07GMK 6250 Suspension

Deutsche GROVE
GMK 6250
Suspension System
General description
The carrier chassis is 12 x 8 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 12 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 6250 Training Information. Feb 98. Carrier suspension system. Page 1
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Suspension cylinders:
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 assemblies, 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
A & B = cylinder ports
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Suspension system
Description of operation:
The suspension cylinders are connected in interactive longitudinal groups of two;

based on a six-axle carrier we have three independent groups on the right and three on
the left. There is no transverse interconnection of the suspension cylinders. Axle
groups 1 – 2 and 3 – 4 have a single accumulator for each group. Axles 5 & 6 have
double accumulators for each group. However, on normal highway travel only one
accumulator is operational for each group. The additional accumulators are
automatically added to the circuit by solenoid valves when low range is selected in the
Kessler transfer box or when the suspension key switch –S1 is engaged. Additionally,
axles 3 – 6 are allowed to interact between their individual groups to give better rough
terrain capability. Control of the oil supply to the suspension cylinders for levelling
and group interaction is by solenoid valves, which are integrated into the suspension
blocking valves. External solenoid valves are installed for the control of additional
accumulators.
The suspension blocking valves isolate the suspension cylinders from the
accumulators. Each suspension group has its own blocking valve adjacent to the
suspension cylinders.
The control of the blocking valves is electro/pneumatic, without an external energy
source the blocking valves will automatically engage. Although the blocking valves
isolate the accumulators they do not prevent interaction within the individual
suspension groups. To ensure that wheels are kept clear of the ground when working
on outriggers it is necessary to fully lower the suspension prior to blocking the
suspension and then raise the crane with the outriggers.
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.
Control of the suspension system:
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 6 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.
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.
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Suspension controls:
The suspension controls are located on the centre console to the right of the operator’s
seat.
1. Level adjustment switch, right 11
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
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The suspension electronic module (+BE550 .A4) 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
Output to integrated
direction control module
solenoid in axle
blocking valve
Output to flow
diverter (pressure
build up) solenoid
valve 47-Y9
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.
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Suspension control:
Description of semi-automatic levelling function for highway travel.
Control principle:
The height reference for highway travel is via proximity switches, which are
integrated into axle 1 & 6 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 also 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
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Suspension control:
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
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.
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Suspension control:
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
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
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Suspension control:
The suspension insert + BE550.A4 includes several relays with the suspension group
prefix (43) that select a particular operating sequence, depending on the function
selected. There are adjacent additional relays, group prefix (41) that are also
controlled by suspension key switch operation, K2 is for a transmission up-shift lock
signal and power to solenoid valves -Y03, -Y04, -Y66 & -Y68. K32 provides power
to the switches for differential locks and engaging the additional drive axle.
Relay Control by: Function:

K26 Key switch – S1 (11 on When energised:
control diagram) via K27 Supplies power to all suspension control
switches.
K27 Axle blocking switch 41 De-energised, (axle blocking released)

– S3, enclosure S1 supplies power to K26
When energised, (axle blocking engaged)
inhibits suspension levelling operation,
supplies power to solenoid valves –Y03 & -
Y04 to allow suspension group interaction
(axles 3 – 6) for rough terrain operation.
Solenoid valves –Y66 & -Y68 for additional
accumulators are also energised to give extra
capacity for displaced annular oil from the
suspension cylinders.
K30 Suspension control When energised:

switches excluding S7 Supplies power to electronic module for
(9) on control diagram solenoid power and inhibits, all wheel rear
steering operation.
For complete electrical system detail, please see electrical schematic group 41, Drive
Unit Chassis & group 43, carrier level adjustment system.
Deutsche GROVE
GMK 6250 suspension control system

Solenoid valve table
Solenoid Function Location
=43 -Y01 Raise / lower control for front left suspension Front left suspension
group, axles 1 & 2 control valve block .UL2*
=43 -Y02 Raise / lower control for front right suspension Front right suspension
group, axles 1 & 2 control valve block .UR2*
=43 -Y03 Raise / lower control for centre left suspension Centre left suspension
group, axles 3 & 4, **plus interaction between control valve block .UL4*
centre and rear suspension groups
=43 -Y04 Raise / lower control for centre right suspension Centre right suspension
group, axles 3 & 4, **plus interaction between control valve block .UR4*
centre and rear suspension groups
=43 -Y05 Raise / lower control for rear left suspension Rear left suspension
group, axles 5 & 6 control valve block .UL4*
=43 -Y06 Raise lower control for rear right suspension Rear right suspension
group, axles 5 & 6 control valve block .UR4*
=41 -Y66 ***Additional accumulator control for right side Rear right remote valve
centre & rear suspension groups adjacent to accumulator
.UR4*
=41 -Y68 ***Additional accumulator control for left side Rear left remote valve
centre & rear suspension groups. adjacent to accumulator
.UL4*
=47 -Y9 Flow diverter (pressure build up) – diverts pump Beside Kessler transfer
P1 from steering to suspension operation for case on left side of chassis
raise function only .UM3*
* Please see electrical schematics for component locations on plan view of carrier.
** Only applicable with suspension key switch –S1 engaged, axle blocking engaged or transfer case in
low range.
*** The additional accumulators are not allowed to be operational during highway travel as this would
have an adverse effect on the handling of the vehicle.
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Suspension control:
An electric/pneumatic solenoid valve (Y6) releases the axle blocking valves. All other
suspension control valves have direct electrical solenoid control.
Y03, Y04, Y66 & Y68 must remain energised when the suspension system is blocked
to ensure suspension group interaction. This function is necessary when (if allowed)
the crane is moved in a rigged condition. Solenoids Y03 & Y04 allow centre & rear
group interaction of the piston areas of the suspension cylinders. The annular areas
are isolated within their own groups by the action of the blocking valves. Subsequent
interaction of the centre & rear groups will displace annular oil into the larger centre
accumulators (2.5 L) and Y66 & Y68 will give additional accumulator capacity (1.5
L) to the rear suspension groups. Additional system safety is given by the integrated
relief valves @ 330 bar.
Carrier function table for suspension interaction and blocking

solenoid valves
Solenoid Y6 Y66 Y68 Y03 Y04
.UR3 .UR4 .UL4 .UL4 .UR4
Highway X
Low range X X X X X
Suspension blocked X X X X
Suspension operation X X X X X
X = Solenoid energised
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Schematic view of right rear suspension group:
Hydraulic
cylinders
Solenoid valve
for suspension
levelling control
Pressure from P1 via 47-Y9

Tank
To centre suspension group
Axle blocking valve with

pneumatic control
Solenoid valve for

additional accumulator
Additional
accumulator
Relief valve
Highway accumulator
Please see hydraulic schematic diagrams for complete system detail.
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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 drawings = 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.
Deutsche GROVE
Suspension control:
Overview of system control and 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
-X19 -X56 -X19

-X54
Solenoid Solenoid
Suspension
- Y03 -X55 control module -X55 - Y04
BE550 .A4
-X1 -X1
-X16 -X54 -X15

-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.
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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 X1/1 = Identification key X2/1 = E3 input from B2 front right
E3 = Input B2 front right X1/2 = Output suspension level light X2/2 = Identification key
E4 = Input A2 front right X1/3 = Input highway auto level X2/3 = E1 input from B1 front left
E5 = Input B3 rear left X1/4 = + 24 volt power supply X2/4 = E7 input from B4 rear right
E6 = Input A3 rear left X1/5 = E9 input front X2/5 = E5 input from B3 rear left
E7 = Input B4 rear right X1/6 = E11 input right X2/6 = E4 input from A2 front right
E8 = Input A4 rear right X1/7 = E12 input rear X2/7 = E2 input from A1 front left
E9 = Input front X1/8 = E14 input left X2/8 = E8 input from A4 rear right
E10 = Input auto suspension X1/9 = E13 input all X2/9 = E6 input from A3 rear left
E11 = Input right X1/10 = E16 Input lower X2/10 = Output to direction solenoid lower
E12 = Input rear X1/11 = E15 Input raise X2/11 = Output to direction solenoid raise
E13 = Input all X1/12 = 24 volt power for solenoids X2/12 = Output to solenoid valve front right
E14 = Input left X1/13 = 0 volt ground for solenoids X2/13 = Output to solenoid valve front left
E15 = Input raise X1/14 = 0 volt ground for proximity switches X2/14 = Output to solenoid valve rear right
E16 = Input lower 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 Front right
B = N/O raise A1 B1 proximity A2 B2 proximity
Crane below switch reference switches switches
(Raise) AX = open / BX = closed Operating
pressure
Crane above switch reference Centre solenoid valve control valve Centre solenoid valve
(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

07GMK 6250 Suspension

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Deutsche GROVE

Cylinder stroke: + 170 / - 130 mm for

Operating pressure: Max 330 bar

The suspension cylinder is

5. Connecting flange for wheel

A & B = cylinder ports

The suspension cylinders are connected in interactive longitudinal groups of two;

Control of the suspension system:

Automatic ride height selection:

1. Level adjustment switch, right 11

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

Inputs = manual control switches and proximity switches

Proximity switch Operator, manual

Description of semi-automatic levelling function for highway travel.

Proximity switch Switch B

At correct height the normally

Control principle: Vehicle too low.

The normally open switch (B) will

The normally closed switch (A)

Control principle: Vehicle too high.

The normally open switch

The normally closed

Relay Control by: Function:

K27 Axle blocking switch 41 De-energised, (axle blocking released)

K30 Suspension control When energised:

GMK 6250 suspension control system

Carrier function table for suspension interaction and blocking

Schematic view of right rear suspension group:

Pressure from P1 via 47-Y9

Axle blocking valve with

Solenoid valve for

Please see hydraulic schematic diagrams for complete system detail.

Front left Front right Rear left Rear right

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

Individual circuits can be checked via the electrical schematic drawings = 43

System trouble shooting:

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

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?

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

Overview of system control and electrical plug interface for group = 43

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

- Y01 -X1 -X1 - Y02

-X19 -X56 -X19