Deutsche GROVE

GMK 3050

Suspension
System
1. General description ...............................................................................................1
2. Suspension cylinders..............................................................................................2
2.1 Description of operation .................................................................................2
3. Suspension system..................................................................................................3
3.1 Description of operation .................................................................................3
4. Control of the suspension system .........................................................................3
4.1 Automatic ride height selection .....................................................................3
4.2 Manual control ................................................................................................4
4.3 Suspension controls.........................................................................................4
4.4 Suspension control principle..........................................................................5
4.5 Semi-automatic levelling function for highway travel.................................6
4.5.1 Control principle..........................................................................................6
4.5.2 Control principle: Vehicle too low. ............................................................7
4.5.3 Control principle: Vehicle too high............................................................8
5. Suspension relay control .......................................................................................9
6. Suspension control solenoids ..............................................................................10
7. Proximity switches...............................................................................................11
8. Overview of electrical plug interface for group = 43........................................12
9. Suspension Electronic Control Module .............................................................13
RC 4.1.99

GMK 3050. Training Information. Carrier suspension system January. 99.

 Deutsche GROVE

1. General description

The carrier chassis is 6 x 6 drive and consists of a one piece, all-welded torsion
resistant box type construction in high strength steel. The suspension system is of
MEGATRAK design and consists of 6 independent hydro-gas suspension cylinders.

A driven, drive axle line consists of a central differential and two wheel head
assemblies connected by drive (cardan) shafts. The suspension cylinders are fixed
directly to the chassis frame and each carries a wheel head assembly.

1. Differential
2. Suspension cylinder
3. Wheel head assembly
4. Wheel
5. Drive (cardan) shaft

Typical installation
Suspension cylinders:

Length: 915 mm

Cylinder stroke: + 170 / - 130 mm for

highway travel

Operating pressure: Max 330 bar

GMK 3050. Training Information. Carrier suspension system. January 99. Page. 1
 Deutsche GROVE

2. Suspension cylinders

2.1 Description of operation

Support tube (4) is installed in the outer body (2) of the suspension cylinder so that it
can turn and slide vertically in the housing, following the steering movements of the
wheel head assembly, and at the same time is able to extend or retract according to
ground conditions. This support tube is designed to withstand all the dynamic forces
placed on the suspension cylinder.

The support tube contains the hydraulic cylinder (6). The cylinder is charged from an
external oil supply to the required height. The piston rod of the hydraulic cylinder
contains rifle drilled oil passageways that connect the cylinder to the external oil
supply and a pressure accumulator. As the accumulator is pre-charged with Nitrogen
gas any displaced oil from the suspension cylinder is forced into the accumulator
which further compresses the gas. This action results in energy absorption (spring
effect). Equally, as the suspension cylinder extends, oil is driven out by gas pressure
to keep the wheels in constant contact with the ground.

The suspension cylinder is

comprised of:

1. Cover

2. Outer body

3. Oil passageways

4. Support tube

5. Connecting flange for wheel

head

6. Hydraulic cylinder

7. A & B = cylinder ports

GMK 3050. Training Information. Carrier suspension system. January 99. Page. 2
 Deutsche GROVE

3. Suspension system

3.1 Description of operation

The suspension cylinders on axles 1 & 3 operate as individual units for highway
travel. Axle 2 has a transverse interconnection of the suspension cylinders, which
connects the piston area to the rod area of the opposite cylinder. This design
arrangement gives anti-roll characteristic for highway travel.

Single pressure accumulators are installed adjacent to each suspension cylinder.

These absorb or displace oil depending on the ground conditions to replace the spring
action of a conventional suspension system. Nitrogen gas is used to pre-charge the
accumulators with axle 1 & 3 having the same pressure of 35 bar. Axle 2 has a pre-
charge pressure of 60 bar, which gives a softer characteristic, necessary to assist
traction on uneven ground conditions.

When the suspension key switch –S1 is engaged or when low range is selected in the
Kessler transfer box, axles 1 & 2 then have a longitudinal interconnection, allowing
interaction between the suspension cylinders. This allows correct weight distribution
when levelling and gives better rough terrain capability in low range. Control of the
oil supply to the suspension cylinders for levelling and interaction is by solenoid
valves, which are integrated into the suspension blocking valves

Suspension blocking valves isolate the suspension cylinders from the accumulators.
Each suspension cylinder has its own blocking valve adjacent to the suspension
cylinder. Control of the blocking valves is electro/pneumatic, without an external
energy source the blocking valves will automatically engage.

Solenoid valves are also integrated into the axle blocking valves; allowing oil flow to
and from the suspension cylinders and are energised to permit oil flow depending on
the selected function.

If moving the crane on wheels in a rigged condition (if allowed) it is important that
the suspension cylinders are in a mid stroke position to allow the system to interact
and have as near as possible, equal axle loading. Please see operator’s manual for
permissible travel configurations and procedure.

4. Control of the suspension system

4.1 Automatic ride height selection

This allows the carrier to conform to a highway height reference via proximity
switches, which are integrated into the suspension cylinders of axles 1 and 3 on the
four corner suspension groups. The system is controlled from within the operator’s
cab and correct height reference is indicated via a control light, which will go out at
the correct height.

GMK 3050. Training Information. Carrier suspension system. January 99. Page. 3
 Deutsche GROVE

4.2 Manual control

Switches within the operator’s cab allow independent control of individual suspension
groups or the whole suspension system can be fully raised or fully lowered.

4.3 Suspension controls

The suspension controls are located on the centre console to the right of the operator’s
seat.

1. Level adjustment switch, right

2. Level adjustment switch, front

3. Level adjustment switch, rear

4. Level adjustment switch, left

5. Indicator light for raise

6. Indicator light for highway level

7. Select raise / lower switch

8. Indicator light for lower

9. Raise lower switch

10. Highway level switch

11. Level adjustment key switch

Figure 1. Suspension controls

GMK 3050. Training Information. Carrier suspension system. January 99. Page. 4
 Deutsche GROVE

4.4 Suspension control principle

The suspension electronic module (+BE550 .A5) is located directly beneath the
control switch module, which is to the right of the operator’s seat. The electronic
module is the interface between all suspension control input and output values.

Inputs = manual control switches and proximity switches.

Outputs = direction and flow diverter (pressure build up) control solenoid valves.

Proximity switch Operator, manual

input normally switch inputs from
open cab controls
Upper edge of support
tube is the control
reference for the 24v power
proximity switches

Proximity switch
Suspension input normally
cylinder closed

Suspension
electronic
module
Output to integrated
direction control
solenoids in axle
blocking valves

47Y10
Relay control

47Y9

Output to flow diverter solenoid valve

47Y10 & direction solenoid valve 47Y9

Figure 2: Suspension control components

On removing the unit and looking on the underside, you will find 16 input LED’s, 8
output LED’s and 1 operating control LED. These can be used to verify all control
switch inputs and all control outputs. Please see attachment drawing for input/output
legend and LED identification. NOTE: There are two power supplies: X1/4 logic
power & X1/12 to power solenoids.

GMK 3050. Training Information. Carrier suspension system. January 99. Page. 5
 Deutsche GROVE

4.5 Semi-automatic levelling function for highway travel.

4.5.1 Control principle

The height reference for highway travel is via proximity switches, which are
integrated into axle 1 & 3 suspension cylinders. There are two switches in each outer
body of four suspension cylinders, one switch is installed slightly higher (10 mm)
than the other. The upper switch (B) is normally open (N/O) and the lower switch (A)
is normally closed (N/C). The upper switch controls raising and the lower switch
controls lowering the suspension cylinders.

The proximity switch circuit is only energised when operating the semi-automatic
levelling function for highway travel. The power supply to the switches is 24 volts.
The switches respond via magnetic reference to the upper edge of the support tube,
which moves within the cylinder outer body as the cylinder extends or retracts. This
gives a pre-defined switching point, where the normally open switch is open and the
normally closed switch is open. At the correct height (shown below) no command
voltage would be routed back to the electronic module.

Proximity switch Switch B

normally open
Support tube The proximity
Upper edge switches will change
state- subject to
reference against the
support tube as it
extends or retracts

Proximity switch
normally closed Switch A

At correct height the normally

Suspension cylinder closed switch is open and the
at correct highway normally open switch remains
travel height open

Figure 3: Control principle

GMK 3050. Training Information. Carrier suspension system. January 99. Page. 6
 Deutsche GROVE

4.5.2 Control principle: Vehicle too low

When the levelling system is operated with the vehicle below highway travel height
the normally open switch (B) will be closed and the normally closed switch (A) will
be open.
This will cause a command voltage to be routed back to the electronic module.
Subsequently, the relevant direction and flow diverter (build up pressure) valves will
be energised and the vehicle will begin to rise until the normally open proximity
switch loses magnetic reference as it travels beyond the top edge of the support tube.

The normally open switch (B) will

remain closed until it travels over
the edge of the support tube as the
cylinder extends

The normally closed switch (A)

will remain open, as it will
maintain reference against the
support tube

Figure 4: Control principle with vehicle too low

Once the proximity switch loses its magnetic reference the contacts will open and the
command voltage to the electronic module will cease. Subsequently, the control
valves for that group will be de-energised when the vehicle is at the correct highway
height. All the four proximity switch groups operate in the same manner. Assuming
the whole vehicle is low, due to the equipment on the vehicle and weight distribution,
some suspension groups will attain highway height prior to others. The warning
indicator light (6) on the control panel will go out once total suspension group
highway travel height is attained.

GMK 3050. Training Information. Carrier suspension system. January 99. Page. 7
 Deutsche GROVE

4.5.3 Control principle: Vehicle too high

When the levelling system is operated with the vehicle above highway travel height
the normally open switch (B) will be open and the normally closed switch (A) will be
closed. This will cause a command voltage to be routed back to the electronic
module. Subsequently, the relevant direction valves will be energised and the vehicle
will begin to lower until the normally closed switch (A) has magnetic reference
against the top edge of the support tube.

The normally open switch

(B) will remain open, as it
has no reference against
the support tube

The normally closed

switch (A) will remain
closed until it travels over
the top edge of the support
tube

Figure 5: Control principle with vehicle too high

Once the proximity switch has magnetic reference the contacts will open and the
command voltage to the electronic module will cease. Subsequently, the control
valves for that group will be de-energised when the vehicle is at the correct highway
travel height. All the four proximity switch groups operate in the same manner.
Assuming the whole vehicle is high, due to equipment on the vehicle and weight
distribution, some suspension groups will attain highway height prior to others. The
warning indicator light (6) on the control panel will go out once total suspension
group highway travel height is attained.

NOTE: Hydraulic pressure is not required, as the vehicle will lower by its own
weight.

GMK 3050. Training Information. Carrier suspension system. January 99. Page. 8
 Deutsche GROVE

5. Suspension relay control

The suspension insert + BE550.A5 includes several relays with the suspension group
prefix (43) that select a particular operating sequence, depending on the function
selected. There are additional relays, group prefix (41) that also interact to control
suspension operation.

Table 1

Relay Control by Function

41-K8 Allison VIM K4 Speed reduction to < 5kph
43-K26 Key switch – S1 (11 on When energised:
control diagram) Supplies power to all suspension control
switches via K27 & K8
41-K27 Axle blocking switch De-energised, (axle blocking released)
41 – S3, enclosure A1 Closed contacts allow power to suspension
controls via K8.
When energised, (axle blocking engaged)
inhibits suspension levelling operation.
43-K30 Suspension control When energised:
switches excluding S7 Supplies power to electronic module for
(9) on control diagram solenoid.
43-K40 De-energised K26 When energised: (Coil ground only in low
range).
Supplies power to solenoid Y04
43-K41 De-energised K26 When energised: (Coil ground only in low
range).
Supplies power to solenoid Y03

For complete electrical system detail, please see electrical schematic group 41, Drive
Unit Chassis & group 43, carrier level adjustment system.

GMK 3050. Training Information. Carrier suspension system. January 99. Page. 9
 Deutsche GROVE

6. Suspension control solenoids

Table 2

GMK 3050 suspension control system

Solenoid valve table
Solenoid Function Location
43 -Y01 Raise / lower control for front left suspension Front left suspension
cylinder, axle 1 & 2. control valve block .UL2*
43 -Y02 Raise / lower control for front right Front right suspension
suspension cylinder, axle 1 & 2. control valve block .UR2*
43 -Y03 Raise / lower control for centre left Centre left suspension
suspension cylinder, axle 2, **plus interaction control valve block .UL2*
between axles 1 & 2
43 -Y04 Raise / lower control for centre right Centre right suspension
suspension cylinder, axle 2, **plus interaction control valve block .UR2*
between axles 1 & 2
43 -Y05 Raise / lower control for rear left suspension Rear left suspension
cylinder, axle 3. control valve block .UL4*
41-Y6 Pneumatic solenoid to release axle blocking Centre left. UL4*
43 -Y06 Raise lower control for rear right suspension Rear right suspension
cylinder, axle 3. control valve block .UR4*
47 -Y9 Direction valve – routes pump P1 from Below operator’s cab.
steering to suspension operation for raise .UM1*
function only
47-Y10 Diverter valve – diverts pump P1 oil flow Below operator’s cab.
from steering to suspension operation. .UM1*
* Please see electrical schematics for component locations on plan view of carrier.
** Only applicable with suspension key switch –S1 engaged, or transfer case in low range.

GMK 3050. Training Information. Carrier suspension system. January 99. Page. 10
 Deutsche GROVE

7. Proximity switches

The eight proximity switches have all been given individual designations.

Front left Front right Rear left Rear right

-A1 N/C -A2 N/C -A3 N/C -A4 N/C

-B1 N/O -B2 N/O -B3 N/O -B4 N/O

Individual circuits can be checked via the electrical schematic drawing group = 43

System trouble shooting

Make sure personnel are clear of vehicle prior to any operation.

Caution! Even with the engine switched off, the vehicle may still lower.

First establish whether the problem is a total or partial system problem.

Is the key switch (11) on control panel turned on?

Is the axle blocking released?

Does the system function OK with manual switch controls?

Is the problem Hydraulic or electric? Always check fuses.

As the outriggers use the same hydraulic supply, do they operate?

Individual solenoids can be checked for power via the LED, which is in the plug.

Input / output values can be checked at the electronic control module via the LED’s.

Individual external components can be checked, and at the closest cable interface plug
to establish component or cable defects.

If it is a proximity switch problem, first establish power supply to switches at closest

interface plug. With the vehicle completely lowered, (manually) all the (B) switches
should be closed and all the (A) switches should be open. The input voltages can be
checked at the electronic module via the LED’s or at the interface plug – X56.

The same checks can be carried out in the fully raised position and now the (B)
switches should be open and all the (A) switches should be closed.

GMK 3050. Training Information. Carrier suspension system. January 99. Page. 11
 Deutsche GROVE

8. Overview of electrical plug interface for group = 43

Proximity switches
Front Proximity switches

- A1 N/C -X86 -X87 N/C - A2

- B1 N/O -X82 -X83 N/O - B2

- Y01 -X1 -X1 - Y02

Solenoid Solenoid
-X21

-X15 -X56 -X16

-X54

Solenoid Solenoid
Suspension
- Y03 -X55 control module -X55 - Y04
BE550 .A5

-X1 -X1

-X15 -X54 -X16

-X56

-X22
-X12 -X12

Solenoid Solenoid
- Y05 -X1 -X1 - Y06

- A3 N/C -X88 -X89 N/C - A4

- B3 N/O -X84 -X85 N/O - B4
Proximity switches Proximity switches

Please see schematic group = 43 for complete detail of the above circuit.

GMK 3050. Training Information. Carrier suspension system. January 99. Page. 12
 Deutsche GROVE

9. Suspension Electronic Control Module

Operation Control
This unit is located below the suspension control module Light Emitting Diode
in the crane cabin

OE1 Electronic control

OE2 unit connection
OE3 plugs to crane
Proximity Switch OE4 electric’s
Inputs OE5 X1 X2
OE6
OE7
OE8 OA1 A1 = Output suspension light
OE9 OA2 A2 = Output solenoid front left
OE10 Input Highway Auto Level OA3 A3 = Output solenoid front right
OE11 OA4 A4 = Output solenoid rear left
Button / Switch OE12 OA5 A5 = Output solenoid rear right
Inputs OE13 OA6 A6 = Output direction solenoid raise
OE14 OA7 A7 = Output direction solenoid lower
OE15 OA8 A8 = Output solenoid operating pressure
Input - Switching
OE16 Lower / Raise

Input LED’s Output LED’s

Connection plug X1 Connection plug X2

E1 = Input B1 front left
E2 = Input A1 front left
E3 = Input B2 front right
E4 = Input A2 front right
E5 = Input B3 rear left
E6 = Input A3 rear left
E7 = Input B4 rear right
E8 = Input A4 rear right
E9 = Input front
E10 = Input auto suspension
E11 = Input right
E12 = Input rear
E13 = Input all
E14 = Input left
E15 = Input raise
E16 = Input lower
X1/1 = Identification key X2/1 = E3 input from B2 front right
X1/2 = Output suspension level light X2/2 = Identification key
X1/3 = Input highway auto level X2/3 = E1 input from B1 front left
X1/4 = + 24 volt power supply X2/4 = E7 input from B4 rear right
X1/5 = E9 input front X2/5 = E5 input from B3 rear left
X1/6 = E11 input right X2/6 = E4 input from A2 front right
X1/7 = E12 input rear X2/7 = E2 input from A1 front left
X1/8 = E14 input left X2/8 = E8 input from A4 rear right
X1/9 = E13 input all X2/9 = E6 input from A3 rear left
X1/10 = E16 Input lower X2/10 = Output to direction solenoid lower
X1/11 = E15 Input raise X2/11 = Output to direction solenoid raise
X1/12 = 24 volt power for solenoids X2/12 = Output to solenoid valve front right
X1/13 = 0 volt ground for solenoids X2/13 = Output to solenoid valve front left
X1/14 = 0 volt ground for proximity switches X2/14 = Output to solenoid valve rear right
X1/15 = Output to solenoid, operating pressure X2/15 = Output to solenoid valve rear left

Front left Front Front right

solenoid valve. solenoid valve.
Proximity switch function A = N/C lower Front left Operating Front right
B = N/O raise A1 B1 proximity pressure A2 B2 proximity
Crane below switch reference switches control valve switches
(Raise) AX = open / BX = closed

Crane above switch reference

(Lower) AX = closed / BX = open Crane Chassis
Crane at highway ride height
(At switch reference) AX = open / BX = open Rear left Rear right
solenoid valve. solenoid valve.
Defect Rear left Rear right
(No function) AX = closed / BX = closed A3 B3 proximity A4 B4 proximity
switches Rear
switches

GMK 3050. Training Information. Carrier suspension system. January 99. Page. 13