fus
es.
READING AND UNDERSTANDING OF CAD ELECTRICA

L CIRCUIT DIAGRAMS
1. Prescribed form
Prescribed form is divided into 8 current paths whitch serve to rapidl
y locate relay and corresponding contacts by this coordinate system.
Cross reference helps here.
5
current path
Fig. 1 Prescribed form
2. Cross reference
Here one understands the instruction to relay coil, where the contacts
to this relay are found and, vice-versa, instructions to the contacts
where corresponding relay coil are found. This cross ference is also
applied in all other electrical components and wires.
Example : extract from dwg no. 599-00021, page 5
6
current path
Continuous
numbering
K is the component symb

ol
for a relay
This 6 means that the relay is

drawn on page 6 of electric cir
-
cuit diagram
6K69 = component symbol
Contact of relay 5K27

5
Current path 5 on the
same page
Page No. Current path No.
/6.2 = Current path 2 on page 6
Fig. 2 Cross reference
Extract from electric circuit diagram 599-00021 page 4
7
Current path
Relay coil of this contact is

found on page 9 in current
path 3
Component symbol
for a valve solenoid
Devicing No. according

to hydraulic circuit dia
g-ram directly below th
e component symbol i.e Hydraulic back
. in the same path pumping control
valve
Fig. 3 Reference to the hydraulic circuit diagram
3. Reference to the hydraulic circuit diagram
8
In order to achieve better relationship between electric and hydra
ulic circuit diagrams appropriate references relating hydraulics are m
ade on electrical circuit diagram – see above – and, vice-versa, elect
rical circuit references are made on hydraulic diagrams.
Extract from hydraulic circuit diagram
Page No. relevent to electric circuit diagram
. Y 3
Component symbol from electrical circuit diagram for

back pumping solenoid valve
Fig. 4. Reference to the electrical circuit diagram
4. Code letters to indicate the nature of a device
9
Code lette Nature of device Examples
r
10
Assemblies, sub-as Combinations of components, assemblies
semblies, chopper and sub-assemblies that from a constructi
A amplifiers ve unit but which cannot clearly allocated
to any other code letter.
Transducers of non Thermo-electrical sensors, tacho-generator
-electrical quantities s, pulse transmitters, transducers indicatin
B to electrical values g pressures, quantities, densities, levels o
and vice-versa r temperatures.
Protective device Fuses, bimetal trips, magnetic trips, press
F ure monitors
Generators, alternat Rotary generators, batteries
G ors, power supplies
Signalling devices Optical and acoustic signalling devices, pi
H lot lamps
Relays and contact Power contactors, auxiliary contactors, au
K ors xiliary relays, time relays
Motors
M
Measuring instrume Indicating instruments, chart recorders, int
P nts, meters and tes egrating meters
ting devices
Power voltage swit Power switches, isolators, switches in a
ches main power circuit, star-delta switches, po
Q le-changing switches, protective motor swi
tches.
Resistors Adjustable resistors, potentiometers, rheos
R tats, fixed resistors, motor starters, PTC r
esistors.
On/off and selector Control switches, key switches, limit switc
S switches hes, non-locking push-button switches, illu
minated push-button switches
Transformers Voltage transformers, current transformers
T , mains voltage transformers, isolating tra
nsformers, control transformers
Modulators, convert Remote control devices
ers of electrical val
ues to other electri
U cal values, PTC re
sistor tripping devic
es
Thermionic valves, Diodes
V transistors, diodes
Terminals, seperabl Isolating plug and socket connectors, test
X e connectors, plugs sockets, multi connectors, terminal strips,
and sockets cable connectors
11
Code lette Nature of device Examples
r
Electrically actuated
Y mechanical device
s, valves
WIRING HARNESS ILLUSTRATIONS

The electrical system diagram(s) is available in the “hydraulic and electrical s
chematic shop manual.” This manual is a collection of diagrams and schemat
ics for a number of models.
OVERVIEW
Electric power supply system of the truck serve operating voltage to the elect
rical equipment for concrete pump control unit. The supply system contains t
wo 12 volt batteries connected in series and a three AC generator with a re
ctifier. The electrical system for this equipment is DC 24 volts. The rated volt
age for all electric components is 24 volts.
INTRODUCTION TO DHI ELECTRICS

Daewoo-truck mounted concrete pumps are equipped with a modern and reli
able 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 th

e 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 deliv
ery and the concrete pump stands still. In pumping position one solenoid of t
he magnet valve is powered. Change over is effected when piston number o
ne has reached rod end or bottom end side proximity limit switch. Change o
ver means the opposite solenoid of the change over valve will be powered a
nd the pistons will change direction.
The concrete pump speed is controlled by a electric driven needle valve. Co

ntrol oil is operating the pump speed internally. The more that needle valve i
s closed (control pressure rises) the more oil is delivered from the hydraulic
pump to the drive cylinder and the pump speed rises.
The cylinder of the delivery boom are also driven hydraulically. Proportional v
12
alves serve for smooth operation of each boom section and the slewing syst
em, on/off valves operate the support system. Due to the operating angle of
the masterswitches 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 remotecontrolled by the DHI equipment :

The vehicle’s engine can be started or stopped by the remote control unit. T
he rpm of the engine can also be controlled. To separate drive and pump op
eration, 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 co
ntrol 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 al
l components outside. Separate from the box are valves, motors, the radio re
mote control and optional the central lubrication system.
AUXILLIARY DRIVE
The auxilliary drive will be activated, when the machine is switched over fro
m drive to pump operation.
1. Electric diagram(599-00021) : page 1

2. Parts concerned :
1S133 = gear neutral position switch

B5 = limit switch in the gearbox
1K27 = main relay
H7 = pilotlamp in the driver’s cab “power supply on”
H1 = pilotlamp 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 su
pply is activated by the ignition key.
Current flows from vehicle’s power supply via the gear neutral position swit
ch (1S133-in the gear box) to the main relay(1K27).
Connection from main relay to minuspole is via the gearbox-limitswitch (B5-

in the gearbox).
The main relay is switching on electric power to the DHI-equipment. The p
13
ilot lamps H7(green-in the driver’s cab) and H1 (green-central control box)
are on.
4. Remark :
The interface between DHI and the vehicle depends on the kind of used v
ehicle. For additional information is as follows
PUMP ON/OFF
Switching on the pump at running engine starts concrete delivery.
1. Electric diagram(599-00021) : page 3, page 4, and page 9

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
14
H2 = pilotlamp in the central control box
H18 = pilotlamp in the remote control unit
3K239 = relay “pump off” disturbance
6A17 = emergency-off switching device
3. Series fuse : 3F81
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 pi
cks up, the contact “pump on”, is closed and current flow from fuse 3F81 vi
a contact 3K2 to the changeover valve with solenoid 4Y4 and 4Y5. In the ce
ntral control box the green LEDs at the label “changeover” are alternating on
.
In between are relaycontacts of 3K239 (pump off-disturbance) , 6A17 (emerg

ency off) and 2K238 (changeover). 3K239 and 6A17 are closed during norma
l operation. Contact 2K238 is changing it’s position after each stroke to suppl
y both changeover solenoids with energy.
In position “pump on” the pilot lamp 3H2 (green-control panel) and H18 (rem
ote control box) are illuminated. As long the switch “pump on” is kept in pre
ssed 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 t
o basic position and the concrete pump stops.
4. Remark :
By pressing a special switch (3S226) it is possible to stop the pump indepen

dent from function on/off. In this case the pump stays in position on but the
movement of the pistons is locked until the pump on/off switchwas pressed t
wo times. See also chapter concrete pump locking and emergency-off co
ntrol.
With switch “operating mode remote/local” (3S44) at central control box the o
peration of function pump on/off and backpumping can be switched over from
remote control to the control panel. The remote control is then out of operat
ion.
CONCRETE PUMP LOCKING

The working concrete pump can be locked in case of different troubles or by
command of the truckmixer driver.
15
1. Electric diagram(599-00021) : page 3, page 6
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
3. Series fuse : 3F81, 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 connectio to minusp
ole is established only when the pump is locked via relay “pump locking” , r
elay “emergency off” or relay “oil overheating”.
The activation of relay “pump locking” (3K81) is done by mixerdriver, pressin

g switch 3S226. Current flows then from the switch to relay 3K81. Relay 3K
239 gets plus potential via contact 3K81 and the pump is locked until the op
erator 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 l
ong the oil overheating system is on, the red pilotlamp at label 3H4 in contr
ol 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 lo
cking can be reset generally by pressing the switch “pump on/off” at the rem
ote control unit.
Condition for further pumping is that all troubles must be rectified before, oth
16
erwise the pump will be locked again. About emergency off system see also
chapter emergency off control
CHANGEOVER
During pumping operation the stroke will change over
after the pistons have reached their end position.
1. Electric diagram(599-00021) : page 2, 4 and 9
2S65 = proximity switch “changeover” around the waterbox

2S65.1 = proximity switch “changeover” around the waterbox
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 controlblock
3. Series fuses : 2F81 and 3F82.
Each delivery piston alternates the limit switch position when in pumping mo
de. Both limit positions are indicated by a limit switch (proximity switches 2F
65 and 2F65.1). One limit switch is screwed inside the drive cylinder 1 on h
ead end side. The second switch is screwed inside the drive cylinder 1 on r
od end side.
Current flows from both limit switches alternatingly to pin 1 and 2 of the pus
h over and reverse electronic (2A23). The input signals are shown at the gre
en LED 1 and 2 on the push over and reverse electronic.
The signals are running through the electronic device to the change over rel
ay (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 solenoi
ds 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 actua

ted approx. 0,3 sec. The signal is indicated at the red LED 10 on the push
over and reverse electronic device.
4. Remark
17
Manual changeover from the switch on the remote control box is indicated b
y a red LED on each plug of the changeover valve and also depending to t
he 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 met
al 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 en
d side.
In case of malfunction of the change over system, the delivery pistons stop
during the stroke or are blocked in endpostion.
When push- over function fails the time needed for change over will be exte
nded.
BACKPUMPING
At function “backpumping” the relation between the movement of the pistions
and the transfer tube is changed. The conrete pump is sucking then concre
te from the pump to the hopper.
2. parts concerned :
S226 = switch “backpumping”in the control panel

S3 = switch “backpumping” in the remote control box
9K3 = relay “backpumping”
1Y3 = valve “backpumping” at pump controlblock
3. Series fuse “ 4F123
In distant mode backpumping is actuated by the switch on the remote control

unit. In local mode, backpumping is effected by the switch on the central co
ntrol box .
Current flows from switch “backpumping” (3S226 or S3) to the relay “backpu
mping” (9K3). The relay picks up and the valve “backpumping” (4Y3) is actu
ated.
The green pilotlamp (labelled 9H3) in the central control box indicates the in
put from the backpumping switch. The red LED at label “backpumping” (lab
elled Y3) in main relay board of the control box indicates the output signal t
o the backpumping valve.
4. Remark :
18
Both switches “backpumping” 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.
OUTPUT CONTROL
Output of the concrete pump is electrically adjusted via the remote control.
1. Electric diagram(599-00021) : page 4 and 8
S54 = output control switch In the remote control

8K48 = relay “output control +”
8K49 = relay “output control -”
4M9 = motor needle valve at pump controlblock
3. Series fuse : 4F119 (fine wire fuse 0,2A)
The switch S54 has operating positions. Activated in “plus direction” the outp
ut is rising, pressed to “minus direction” the output is decreasing.
The current flows at “plus operation” from switch “output control” (S54) to rel
ay “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 (s

ee operation and maintenance manual section 3.6.5)
OUTRIGGER OPERATION
The outrigger system prevents the pump from falling down when the delivery
boom is extended.
19
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 modula
r boom
controlblock
6A17 = emergency off switching device
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 outri
gger is selected by hydraulic levers. Also the speed depends on the operatio
n angle of these levers.
“Outrigger system on” is indicated by a yellow pilotlamp at the label “9H74”

in the control box. Power output to the valve “outrigger” is indicated by a re
d 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.
SLEWING OPERATION
The whole arm assembly can be moved right or left. The slewing is operate
d hydraulically by 0cylinders or a slewing gear.
1. Electric diagram(599-00021) : page 10, 11, 12 and 13
S223.1 = microswitch boom control “ready

for operation” in the masterswitch
S30 = masterswitch in the remote control box
R26 = speed preselector potentionmeter in the remote control
box
20
10Y125 = proportional valve slewing at the modular boom co
ntrol
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 b
oom
control block
3. Series fuses : 6F76, 13F135
For slewing operation the masterswitch “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 microswitch (S 223.1) is provi

ding relay boom control “ready for operation” (10K251) with current. That rela
y is responsible for power supply of the proportional valve “boom operation”
(13Y148). Input to central control box from the microswitch 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 masterswitch operatio
n, a control signal is established at the pin 2 and 3 of the slewing valve (10
Y125). The slewing valve is no movement if current does not exceed 120mA
. At a current between the approx. 120mA and approx. 650mA the movemen
t is more and more accelerated to the right. And at a previous value the mo
vement 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 maste
rswitch but by a separate potentiometer (R26). The more this potentiometer i
s turned to the right, the more the boom speed is accelerated. The direction
depends again on the switching direction of the masterswitch.
At all pumps with a slewing gear motor the slewing is stopped by a limit swi
tch. 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 p
21
osition. Both inputs from the limit switch are indicated by green LEDs at labe
l “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 la
bel “7K43” relay in the main relay board of the control box.
Relay “driver’s cab protection” (7K45) right side is actuated by the right switc
h “driver’s cab protection” (7S41). Indication for the input is the green LED a
t 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 con
trol box.
3. Remark :
Using the cable remote control only the direction of movement is created by
the masterswitches. 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.
A-SECTION MOVEMENT
A- section is the first of the boom assembly. It is controlled
hydroproportionally.

oom
control block
S15 = masterswitch A-section movement
S223.1 = microswitch boom control “ready for operation” at the
masterswitch
7K43 = relay “driver’s cab protection”
10Y126 = proportional valve A-section at the modular boom contr
ol
block
22
7S40 = left switch “driver’s cab protection” at A-cylinder
7S41 = right switch “driver’s cab protection” at A-cylinder
3. Series fuse : 6F76 and 13F135
For A-section operation the masterswitch “A-section” (S15) in the remote cont
rol box is pressed forward for moving the A-section down backward for movi
ng it up.

n, 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 12
0mA. At a current between the approx. 120mA and approx. 650mA the move
ment is more and more accelerated to upwards. And at a previous value the
movement is more and more accelerated to downwards. The speed depend
s on the distance from the maximum current value to the minimum current v
alue.
Using the cable remote control the voltage value is created not by the maste
rswitch but by a separate reostat (R26). The more this reostat is turned to t
he right, the more the boom speed is accelerated. The direction depends ag
ain on the switching direction of the masters witch
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 la
bel “7K43” relay in the main relay board of the control box.
Relay “driver’s cab protection” (7K45) right side is actuated by the right switc
h “driver’s cab protection” (7S41). Indication for the input is the green LED a
t 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 con
trol box.
4. Remark :
23
The driver’s cab protection system is only installed on machines where a de
struction 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 chapt
er SLEWING OPERATION.
B-SECTION MOVEMENT
The B-section is the second of the whole boom assembly.
It is controlled proportionally.
1. Electric diagram(599-00021) : page 10, 11, and 13
S16 = masterswitch for B-section movement

In the remote control box
11Y127 = proportional valve B-section at the modular boom
control block
masterswitch
oom
control block
3. Series fuses : 6F76 and 13F135
For B-section operation the masterswitch “B-section” (S16) in the remote cont
rol box is pressed to direction up or direction down.

n, a control signal is established at the pin 2 and 3 of the B-section valve (
24
11Y127). The B-section valve is no movement if current does not exceed 12
alue.
4. Remark
For basic function of the proportional boom control see also remark of chapt
er SLEWING OPERATION.
C-SECTION MOVEMENT
The C-section is the third arm of the whole boom assembly.
It is controlled proportional
S17 = masterswitch C-section-movement

In the remote control box
11Y128 = proportional valve C-section at the modular boom
control block
Masterswitch
oom
control block
For C-section operation the masterswitch “C-section” (S17) in the remote con
trol box is pressed to the right side for moving the A-section down and towa
rds the left side for moving it up.

25
n, 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 12
alue.
4. Remark :
For basic functions of the proportional boom control see also remark of chap
ter SLEWING OPERATION.
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 diagram(599-00021) : page 10, 12, and 13
S18 = masterswitch D-section In the remote control bo

x
12Y129 = proportional valve D-section at the modular boom
control block
S223.3 = microswitch boom control “ready foro peration”
at the masterswitch
13Y148 = hydraulic valve support legs or boom at the modular
boom control block
3. Series fuses “ 6F76 and 13F135
For D-section operation the masterswitch “D-section” (S18) in the remote con
trol box pressed to direction up or direction down.
26
n, 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 12
alue.
4. Remark :
For basic functions of the proportional boom control see also remark of chap
ter SLEWING OPERATION.
ENGINE START / STOP REMOTE CONTROL

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

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 = pneumaticvalve engine stop in the vehicle’s chassis
3. Series fuses : 6F76
The switch engine start is operating the relay engine start in the driver’s cab.
27
Depending on the kind of vehicle the relay belongs to the vehicle or is inst
alled by DAEWOO HEAVY INDUSTRIES Ltd.
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.
Pressing switch S22 in stop position during running engine, current flows to t
he 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 mi
nimum level before engine stop procedure. Otherwise it is not possible to sto
p the engine. The input to the control box is indicated by a green LED at th
e label “9K82” in the main relay board. Output signal to the valve is indicate
d by a red LED at the label “Y60”.
4. Remark
The exact wiring of the interface between the DHI equipment and the vehicle
’s manufacturer must occur in accordance with driver’s cab, divided into the
different types of vehicles used.
RPM CONTROL OF THE ENGINE

Increasing and decreasing of the engine’s rpm via remote control
is possible.
S21 = switch “gas +/gas –“ in the remote control bo

x
6Y22 = pneumatic valve “gas +”
28
6Y23 = pneumatic valve “gas –“
3. Series fuse : 6F74, 6F75 and 6F76
The switch for rpm control has two operating positions.
Current flows in position “gas+” from the switch (S21) to valve “gas +” (6Y22
). The input from the switch to main relay board of the control box is indicat
ed by a green LED at label “rpm +”.
Current flows in position “gas –“ from the switch (S21) to valve “gas –“ (6Y2
3). The input from the switch to main relay board of the control box is indic
ated by a green LED at label “rpm –“. The LED is on as long the switch is
not pressed (normally closed type).
The output to the valve “gas –“ is indicated by a green LED at label “rpm –
“.
4. Remark
In case of emergency the rpm are reduced automatically to minimum due to

contact 33/34 of the emergency control device (6A17)
Both pneumatic valves are situated in a separate housing around the boom
pedestal.
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.
5S175 = switch “horn” at the control panel

5K24 = relay “horn”
S219 = switch “horn” in the remote control box
29
When the switch “horn” is pressed at the remote control box or at the contro
l 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. T
he 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 indi
cated by a red LED at label “horn or H12”.
As long one of the driver’s cab protection switches is on, the appropriate pro
tection relays (7K43 or 7K45) supply also relay “horn” (5K24) with current. T
he input signal from these switches to the control box are indicated by two
green LEDs at relay “boom slewing” (7K46 resp. 7K47).
4. Remark
The horn (5H12) is regular the vehicle’s one.
On some vehicles the horn is controlled by a minus signal (for example MA

N). In these cases a second horn is used or a signal changing relay is insta
lled in the driver’s cab.
COOLER FAN
When the hydraulic oil Temperatureis rising above 55℃,
a fan behind the oil cooler is switched on automatically.
It can also be started manually.
5B2 = thermoprobe 55℃

5K40 = power relay cooler fan on
5S19 = switch “cooler fan on” at the control box
1M2 = cooler fan
5H19 = green pilotlamp “cooler fan on” at the control box
The cooler fan is started at a temperature of 55℃ or by a switch at the con

trol box.
30
Current flows directly to the power relay “cooler fan” (5K40). The connection
to minus is established via switch “cooler fan” (5S19) or thermoprobe (5B2).
Minus signal input to the control box is indicated by a green pilotlamp of the
indicator “cooler fan” (5H19). Outside at the control box a green pilotlamp at
label “cooler fan” is on.
The power relay “cooler fan” supplies the cooler fan itself with current, indica
tion in the power/toggle relay board of the control box is the red LED label “
cooler fan” (K40).
1. 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.
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.
6A17 = emergency off switching device

6K69 = relay emergency off
6H28 = red pilotlamp “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 contr
ol
box
3. Series fuses : 3F82, 6F76
When all emergency off buttons are released, the emergency off switching d
evice is in operating position.
Under normal conditions the input to the emergency off switching device (6A
17) A1 and A2 is provided with power. It is indicated by the red LED at the
31
emergency off switching device (6A17). The device itself is equipped with tw
o green LED indicators to show the situation “ready for service”. If at least o
ne emergency button (S 39…) is pressed down, the LED indicators on the e
mergency off device go out.
When no emergency button is pressed but the device realizes an internal fail
ure only the green LED indicators on the device itself go out but the red LE
D at the emergency off switching device (6A17) stays on.
The three n/o and n/c curcuits of the emergency system are shown on the c
over of the emergency off switching device. Under operating conditions conta
cts 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 d
evice
Due to open contact 13-14 in case of emergency, both plugs of the changeo
ver valve are getting currentless, the concrete pump stops running.
Due to open contact 23-24 the hydraulic support legs or boom selection valv
e “boom and legs operation” are off. Pilot oil is running into the oiltank and
neither boom nor outriggers can be operated.
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 t
he concrete pump is stopped additionally via relay “pump off” disturbance (3
K239). 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” (6
H28) outside the control box.
There is a second red LED “emergency off” (H14) at the cable remote contr
ol 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 :
32
- 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 CON
CRETE PUMPING LOCKING.
33

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ELECTRICAL SYSTEM

Reading and Understanding of CAD Electrical Circuit Diagram ………

Wiring Harness Illustrations …………………………………………………..

Introduction To DHI Electrics ……………………………………………….

Auxillary Drive …………………………………………………………………... 1

Pump On/off ……………………………………………………………………... 1

Concrete Pump Locking ……………………………………………………….

Output Control ……………………………………………………………………1

Outrigger Operation ……………………………..…………………………….. 1

Slewing Operation ……………………………………………………………… 1

A-section Movement …………………………………………………………… 2

B-section Movement …………………………………………………………… 2

D-section Movement …………………………………………………………… 2

Engine Start/stop Remote Control …………………………………………...

RPM Control Of The Engine ………………………………………………...…

Cooler Fan ………………………………………………………………..……… 2

Emergency Off Control …………………………………………………………

TROUBLESHOOTING – ELECTRICAL SYSTEM

Problem Cause Remedy

EMERGENCY SHUT-DOWN Unlock EMERGENCY

Problem Cause Remedy

READING AND UNDERSTANDING OF CAD ELECTRICA

Fig. 1 Prescribed form

Example : extract from dwg no. 599-00021, page 5

K is the component symb

This 6 means that the relay is

6K69 = component symbol

Contact of relay 5K27

Current path 5 on the

Page No. Current path No.

/6.2 = Current path 2 on page 6

Fig. 2 Cross reference

Extract from electric circuit diagram 599-00021 page 4

Relay coil of this contact is

Devicing No. according

Fig. 3 Reference to the hydraulic circuit diagram

3. Reference to the hydraulic circuit diagram

Extract from hydraulic circuit diagram

Page No. relevent to electric circuit diagram

Component symbol from electrical circuit diagram for

Fig. 4. Reference to the electrical circuit diagram

4. Code letters to indicate the nature of a device

WIRING HARNESS ILLUSTRATIONS

INTRODUCTION TO DHI ELECTRICS

The concrete pump is driven hydraulically. The movement of the piston in th

The concrete pump speed is controlled by a electric driven needle valve. Co

All important vehicle functions are remotecontrolled by the DHI equipment :

The electric control system components are in limited areas.

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

1S133 = gear neutral position switch

3. Series fuse : 1F78, 1F100

Connection from main relay to minuspole is via the gearbox-limitswitch (B5-

The main relay is switching on electric power to the DHI-equipment. The p

1. Electric diagram(599-00021) : page 3, page 4, and page 9

3S226 = switch “pump on”

3. Series fuse : 3F81

In between are relaycontacts of 3K239 (pump off-disturbance) , 6A17 (emerg

By pressing a special switch (3S226) it is possible to stop the pump indepen

CONCRETE PUMP LOCKING

3S226 = switch at the control panel

3. Series fuse : 3F81, 6F76

The activation of relay “pump locking” (3K81) is done by mixerdriver, pressin