Documente Academic
Documente Profesional
Documente Cultură
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
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
GMK 3050. Training Information. Carrier suspension system. January 99. Page. 1
Deutsche GROVE
2. Suspension cylinders
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.
1. Cover
2. Outer body
3. Oil passageways
4. Support tube
6. Hydraulic cylinder
GMK 3050. Training Information. Carrier suspension system. January 99. Page. 2
Deutsche GROVE
3. Suspension system
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.
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.
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
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.
The suspension controls are located on the centre console to the right of the operator’s
seat.
GMK 3050. Training Information. Carrier suspension system. January 99. Page. 4
Deutsche GROVE
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.
Outputs = direction and flow diverter (pressure build up) control solenoid valves.
Proximity switch
Suspension input normally
cylinder closed
Suspension
electronic
module
Output to integrated
direction control
solenoids in axle
blocking valves
47Y10
Relay control
47Y9
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
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
normally closed Switch A
GMK 3050. Training Information. Carrier suspension system. January 99. Page. 6
Deutsche GROVE
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.
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
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.
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
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
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
Table 2
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.
Individual circuits can be checked via the electrical schematic drawing group = 43
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.
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
Proximity switches
Front Proximity switches
Solenoid Solenoid
Suspension
- Y03 -X55 control module -X55 - Y04
BE550 .A5
-X1 -X1
-X22
-X12 -X12
Solenoid Solenoid
- Y05 -X1 -X1 - Y06
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
Operation Control
This unit is located below the suspension control module Light Emitting Diode
in the crane cabin
GMK 3050. Training Information. Carrier suspension system. January 99. Page. 13