Global Service Training

R1600H Underground Loader

Implement System
Module 5 - Text Reference

SERV2052

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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.
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SERV2052 - 03/15 -2- Module 5 - Implement System

TABLE OF CONTENTS
Safety Briefing��������������������������������������������������������������������������������������������������������������������� 3
Purpose����������������������������������������������������������������������������������������������������������������������������������� 4
Reason������������������������������������������������������������������������������������������������������������������������������������� 5
Competency statement����������������������������������������������������������������������������������������������������� 6
Learning outcomes������������������������������������������������������������������������������������������������������������ 7
IMPLEMENT HYDRAULIC SYSTEM������������������������������������������������������������������������������������������ 8
HYDRAULIC TANK��������������������������������������������������������������������������������������������������������������������� 9
IMPLEMENT PUMP AND PILOT SYSTEM COMPONENTS���������������������������������������������������� 10
PILOT CONTROL VALVE�����������������������������������������������������������������������������������������������������������11
PILOT CONTROL VALVE components������������������������������������������������������������������������������� 12
main control valve����������������������������������������������������������������������������������������������������������� 13
AUXILIARY FUNCTION SWITCH��������������������������������������������������������������������������������������������� 14
PILOT DIVERTER SOLENOID VALVES����������������������������������������������������������������������������������� 15
MAIN CONTROL VALVE - HOLD���������������������������������������������������������������������������������������������� 16
MAIN CONTROL VALVE - TILT BACK�������������������������������������������������������������������������������������� 17
IMPLEMENT HYDRAULIC SCHEMATIC - HOLD��������������������������������������������������������������������� 18
IMPLEMENT HYDRAULIC SYSTEM - TILT BACK������������������������������������������������������������������� 20
IMPLEMENT HYDRAULIC SYSTEM - DUMP�������������������������������������������������������������������������� 21
IMPLEMENT HYDRAULIC SYSTEM - RAISE�������������������������������������������������������������������������� 23
LIFT ARM POSITIONER����������������������������������������������������������������������������������������������������������� 24
IMPLEMENT HYDRAULIC SYSTEM - LOWER������������������������������������������������������������������������ 25
IMPLEMENT HYDRAULIC SYSTEM - FLOAT�������������������������������������������������������������������������� 27
IMPLEMENT HYDRAULIC SYSTEM - LOWER/ENGINE OFF������������������������������������������������� 28
Ride Control System�������������������������������������������������������������������������������������������������������� 29
IMPLEMENT HYDRAULIC SYSTEM - RIDE CONTROL SYSTEM ACTIVATED���������������������� 30
Purpose review������������������������������������������������������������������������������������������������������������������ 32
Reason review�������������������������������������������������������������������������������������������������������������������� 33
Competency Statement review������������������������������������������������������������������������������������ 34
Learning Outcomes Review������������������������������������������������������������������������������������������� 35
Module Conclusion���������������������������������������������������������������������������������������������������������� 36

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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.™

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SERV2052 - 03/15 -4- Module 5 - Implement System

PURPOSE

This module is designed to ensure participants can

locate and identify the function of all implement system
components and test and adjust the implement system.

4
Purpose

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REASON

This training is necessary for participants to identify

implement system components and test and adjust
the implement system in order to be able to efficiently
diagnose and repair the implement system. This will
ensure customers will experience quick and accurate
resolution of implement system issues.

5
Reason

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COMPETENCY Statement

At the completion of this module, participants will

be able to locate and identify the implement system
components and test and adjust the implement
system during lab exercises. Participants will also be
able to identify the function of the implement system
components during a post-assessment.

6
Competency statement

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LEARNING OUTCOMES

You will meet the following learning outcomes during

this R1600H Underground Loader Implement System
module:
• Locate and identify the implement system components.
• Test and adjust the implement system.
• Identify the function of the implement system
components.

7
Learning outcomes

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HYDRAULIC SYSTEM
COMPONENENTS IDENTIFICATION

Ride Control
Solenoid
Lift Arm Float Valve (5) Implement Pilot Oil
Ride Control Hydraulic
Positioner Sequence Main and Steering Pressure
Solenoid Tank (7)
Valve (3) Valve (4) Relief Solenoid Reducing
Tilt Valve (2)
Valve (6) Pilot Valve (9) Valve (10)
Cylinder (1)
Control Implement
Valve (8) Pump (11)

Lift Main
Cylinders Ride Control Selector Pilot and
Pilot
(17) Control Valve and Braking
Diverter
Accumulator (15) Pressure Pump (12)
Solenoid
(16) Control Valve
Valve (14)
(13)

8
IMPLEMENT HYDRAULIC SYSTEM

• Identify the major components of The implement hydraulic system has two systems: the pilot system and the main
the implement hydraulic system. system. The main (implement) oil system is an open-center system controlled by
the pilot oil system. The implement system oil is stored in the hydraulic tank.

The main components of the pilot system are: pilot and braking pump (12), pilot oil
pressure reducing valve (10), selector and pressure control valve (13), pilot control
valve (8), and implement and steering solenoid valve (9).

The major components of the main implement system are: implement pump (11),
main control valve (15), tilt cylinder (1), and lift cylinders (17).

Other components shown in the image above are:

• Ride control solenoid valve (2)
• Lift arm positioner valve (3)
• Float sequence valve (4)
• Ride control solenoid valve (5)
• Main relief valve (6)
• Hydraulic tank (7)
• Pilot diverter solenoid valves (14)
• Ride control solenoid valve (16)

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4
5

9
HYDRAULIC TANK

• Identify the hydraulic tank
components.
Hydraulic filters are located in the hydraulic tank (1) and can be accessed by
removing a cover (2) on the side of the tank. If the oil restriction through the
hydraulic filters is too high (filter elements too dirty), a filter bypass valve in the tank
will open and allow oil to bypass the hydraulic filters and return to the hydraulic
tank. The hydraulic tank filler cap (3) is removed to add hydraulic oil to the tank.

A sight gauge (4) is located on the side of the tank to check the hydraulic oil level.

A breaker relief valve (not visible) is located on top of the tank.

The transmission oil sight gauge (5) is also visible in this image.

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1 3
2 4
• Identify the implement pump and
pilot system components.
-10- Module 5 - Implement System
8
7
6
10
IMPLEMENT PUMP AND PILOT SYSTEM COMPONENTS
The implement, steering, and pilot braking pump is a three-section vane pump,
mounted to the torque converter updrive housing, which pulls oil from the hydraulic
tank through the inlet port (1). The implement pump section (2) provides oil to the
main control valve. The pilot and braking pump section (3) is attached to the
steering pump section (4) and provides oil to the implement and steering pilot
systems and the brake system. The implement system discharge pressure tap (5)
can be used to check implement system pressure.
The pilot and braking pump sends oil to the pilot pressure reducing valve (6), which
regulates oil pressure for the implement and steering pilot systems.
The implement and steering solenoid valve (7) is controlled by the Power Train
ECM. When ENERGIZED by the Power Train ECM, the implement and steering
solenoid valve directs pilot oil to the implement and steering pilot valves.
The selector and pressure control valve (8) reduces high-pressure oil from the lift
cylinders. This oil is used in the pilot system when the engine is stopped and when
the bucket is raised. The selector and pressure control valve routes the oil to the
pilot control valve via the implement and steering solenoid valve. A raised bucket
can be lowered or dumped when the engine is stopped and the key start switch is
in the ON position.
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11
PILOT CONTROL VALVE

• Identify the pilot control valve. The pilot control valve (1) is located at the base of the joystick (2) and is accessed
by removing a cover below the joystick.

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PILOT CONTROL VALVE

Rod (1)

Seat (2)

Return Spring (3)

Metering Spring (4)

Return Chamber (5)

Pilot Oil Supply (6) Spool

(7)

12
PILOT CONTROL VALVE components

• Identify the pilot control valve The pilot control valve controls the displacement and direction of pilot oil flow to the
components. main control valve. The two pilot valve assemblies work basically the same as any
modulating pressure reducing valves.

The two pilot valve assemblies are identical, and their major components include a
rod (1) or plunger, return spring (3), metering spring (4), and a spool (7). Supply oil
is available from the pilot and braking pump to the supply passage.

When the joystick control lever is in the HOLD (centered) position, return spring
force keeps the pilot control valve assemblies in the centered position and pilot oil
is blocked by both spools. The pilot oil ports at the bottom of the valve assemblies
are open to drain and no pilot oil is sent to the main control valve.

When the operator moves the joystick control lever, the rod depresses the spool
and metering spring. The increased force on the metering spring pushes the spool
down and opens a passage through the spool from the pilot pressure supply
passage to the signal port.

The spool meters the pilot oil from the supply passage to the pilot port. This
metering controls the signal pressure to the main control valve. The pressure of
this signal is determined by the force of the metering spring, which depends on the
distance the rod is depressed. The amount the rod is depressed is controlled by
how far the joystick control lever is moved.
NOTE: Callouts not listed in the text are shown for reference purposes only.

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6
4
1
7
3

2 5

13
main control valve

• Identify the main control valve The main control valve (1) is located on the front frame and directs oil from the
components. implement pump to the implement cylinders. The optional auxiliary valve (2) is
attached to the bottom of the main control valve and directs oil from the implement
pump to the auxiliary cylinders.

The main relief valve (3) limits the oil pressure in the implement hydraulic circuit.
The tilt line relief valves (4) limit the oil pressure in the rod end and head end of the
tilt cylinder. The auxiliary line relief valves (5) limit the oil pressure in the rod end
and head end of the auxiliary cylinders.

With the joystick control lever in the float position, the float sequence valve (6)
directs oil to open the makeup valve in the main control valve. The makeup valve
allows the oil from the rod end of the lift cylinders to return to the tank. The bucket
will then follow the contour of the ground.

Also shown is the lift arm positioner solenoid (7)

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14
AUXILIARY FUNCTION SWITCH

• Identify the auxiliary function The auxiliary system is activated using the auxiliary function switch (arrow) located
switch. on the joystick.

NOTE: The auxiliary function switch is used to operate the ejector bucket.

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SERV2052 - 03/15 -15- Module 5 - Implement System

1
3

15
PILOT DIVERTER SOLENOID VALVES

• Identify the pilot diverter solenoid The pilot diverter solenoid valves (1) are located on the rear of the front frame (one
valves. on each side of the frame) near the articulation hitch.

The flow of pilot pressure oil from the pilot control valve changes when the machine
is equipped with the auxiliary system. When the auxiliary system is not activated,
the pilot diverter solenoids are DE-ENERGIZED by the Machine ECM and direct
pilot oil to the tilt spool in the main control valve (2). When the auxiliary system is
activated, pilot diverter solenoids are ENERGIZED by the Machine ECM and direct
pilot oil to the auxiliary spool in the auxiliary control valve (3).

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MAIN CONTROL VALVE

HOLD
Tilt Tilt Tilt Load
Cylinder Cylinder Check
Rod End Head End Valve (7)
(5) (6)
Makeup Valve (4) Implement
Pump (8)

Tilt Spool
(9)

Tilt Pilot
Control Valve
(3)

Lift Pilot
Control Valve
(2)
Lift Spool
(10)
Makeup
Valve (1) Lift Load
Tank
Lift Lift Check Valve
(12)
Cylinders Cylinders (11)
Rod End Head End
(14) (13)

16
MAIN CONTROL VALVE - HOLD

• Explain the operation of the main The main valve has an open center. Oil from the implement pump flows to the tilt
control valve when in HOLD. spool (9) and then to the lift spool (10). The tilt and lift spools are spring centered.
The valve spools are controlled by pilot oil pressure.

Springs keep the valve spools in the HOLD position when there is no pilot oil
pressure in the chambers. Spool movement is controlled by pilot oil pressure in the
chambers.

The main control valve is in the HOLD position in this illustration. In the HOLD
position, oil from the implement pump (8) flows into the control valve, around the tilt
spool and lift spool, and to the tank (12). The position of the valve spool prevents
oil flow to the tilt cylinders (5) and (6) and the lift cylinders (13) and (14). The valve
spools block the oil in both ends, which prevents the cylinders from moving.

NOTE: Callouts not listed in the text are shown for reference purposes only.

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MAIN CONTROL VALVE

TILT BACK
Tilt Tilt Tilt Load
Cylinder Cylinder Check
Rod End Head End Valve (7)
(5) (6)
Makeup Valve (4) Implement
Pump (8)

Tilt Spool
(9)

Tilt Pilot
Control Valve
(3)

Lift Pilot
Control Valve
(2)
Lift Spool
Makeup (10)
Valve (1)
Tank Lift Load
Lift Lift (12) Check Valve
Cylinders Cylinders (11)
Rod End Head End
(14) (13)

17
MAIN CONTROL VALVE - TILT BACK

• Explain the operation of the main When the joystick control lever is moved to the TILT BACK position, pilot oil flows to
control valve during TILT BACK. the tilt pilot control valve (3) and the left side of the tilt spool (9). The tilt spool
moves right and oil from the implement pump (8) opens the tilt load check
valve (7). Oil flows to the tilt cylinder head end (6) and the bucket tilts back.

Oil from the tilt cylinder rod end (5) flows into the implement control valve around
the tilt spool and lift spool (10) to the tank (12).

NOTE: Callouts not listed in the text are shown for reference purposes only.

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Tilt Cylinder (20) Ride Control

Ride Control
Accumulator
Solenoid Valve
Auxiliary Main Control (21)
(22)
Cylinders (17) Valve (19)
Auxiliary Lift
Tilt Control Cylinders (23)
Control Valve (16)
Valve Spool (18)

Lift Circuit
Aux Circuit Lift Control
Tilt Circuit Relief Valve (12)
Relief Valves Valve
Relief Valve
(15) Spool (13)
(14)

Ride Control
Solenoid
Valve (11)
Main Relief
Lift Arm
Valve (10)
Positioner
Valve (8)

Pilot Diverter
Float R1600H IMPLEMENT
Sequence
Solenoid Valves
(9)
Valve (7) HYDRAULIC SYSTEM
HOLD

Remote Control Lower Lift Dump Tilt Back

Steering and Pilot
Bucket Control Control
Valve (27) Valve (5) Implement and Parking Brake
Steering Solenoid Control Valve
Valve (26) (25)
STIC Steering
Pilot Valve
Pilot Oil Pressure
(28)
Reducing Valve (6)

Steering Brake
System Steering
Accumulator
(29) System
Charging Valve
(24)

Selector and Pilot and

Pressure Control Braking
Valve (4) Pump (3)
Steering Implement

18
Pump (2) Pump (1)

IMPLEMENT HYDRAULIC SCHEMATIC - HOLD

• Explain the flow of oil through Oil for the parking brake, service brake, and pilot systems is supplied by the pilot
the implement hydraulic system and braking pump (3). The oil flows through the check valve to the brake
when in HOLD. accumulator charging valve (24) for the braking system. The pilot oil also flows to
the pilot oil pressure reducing valve (6), which decreases the oil pressure to pilot oil
pressure.

When the engine is running, pilot oil flows to the parking brake control valve (25).
Pilot oil also flows through a check valve to the selector and pressure control
valve (4), and to the implement and steering solenoid valve (26) located in the
parking brake control valve. When the Power Train ECM energizes the implement
and steering solenoid valve, pilot oil is allowed to flow to the pilot control valve (5),
the remote control steering and bucket control valve (27), and the STIC steering
pilot valve (28).

The joystick control lever in the operator station controls the movement of the pilot
control valve. The pilot oil is blocked at the pilot control valve when the joystick
control lever is in the HOLD position. Moving the joystick control lever will send
pilot oil through the pilot control valve to the main control valve (19) to move the tilt
control valve spool (18) or the lift control valve spool (13).

While the pilot and braking pump is supplying oil to the pilot oil system, the selector
and pressure control valve will block the flow of alternate oil into the pilot oil
system.

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SERV2052 - 03/15 -19- Module 5 - Implement System

If the pilot and braking pump fails, or oil is not available, then the selector and
pressure control valve will allow alternate oil to flow into the pilot oil system from
the steering system and the main hydraulic system.

When the engine is stopped, high pressure oil from the head end of the lift
cylinders (23) enters the pilot system through the selector and pressure control
valve. The selector and pressure control valve reduces the oil pressure and lets
lower pressure oil flow to the pilot control valve via the implement and steering
solenoid valve. When the pilot control valve is moved to the LOWER position, pilot
oil flows to the lift control valve spool in the main control valve. The lift control valve
spool moves to the LOWER position, allowing the bucket to be lowered.

The implement pump (1) sends oil to the main relief valve, which controls the
maximum pressure in the implement hydraulic system.

With the control valve spools in the HOLD position, oil flows through the main
control valve and through the hydraulic oil filters to the hydraulic tank. If the
hydraulic filters get full of foreign material (debris), the filter bypass valve (in the
filter group) opens and lets the return oil flow to the hydraulic tank.

NOTE: Callouts not listed in the text are shown for reference purposes only.

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SERV2052 - 03/15 -20- Module 5 - Implement System
Ride Control Ride Control
Tilt Cylinder (20)
Accumulator Solenoid Valve
Auxiliary Main Control (21) (22)
Cylinders (17) Valve (19)
Auxiliary Lift
Tilt Control Cylinders (23)
Control Valve (16)
Valve Spool (18)

Lift Circuit
Aux Circuit
Tilt Circuit Lift Control Relief Valve (12)
Relief Valves
Relief Valve Valve
(15)
(14) Spool (13)

Ride Control
Solenoid
Valve (11)
Main Relief
Lift Arm
Valve (10)
Positioner
Valve (8)

Pilot Diverter
Float R1600H IMPLEMENT
Sequence
Solenoid Valves
(9)
Valve (7) HYDRAULIC SYSTEM
TILT BACK

Remote Control Lower Lift Dump Tilt Back

Steering and Pilot
Bucket Control Control
Valve (27) Valve (5) Implement and Parking Brake
Steering Solenoid Control Valve
Valve (26) (25)
STIC Steering
Pilot Valve
Pilot Oil Pressure
(28)
Reducing Valve (6)

Steering Brake
System Steering
Accumulator
(29) System
Charging Valve
(24)

Selector and Pilot and

Pressure Control Braking
Valve (4) Pump (3)
Steering Implement
Pump (2) Pump (1)
20
IMPLEMENT HYDRAULIC SYSTEM - TILT BACK

• Explain the operation of the When the joystick control lever is moved to the TILT BACK position, pilot oil flows
implement hydraulic system through the pilot control valve (5) to the tilt back end of the tilt control valve
during TILT BACK. spool (18), which causes the tilt control valve spool to move. The pilot oil at the
dump end of the tilt control valve spool flows back to the pilot control valve, through
the pilot valve dump stem to the hydraulic tank.

The tilt control valve spool stops oil flow through the main control valve (19) and
implement pump pressure increases, which opens the load check valve. Oil flows
to the head end of the tilt cylinder (20) and causes the cylinder rod to extend, and
the bucket tilts back. The movement of the cylinder piston and rod pushes the oil
out of the rod end of the tilt cylinder, and the oil flows into the main control valve
and returns to the hydraulic tank.

When the joystick control lever is released the dump stem returns to the HOLD
position, causing pilot oil flow to stop. The springs on the tilt control valve spool
move the valve spool back to the HOLD position. The pilot oil at the tilt back end of
the tilt control valve spool flows back to the pilot control valve, through the tilt back
stem, and returns to the hydraulic tank.

The implement oil in the tilt cylinder is held by the tilt control valve spool, and
movement of the cylinder piston and rod stops. The bucket will not move until the
joystick control lever is moved again.
NOTE: Callouts not listed in the text are shown for reference purposes only.

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SERV2052 - 03/15 -21- Module 5 - Implement System
Tilt Cylinder (20) Ride Control Ride Control
Accumulator Solenoid Valve
Auxiliary Main Control (21) (22)
Cylinders (17) Valve (19)
Auxiliary Lift
Tilt Control Cylinders (23)
Control Valve (16)
Valve Spool (18)

Lift Circuit
Aux Circuit
Tilt Circuit Lift Control Relief Valve (12)
Relief Valves
Relief Valve Valve
(15)
(14) Spool (13)

Ride Control
Solenoid
Main Relief Valve (11)
Lift Arm
Valve (10)
Positioner
Valve (9)

Pilot Diverter Float R1600H IMPLEMENT

Sequence
Solenoid Valves
(9) Valve (7) HYDRAULIC SYSTEM
DUMP

Remote Control Lower Lift Dump Tilt Back

Steering and Pilot
Bucket Control Control Implement and
Valve (27) Valve (5) Parking Brake
Steering Solenoid
Control Valve
Valve (26)
(25)
STIC Steering
Pilot Valve
Pilot Oil Pressure
(28)
Reducing Valve (6)

Steering Brake
Steering Implement
System Accumulator
System and Steering
(29) Charging Valve
Solenoid Valve
(26) (24)

Selector and Pilot and

Pressure Control Braking
Valve (4) Pump (3)
Steering Implement
Pump (2) Pump (1)
21
IMPLEMENT HYDRAULIC SYSTEM - DUMP

• Explain the operation of the When the joystick control lever is moved to the DUMP position, pilot oil flows
implement hydraulic system through the pilot control valve (5) to the dump end of the tilt control valve
during DUMP. spool (18), which causes the tilt control valve spool to move. The pilot oil at the tilt
back end of the tilt control valve spool flows back to the tilt back stem of the pilot
control valve and returns to the hydraulic tank.

The tilt control valve spool stops oil flow through the main control valve (19) and
implement pump pressure increases, which opens the load check valve. Oil flows
to the rod end of the tilt cylinder (20) and causes the cylinder rod to retract.

The movement of the cylinder piston and rod pushes the oil out of the head end
of the tilt cylinder and the oil flows into the main control valve and returns to the
hydraulic tank.

If the tilt cylinder retracts too fast, the implement pump (1) cannot supply enough
oil flow to the rod end of the tilt cylinder. The oil pressure then decreases, which
causes the makeup valve to move against spring force. The makeup valve allows
the addition of return line oil to the implement pump oil to prevent damage from
cavitation (vacuum) in the hydraulic system.

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SERV2052 - 03/15 -22- Module 5 - Implement System

When the joystick control lever is released, the dump stem returns to the HOLD
position, causing pilot oil flow to stop. The springs on the tilt control valve spool
move the valve spool back to the HOLD position. The pilot oil at the dump end of
the tilt control valve spool flows back to the dump stem in the pilot control valve and
returns to the hydraulic tank.

The implement oil in the tilt cylinder is held by the tilt control valve spool, and
movement of the cylinder piston and rod stops. The bucket is held in the DUMP
position until the joystick control lever is moved again.

NOTE: Callouts not listed in the text are shown for reference purposes only.

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SERV2052 - 03/15 -23- Module 5 - Implement System
Ride Control Ride Control
Tilt Cylinder (20)
Accumulator Solenoid Valve
Auxiliary Main Control (21) (22)
Cylinders (17) Valve (19)
Auxiliary Lift
Tilt Control Cylinders (23)
Control Valve (16)
Valve Spool (18)

Lift Circuit
Aux Circuit
Tilt Circuit Lift Control Relief Valve (12)
Relief Valves (15)
Relief Valve Valve
(14) Spool (13)

Ride Control
Solenoid
Main Relief Valve (11)
Lift Arm
Valve (10)
Positioner
Valve (8)

Pilot Diverter Float R1600H IMPLEMENT

Sequence
Solenoid Valves
(9) Valve (7) HYDRAULIC SYSTEM
RAISE

Remote Control Lower Lift Dump Tilt Back

Steering and Pilot
Bucket Control Control
Valve (27) Valve (5) Implement and Parking Brake
Steering Solenoid Control Valve
Valve (26) (25)
STIC Steering
Pilot Valve
Pilot Oil Pressure
(28)
Reducing Valve (6)

Steering Brake
System Steering Accumulator
(29) System Charging Valve
(24)

Selector and Pilot and

Pressure Control Braking
Valve (4) Pump (3)
Steering Implement

23
Pump (2) Pump (1)

IMPLEMENT HYDRAULIC SYSTEM - RAISE

• Explain the operation of the When the joystick control lever is moved to the RAISE position, pilot oil flows
implement hydraulic system through the pilot control valve (5) to the raise end of the lift control valve spool (13),
during RAISE. which causes the lift control valve spool to move. The pilot oil at the lower end of
the lift control valve spool flows back to the lower stem in the pilot control valve and
returns to the hydraulic tank.

The lift control valve spool stops oil flow through the main control valve (19). The
implement pump (1) pressure increases, which opens the load check valve. Oil
flows to the head end of the lift cylinders (23) and causes the cylinder rods to
extend, and the bucket lifts.

The movement of the cylinder pistons and rods pushes the oil out of the rod end
of the lift cylinders and oil flows into the main control valve and returns to the
hydraulic tank.

When the joystick control lever is released, the lift stem returns to the HOLD
position, causing pilot oil flow to stop. The springs on the lift control valve spool
move the valve spool to the HOLD position. The pilot oil at the lift end of the lift
control valve spool flows back through the pilot control valve and returns to the
hydraulic tank. The implement oil in the lift cylinders is held by the lift control valve
spool, and movement of the cylinder pistons and rods stops. The lift arms and
bucket are held until the joystick control lever is moved again.
NOTE: Callouts not listed in the text are shown for reference purposes only.

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SERV2052 - 03/15 -24- Module 5 - Implement System

1
LIFT ARM
POSITIONER

4
2

24
LIFT ARM POSITIONER

• Identify the components of the lift The lift arm positioner system returns the lift arms to a preset height when the lift
arm positioner system. arms are lowered. The main components of the lift arm positioner circuit are the lift
arm positioner switch (1), the magnetic switch (2), the magnet (3), and the lift arm
positioner solenoid valve (4).

The lift arm positioner switch is located in the top keypad in the operator’s station.
When the lift arm positioner switch is in the ON position, power is supplied to the
magnetic switch.

The magnetic switch is located on the right side of the front frame. The magnet
is located on the lift arm. When the joystick control lever is moved to the LOWER
position, the lift arms move downward. As the lift arms move downward, the
magnet passes the magnetic switch, which causes the magnetic switch to close.

The lift arm positioner valve is located on the right side of the front frame in front of
the articulation joint. When the magnetic switch closes, power is supplied to the lift
arm positioner valve, which causes the lift arm positioner valve to close.

The height at which the lift arm comes to rest can be varied by adjusting the
position of the magnetic switch. Moving the magnetic switch up will raise the lift arm
height. Moving the magnetic switch down will lower the lift arm height.

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SERV2052 - 03/15 -25- Module 5 - Implement System
Ride Control Ride Control
Tilt Cylinder (20)
Accumulator Solenoid Valve
Auxiliary Main Control (21) (22)
Cylinders (17) Valve (19)
Auxiliary Lift
Tilt Control Cylinders (23)
Control Valve (16)
Valve Spool (18)

Lift Circuit
Aux Circuit Lift Control
Tilt Circuit Relief Valve (12)
Relief Valves Valve
Relief Valve
(15) Spool (13)
(14)

Ride Control
Solenoid
Valve (11)
Main Relief
Lift Arm
Valve (10)
Positioner
Valve (8)

Pilot Diverter Float R1600H IMPLEMENT

Sequence
Solenoid Valves
(9) Valve (7) HYDRAULIC SYSTEM
LOWER

Remote Control Lower Lift Dump Tilt Back

Steering and Pilot
Bucket Control Control
Valve (27) Valve (5) Implement and Parking Brake
Steering Solenoid Control Valve
Valve (26) (25)
STIC Steering
Pilot Valve
Pilot Oil Pressure
(28)
Reducing Valve (6)

Steering Brake
System Steering Accumulator
(29) System Charging Valve
(24)

Selector and Pilot and

Pressure Control Braking
Valve (4) Pump (3)
Steering Implement
Pump (2) Pump (1)
25
IMPLEMENT HYDRAULIC SYSTEM - LOWER

• Explain the operation of the When the joystick control lever is moved to the LOWER position, pilot oil flows
implement hydraulic system through the pilot control valve (5) and the lift arm positioner valve (8) to the lower
during LOWER. end of the lift control valve spool (13), which causes the lift control valve spool to
move. The pilot oil at the raise end of the lift control valve spool flows back to the
pilot control valve lift stem and returns to the hydraulic tank.

The lift control valve spool stops oil flow through the main control valve (19).
Implement pump (1) pressure increases, which opens the load check valve. Oil
flows to the rod end of the lift cylinders (23) and causes the cylinder rods to retract,
and the bucket lowers. The movement of the cylinder pistons and rods pushes the
oil out of the head end of the lift cylinders, and oil flows into the main control valve
and returns to the hydraulic tank.

If the lift cylinder rod retracts too fast the implement pump cannot supply enough
oil flow to the rod end of the lift cylinders. The pressure then decreases, which
causes the makeup valve to move against spring force. The makeup valve allows
the addition of return line oil to the implement pump oil to prevent damage from
cavitation (vacuum) in the hydraulic system.

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SERV2052 - 03/15 -26- Module 5 - Implement System

When the joystick control lever is released, the lower stem returns to the HOLD
position, causing pilot oil flow to stop. The springs on the lift control valve spool
move the valve spool back to the HOLD position. The pilot oil at the lower end of
the lift control valve spool flows back to the pilot control valve and returns to the
hydraulic tank. The implement oil in the lift cylinders is held by the lift control valve
spool, and movement of the cylinder pistons and rods stops. The bucket is held in
the lowered position until the joystick control lever is moved again.

The lift arm positioner valve controls pilot oil flow to and from the main control
valve. When the lift arm positioner valve closes, pilot oil from the main control valve
returns to the tank through an orifice, which causes the lift control valve spool in
the main control valve to gradually return to the CENTER position. The lift arms will
come to a controlled stop.

NOTE: Callouts not listed in the text are shown for reference purposes only.

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SERV2052 - 03/15 -27- Module 5 - Implement System

Tilt Cylinder (20) Ride Control

Ride Control
Accumulator
Solenoid Valve
Auxiliary Main Control (21)
(22)
Cylinders (17) Valve (19)
Auxiliary Lift
Tilt Control Makeup
Control Valve (16) Cylinders (23)
Valve Spool (18) Valve (27)

Lift Circuit
Aux Circuit
Tilt Circuit Lift Control Relief Valve (12)
Relief Valves
Relief Valve Valve
(15)
(14) Spool (13)

Ride Control
Solenoid
Main Relief Valve (11)
Lift Arm
Valve (10)
Positioner
Valve (8)

Pilot Diverter
Float R1600H IMPLEMENT
Sequence
Solenoid Valves
(9)
Valve (7) HYDRAULIC SYSTEM
FLOAT

Remote Control Lower Lift Dump Tilt Back

Steering and Pilot
Bucket Control Control Implement and
Valve (27) Valve (5) Parking Brake
Steering Solenoid
Control Valve
Valve (26)
(25)
STIC Steering
Pilot Valve
Pilot Oil Pressure
(28)
Reducing Valve (6)

Steering Brake
System Steering Accumulator
(29) System Charging Valve
(24)

Selector and Pilot and

Pressure Control Braking
Valve (4) Pump (3)
Steering Implement

27
Pump (2) Pump (1)

IMPLEMENT HYDRAULIC SYSTEM - FLOAT

• Explain the operation of the When the joystick control lever is moved to the FLOAT position, oil flow to the lift
implement hydraulic system control valve spool (13) is the same as in the LOWER position. The extra
during FLOAT. movement of the joystick control lever increases pilot oil flow to the float sequence
valve (7). Oil pressure moves the float sequence valve spool and allows oil in the
spring chamber of the makeup valve (27) to vent to the tank. The makeup valve
opens and allows oil from the rod end of the lift cylinders (23) to flow directly to the
hydraulic tank. The head end and rod end of the lift cylinders are now open to the
hydraulic tank. Outside forces on the bucket will control the movement of the lift
cylinder pistons and rods.

NOTE: Callouts not listed in the text are shown for reference purposes only.

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SERV2052 - 03/15 -28- Module 5 - Implement System
Ride Control Ride Control
Tilt Cylinder (20)
Accumulator Solenoid Valve
Auxiliary Main Control (21) (22)
Cylinders (17) Valve (19)
Auxiliary Lift
Tilt Control Cylinders (23)
Control Valve (16)
Valve Spool (18)

Lift Circuit
Aux Circuit
Tilt Circuit Lift Control Relief Valve (12)
Relief Valves
Relief Valve Valve
(15)
(14) Spool (13)

Ride Control
Solenoid
Valve (11)
Main Relief
Lift Arm
Valve (10)
Positioner
Valve (8)

Pilot Diverter Float R1600H IMPLEMENT

Sequence
Solenoid Valves
(9) Valve (7) HYDRAULIC SYSTEM
LOWER / ENGINE OFF

Remote Control Lower Lift Dump Tilt Back

Steering and Pilot
Bucket Control Control
Valve (27) Implement and Parking Brake
Valve (5)
Steering Solenoid Control Valve
Valve (26) (25)
STIC Steering
Pilot Valve
Pilot Oil Pressure
(28)
Reducing Valve (6)

Steering Brake
System Steering Accumulator
(29) System Charging Valve
(24)

Selector and Pilot and

Pressure Control Braking
Valve (4) Pump (3)
Steering Implement

28
Pump (2) Pump (1)

IMPLEMENT HYDRAULIC SYSTEM - LOWER/ENGINE OFF

• Explain the operation of the The bucket can be lowered with the engine off. The pilot oil supply comes from the
implement hydraulic system head end of the lift cylinders (23) and oil flows to the selector and pressure control
during LOWER with the ENGINE valve (4), which decreases the oil pressure to pilot oil pressure. The pilot oil from
OFF. the selector and pressure control valve flows through the implement and steering
solenoid valve (26) to the pilot control valve (5).

When the joystick control lever is moved to the LOWER position with the key
start switch on, pilot oil flows to the lift control valve spool (13) and moves it to the
LOWER position. The head end of the lift cylinders is now open to the hydraulic
tank. The makeup valve in the main control valve (19) opens so that the rod ends
of the lift cylinders are also open to the hydraulic tank. The weight of the bucket
and lift arms causes the bucket to lower to the ground.

NOTE: Callouts not listed in the text are shown for reference purposes only.

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SERV2052 - 03/15 -29- Module 5 - Implement System

2
1
2

29
Ride Control System

• Identify the ride control system The ride control system provides a means for dampening the bucket forces that
components. produce a pitching motion as the machine travels over rough terrain.

The main components of the ride control system are the ride control
accumulator (1), the ride control solenoid valves (2), and the ride control switch (3).

The ride control accumulator and the ride control solenoid valves are mounted on
the front frame forward of the articulation joint. One of the ride control solenoid
valves is mounted to the front end of the ride control accumulator. The other ride
control solenoid valve is mounted to a block, which is attached to the main control
valve (4). The ride control switch is located on the operator’s station switch panel
and has three positions: OFF, AUTO, and SERVICE.

When the ride control system is activated (AUTO), the head end of the lift cylinders
are connected to the ride control accumulator and the rod end of the lift cylinders
are connected to the tank.

The ride control accumulator provides a cushioning effect to the lift cylinder head
end oil, allowing the lift cylinders to extend and retract slightly. The bucket can
move as a balance weight against the movement of the machine.

The SERVICE position is used for troubleshooting the ride control system.

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SERV2052 - 03/15 -30- Module 5 - Implement System

Tilt Cylinder (20) Ride Control Ride Control

Accumulator Solenoid
Auxiliary Main Control (21) Valve (22)
Cylinders (17) Valve (19)
Auxiliary Lift
Tilt Control Cylinders (23)
Control Valve (16)
Valve Spool (18)

Lift Circuit
Aux Circuit
Tilt Circuit Lift Control Relief Valve (12)
Relief Valves
Relief Valve Valve
(15)
(14) Spool (13)

Ride Control
Solenoid
Main Relief Valve (11)
Lift Arm
Valve (10)
Positioner
Valve (8)

Pilot Diverter Float R1600H IMPLEMENT

Sequence
Solenoid Valves
(9) Valve (7) HYDRAULIC SYSTEM
RIDE CONTROL SYSTEM ACTIVATED

Remote Control Lower Lift Dump Tilt Back

Steering and Pilot
Bucket Control Control
Valve (27) Valve (5) Implement and Parking Brake
Steering Solenoid Control Valve
Valve (26) (25)
STIC Steering
Pilot Valve
Pilot Oil Pressure
(28)
Reducing Valve (6)

Steering Brake
System Steering
Accumulator
(29) System
Charging Valve
(24)

Selector and Pilot and

Pressure Control Braking
Valve (4) Pump (3)
Steering Implement
Pump (2) Pump (1)
30_1
30
IMPLEMENT HYDRAULIC SYSTEM - RIDE CONTROL SYSTEM ACTIVATED

• Explain the operation of the The ride control solenoid valves (11) and (22) are normally closed valves. When the
implement hydraulic system with lift control valve spool (13) in the main control valve (19) is in the HOLD position
the RIDE CONTROL SYSTEM and the ride control switch is in the OFF position, the coils in the ride control
ACTIVATED. solenoid valves are not energized and the solenoid valves are in the closed
position. With the solenoid valve spools in the closed position, the ride control
system will not operate.

When the ride control switch is in the OFF position, the check valve between the lift
cylinders (23) and the ride control accumulator (21) allows a continual sensing of
the lift cylinder pressure. When a load is in the bucket, oil pressure increases in the
head end of the lift cylinders. The increased oil pressure opens the check valve and
compresses the nitrogen in the ride control accumulator, which prevents the bucket
from moving when the ride control system is activated.

When the ride control switch is moved to the AUTO position, the ride control system
will automatically activate when the machine ground speed exceeds approximately
5 km/h (3 mph). The ride control indicator will illuminate when the ride control
system is activated.

When the lift control valve spool is in the HOLD position, the ride control switch is
moved to the AUTO position, and the ground speed of the machine exceeds
5 km/h (3 mph), the coils in the ride control solenoid valves are energized. When
the solenoid valve coils are energized, the solenoid valve spools move against
spring force to the OPEN position.
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SERV2052 - 03/15 -31- Module 5 - Implement System

The lift cylinder head end oil is now open to the ride control accumulator and the lift
cylinder rod end oil is open to the hydraulic tank.

As the machine moves across rough terrain with a loaded bucket, the forces of the
load act against the lift cylinders, and the oil in the head end of the lift cylinders.
The oil in the head end of the lift cylinders is felt at the ride control accumulator.

The ride control accumulator has a nitrogen pre-charge that resists the head end oil
pressure and acts as a shock absorber.

• SERVICE position The SERVICE position is used for testing and troubleshooting the ride control
system. When the ride control switch is moved to the SERVICE position, the ride
control system will be activated. The ride control switch will return to the OFF
position when released. The ride control indicator will illuminate when the ride
control system is activated.

In the SERVICE position, the ride control system operates the same as the AUTO
position except that the system is activated regardless of ground speed.

NOTE: Callouts not listed in the text are shown for reference purposes only.

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SERV2052 - 03/15 -32- Module 5 - Implement System

PURPOSE

This module was designed to ensure participants can

locate and identify the function of all implement system
components and test and adjust the implement system.

32
Purpose review

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SERV2052 - 03/15 -33- Module 5 - Implement System

REASON

This training was necessary for participants to identify

implement system components and test and adjust
the implement system in order to be able to efficiently
diagnose and repair the implement system. This will
ensure customers will experience quick and accurate
resolution of implement system issues.

33
Reason review

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SERV2052 - 03/15 -34- Module 5 - Implement System

COMPETENCY Statement

Participants are now able to locate and identify the

implement system components and test and adjust the
implement system during lab exercises. Participants
are also able to identify the function of the implement
system components during a post-assessment.

34
Competency Statement review

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SERV2052 - 03/15 -35- Module 5 - Implement System

LEARNING OUTCOMES

You have met the following learning outcomes during

this R1600H Underground Loader Implement System
module:
• Located and identified the implement system
components.
• Tested and adjusted the implement system.
• Identified the function of the implement system
components.

35
Learning Outcomes Review

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SERV2052 - 03/15 -36- Module 5 - Implement System

Module Conclusion

This concludes the Implement System module for the

R1600H Underground Loader course.

36
Module Conclusion

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