R1600H UndrgndLdr M08 RemoteCtrlSys EN TXT-Instructor

Global Service Training
R1600H Underground Loader

Remote Control System
Module 8 - Text Reference
SERV2052
CAT, CATERPILLAR, their respective logos, ACERT, “Caterpillar Yellow” and the POWER EDGE
trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar
and may not be used without permission. © 2015 Caterpillar Inc. All Rights Reserved.
Caterpillar: Confidential Yellow
SERV2052 - 03/15 -2- Module 8 - Remote Control System
TABLE OF CONTENTS
Safety Briefing�� 3
Purpose�� 4
Reason�� 5
Competency statement�� 6
Learning outcomes�� 7
INTRODUCTION�� 8
REMOTE CONTROL COMPONENTS�� 9
REMOTE CONTROL SWITCH��11
TRANSMITTER�� 12
RECEIVER�� 13
INTERFACE CONTROL MODULE�� 15
STEERING AND BUCKET CONTROL VALVE - BUCKET OPERATION/RAISE�� 16
STEERING AND BUCKET CONTROL VALVE - STEERING OPERATION/LEFT TURN�� 18
Purpose review�� 19
Reason review�� 20
Competency Statement review�� 21
Learning Outcomes Review�� 22
Module Conclusion�� 23

Safety Briefing
• Emergency Phone Numbers
• First Aid Responders
• Location of Exits
• Location of Fire Extinguisher
• Room Alerts or Hazards
• Designated Location for Evacuation
• Storm Shelter
• Hazardous Material
Safely Home. Everyone. Every Day.™
3
Safety Briefing
Before beginning this module, the following topics will be reviewed:

• Emergency Phone Numbers
• First Aid Responders
• Location of Exits
• Location of Fire Extinguisher
• Room Alerts or Hazards
• Designated Location for Evacuation
• Storm Shelter
• Hazardous Material
Safely Home. Everyone. Every Day.™

PURPOSE
This module is designed to ensure participants can

locate and identify the function of all major components
of the remote control system.
4
Purpose

REASON
This training is necessary for participants to identify

the components of the remote control system and
to demonstrate knowledge of the remote control
system in order to troubleshoot the system. This will
ensure customers will experience quick and accurate
resolution of remote control issues.
5
Reason

COMPETENCY Statement
At the completion of this module, participants will be

able to locate and identify the remote control system
components during lab exercises. Participants will also
be able to identify the function of the remote control
system components during a post-assessment.
6
Competency statement

LEARNING OUTCOMES
You will meet the following learning outcomes during

this R1600H Underground Loader Remote Control
System module:
• Locate and identify the function of all remote control
system components.
7
Learning outcomes

REMOTE CONTROL SYSTEM

COMPONENTS IDENTIFICATION
Receiver
Interface (2) Remote Remote Control
Control Control Activation Light (Green) (4)
Module (1) Switch (3)
Remote Control
Brake Light (Amber) (5)
Steering and
Bucket control
Valve (6)
8
INTRODUCTION
• Identify the main components of The proportional type remote control system can be installed on Underground
the remote control system. Loader machines. There may be some variation between this standard
configuration and a customer driven modification to the remote control system.
The remote control system is made up of the following main components: the
receiver (2), the interface control module (1), the steering and bucket control
valve (6), the remote transmitter, and the machine electrical and hydraulic
components. The green remote control activation light (4) and amber remote
control brake light (5) are mounted on the rear of the operator’s station.
The remote control switch (3) is located on the upper keypad in the operator’s
station.

1
4
3
7
6
4 5
9
REMOTE CONTROL COMPONENTS
• Identify the remote control The transmitter (1) is used by the operator to control machine functions by remote
system components. control. The transmitter sends radio signals to the receiver (3). The receiver is
located above the hydraulic tank.
The transmitter is powered by a 12 volt battery (2). All other components in the
remote control system are powered by the machine electrical system.
The receiver interprets the radio signals from the transmitter. The receiver sends
an electrical signal for on/off functions or a Pulse Width Modulated (PWM) electrical
signal for proportional functions to the interface control module (4). The interface
control module is located above the hydraulic tank.
The interface control module contains a relay for each remote control on/off
function. The interface control module has two types of outputs: on/off electrical
signals and PWM electrical signals.
Electrical signals for on/off functions from the receiver energize a relay for
each remote control function. The relay will switch the power or ground to the
corresponding machine electrical circuits.
The PWM electrical signals for proportional functions are sent directly to the
solenoid valves mounted on the steering and bucket control valve (5). Also the
PWM electrical signal is sent to the Engine ECM for the throttle control.

The steering and bucket control valve is located beside the operator station door in
the articulation hitch area of the machine. This view shows the steering and bucket
control valve on a STIC steering machine.
The steering and bucket control valve contains four proportional solenoids (6)
that control the machine bucket functions, and two proportional solenoids (7) that
control the machine steering functions.

3 4
11
REMOTE CONTROL SWITCH
• Identify the remote control switch The remote control switch (1) is located on keypad 1 in the cab. When pressed, the
and the remote control activation keypad communicates with the Power Train ECM to supply power to the receiver
light. and interface control module.
To operate the machine by remote control, the parking brake switch (2) and the
remote control switch must be in the ON position.
The green remote control activation light (3) and amber remote control brake
light (4) are mounted on the rear of the operator’s station and controlled by the
Power Train ECM. The remote control activation light will be on whenever the key
start switch (5), the parking brake switch, and the remote control switch in the
operator station are in the ON position, which indicates that the machine is ready to
be operated by remote control.
The remote control brake light will be on when the remote control parking brake is
engaged or the remote control service brake is applied at the transmitter. When the
remote control parking brake is disengaged and the remote control service brake is
released at the transmitter, the remote control brake light will go out.
If the remote control switch is in the ON position while the machine is being
operated manually, the engine will shut down and the parking brake will
automatically engage.

5 6
3
1
4
7 8
13
9 10 11 14 15 16
12
12
TRANSMITTER
• Identify the transmitter The transmitter allows the operator to operate the machine by remote control. The
components. transmitter output is a radio signal to the receiver.
When a function is selected on the transmitter, a radio signal is sent to the receiver.
The receiver, the interface control module, and the machine electrical system
cause a machine function to occur.
The transmitter has several safety features. The transmitter must be on and in
radio signal range of the receiver. The parking brake will engage and the engine
will shut down if the transmitter is out of radio signal range.
The transmitter contains a tilt switch which will cause the transmitter to turn off if it
is tilted beyond 45°, which causes the parking brake to engage and the engine to
shut down.
Components visible on the transmitter are:
-- Fire extinguisher switch (1) -- Horn switch (9)

-- Antenna (2) -- Front light switch (10)
-- Monitoring display (3) -- Rear light switch (11)
-- Start switch (4) -- Remote shutdown switch (12)
-- Motion control lever (5) -- Main power indicator (13)
-- Bucket control lever (6) -- Engine stop switch (14)
-- Rocker switch (lower rpm) (7) -- Fault override switch (15)
-- Rocker switch (raise rpm/auto dig) (8) -- Parking brake switch (16)

2
3
4 5 6 7
13
RECEIVER
• Identify the remote control The receiver has an input and an output. The input is a radio signal from the
receiver. transmitter. The output is an electrical signal or a Pulse Width Modulated (PWM)
electrical signal to the interface control module.
When a function is selected on the transmitter, a radio signal is sent to the receiver.
The receiver will interpret the radio signal and send an electrical signal or a PWM
electrical signal through the harness connector and the electrical harness to the
interface control module. The interface control module causes a machine function
to occur.
The display on the receiver (1) consists of 28 Light Emitting Diodes (LED). There
are 24 remote control function LEDs (2) and four status LEDs (3).
The remote control function LEDs each have an individual function. The remote
control function LED will be on when a function is selected on the transmitter.
The power LED (4) will be on when the receiver is operating correctly and the
transmitter is on and in radio signal range.
The receive signal LED (5) will be on when the receiver is operating correctly and
the transmitter is on and in radio signal range.

The valid data LED (6) will be on when the receiver is receiving correct data from
the transmitter.
The battery low LED (7) will be on when the machine electrical system voltage
drops below approximately 13 volts.

1 2
15
INTERFACE CONTROL MODULE
• Identify the interface control The interface control module is located in the hydraulic tank compartment. The
module. function of the interface control module is to provide a connection between the
remote control system and the machine electrical system. The interface control
module also minimizes the current draw through the contacts in the receiver.
Harness connectors are mounted on the side of the interface control module.
Harness connector (2) is connected to the receiver. Harness connector (1) is
connected to the machine electrical system. The interface control module contains
21 relays, one relay for each remote control function. All relays are on/off function
relays.
When the remote control switch in the operator’s station is in the ON position, the
21 on/off function relays have 24 VDC available at the contacts. When an on/off
function on the transmitter is selected, an electrical signal is sent from the receiver
to energize the corresponding relay. The relay switches 24 VDC to the machine
electrical system.
The tilt, dump, raise, and lower functions have no relays and are controlled directly
by the receiver.
NOTE: The fuses and relays inside the interface control module
are identified in the R1600H Remote Control Systems Operation,
Troubleshooting, Testing and Adjusting module (UENR1456)

STEERING AND BUCKET CONTROL VALVE CIRCUIT

BUCKET RAISE
Pilot Oil Supply Steering Neutralizer
Valves (2)
Steering and Bucket
Control Valve (1)
EL551-GN
1 1
Steering
200-BK
2 2 Control
Valve (3)
Steer
Left (5)
EL552-GN
200-BK
1 1 Steering Pilot Line
2 2
Steering Pilot Line
Steer Tilt Pilot Line
Right (6) Dump Pilot Line
Raise Pilot Line
EL333-WH
1 1
Lower Pilot Line
200-BK
2 2
Tilt
Back (7)
EL334-GN
1 1
200-BK
2 2
Dump
(8)
EL336-YL
1 1
200-BK
2 2
Raise
(9) Main
EL568-GN
Control
1 1
200-BK
2 2 Valve (4)
EL333-WH
EL551-GN
EL552-GN
EL334-GN
EL568-GN
EL335-YL
Lower (10)
200-BK
200-BK
200-BK
200-BK
300-BK
200-BK
12
10
11
16
1
6
7
5
4
8
3
9
2
STEERING AND BUCKET CONTROL VALVE - BUCKET OPERATION/RAISE
• Explain the operation of the The remote control operation of the machine steering and bucket functions is
steering and bucket control valve controlled by the steering and bucket control valve (1).
during BUCKET RAISE.
• Solenoid valves The steering and bucket control valve contains four solenoid control valves: tilt
back (7), dump (8), raise (9), and lower (10) to control the bucket. Two directional
control solenoid valves, steer left (5) and steer right (6), control the machine
steering functions.
The solenoid valves and the directional control valve share a common supply from
the pilot oil supply line.
• Shuttle valves Shuttle valves are also located in the steering and bucket control valve. Check
valves are located in the steering and bucket control valve between the directional
control solenoids and the steering pilot circuit.
Pilot oil lines from the implement pilot control valve are connected to the steering
and bucket control valve.
• Pilot control valve - RAISE When the pilot control valve is in the RAISE position, pilot oil is directed to the
steering and bucket control valve. The shuttle valve directs pilot oil to the main
control valve (4) in the front frame.
The operation of the lower, the tilt back, and the dump functions are the same as
the raise function.

• Bucket control lever - RAISE When the bucket control lever on the transmitter is moved to the RAISE position,
the receiver sends a PWM electrical signal via the interface control module to
energize the raise solenoid control valve. The raise solenoid control valve directs
pilot oil to the shuttle valve in the steering and bucket control valve.
The shuttle valve directs pilot oil to the main control valve, and moves the lift
control valve spool to the RAISE position.
• Bucket control lever - HOLD When the bucket control lever on the transmitter is released, it will return to the
HOLD position. The raise solenoid control valve will de-energize, allowing the pilot
oil from the main control valve to return through the shuttle valve and to the tank.
The lift control valve spool in the main control valve is moved to the HOLD position
by spring force and the bucket remains stationary.
NOTE: Callouts not listed in the text are shown for reference purposes only.

STEERING AND BUCKET CONTROL VALVE CIRCUIT

LEFT TURN
Pilot Oil Supply Steering Neutralizer
Steering and Bucket Valves (2)
Control Valve (1)
EL551-GN
1 1
Steering
200-BK
2 2 Control
Valve (3)
Steer
Left (5)
EL552-GN
200-BK
1 1 Steering Pilot Line
2 2
Steering Pilot Line
Steer Tilt Pilot Line
Right (6) Dump Pilot Line
Raise Pilot Line
EL333-WH
1 1
Lower Pilot Line
200-BK
2 2
Tilt
Back (7)
EL334-GN
1 1
200-BK
2 2
Dump
(8)
EL336-YL
1 1
200-BK
2 2
Raise
(9) Main
EL568-GN
Control
1 1
200-BK
2 2 Valve (4)
EL333-WH
EL551-GN
EL552-GN
EL334-GN
EL568-GN
EL335-YL
Lower (10)
200-BK
200-BK
200-BK
200-BK
300-BK
200-BK
12
10
11
18
1
6
7
5
4
8
3
9
2
STEERING AND BUCKET CONTROL VALVE - STEERING OPERATION/LEFT

TURN
• Explain the operation of the Pilot oil lines from the STIC steering pilot valve are connected to the steering and
steering and bucket control valve bucket control valve (1).
during a LEFT TURN.
• STIC steering pilot valve When the STIC steering pilot valve is moved to the LEFT TURN position, pilot oil is
directed to the steering and bucket control valve and steering neutralizer valves (2).
Pilot oil is blocked by the check valve. Pilot oil is then directed through the steering
neutralizer valves to the steering control valve (3). The spool in the steering control
valve moves and the machine turns to the left.
The operation for a right turn is the same as a left turn.
• Motion control lever - LEFT TURN When the motion control lever on the transmitter is moved to the LEFT TURN
position, the receiver sends a PWM electrical signal via the interface control
module to energize the left steer solenoid (5). The left steer solenoid moves the
directional control valve spool, which directs pilot oil to the steering neutralizer
valves and steering control valve. The spool in the steering control valve moves
and the machine turns to the left.
• Motion control lever - HOLD When the motion control lever on the transmitter is released, it will return to the
HOLD position. The left steer solenoid is de-energized and the spool in the steering
control valve is moved to the HOLD position by spring force. The machine stops
articulating.

PURPOSE
This module was designed to ensure participants can

locate and identify the function of all major components
of the remote control system.
19
Purpose review

REASON
This training was necessary for participants to identify

the components of the remote control system and
to demonstrate knowledge of the remote control
system in order to troubleshoot the system. This will
ensure customers will experience quick and accurate
resolution of remote control issues.
20
Reason review

COMPETENCY Statement
Participants are now able to locate and identify

the remote control system components during lab
exercises. Participants are also able to identify the
function of the remote control system components
during a post-assessment.
21
Competency Statement review

LEARNING OUTCOMES
You have met the following learning outcomes during

this R1600H Underground Loader Remote Control
System module:
• Located and identified the function of all remote control
system components.
22
Learning Outcomes Review

Module Conclusion
This concludes the Remote Control System module for

the R1600H Underground Loader course.
23
Module Conclusion

R1600H UndrgndLdr M08 RemoteCtrlSys EN TXT-Instructor

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Global Service Training

R1600H Underground Loader

Caterpillar: Confidential Yellow

Safely Home. Everyone. Every Day.™

Before beginning this module, the following topics will be reviewed:

Safely Home. Everyone. Every Day.™

Caterpillar: Confidential Yellow

This module is designed to ensure participants can

Caterpillar: Confidential Yellow

This training is necessary for participants to identify

Caterpillar: Confidential Yellow

At the completion of this module, participants will be

Caterpillar: Confidential Yellow

You will meet the following learning outcomes during

Caterpillar: Confidential Yellow

REMOTE CONTROL SYSTEM

Caterpillar: Confidential Yellow

Caterpillar: Confidential Yellow

Caterpillar: Confidential Yellow

Caterpillar: Confidential Yellow

-- Fire extinguisher switch (1) -- Horn switch (9)

Caterpillar: Confidential Yellow

Caterpillar: Confidential Yellow

Caterpillar: Confidential Yellow

Caterpillar: Confidential Yellow

STEERING AND BUCKET CONTROL VALVE CIRCUIT

STEERING AND BUCKET CONTROL VALVE - BUCKET OPERATION/RAISE

Caterpillar: Confidential Yellow

Caterpillar: Confidential Yellow

STEERING AND BUCKET CONTROL VALVE CIRCUIT

STEERING AND BUCKET CONTROL VALVE - STEERING OPERATION/LEFT

The operation for a right turn is the same as a left turn.

Caterpillar: Confidential Yellow

This module was designed to ensure participants can

Caterpillar: Confidential Yellow

This training was necessary for participants to identify

Caterpillar: Confidential Yellow

Participants are now able to locate and identify

Caterpillar: Confidential Yellow

You have met the following learning outcomes during

Caterpillar: Confidential Yellow

This concludes the Remote Control System module for

Caterpillar: Confidential Yellow

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