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R1600H Load Haul Dump Hydraulic System (UENR1455)

" Systems Operation

General Information

General Information

Pilot Hydraulic System

Vane Pump (Implement, Steering, Pilot and Braking)

Gear Pump (Steering, Pilot, and Braking)

Gear Pump (Implement)

Pressure Reducing Valve (Pilot Oil)

Solenoid Valve (Implement and Steering)

Check Valve

Pilot Control Valve

Selector and Pressure Control Valve

Main Hydraulic System

Main Hydraulic System

Main Control Valve

Relief Valve (Main)

Relief Valve (Line)

Relief Valve (Lift Circuit)

Bucket Control

Ride Control System

Ride Control System

Lift Arm Positioner

# Testing and Adjusting

SMCS - 5050 i06852155

2019/07/16 Main Hydraulic System (UENR1455) $

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serialNumber=9SD&ieSystemControlNumber=i06852155&mediaNumber=UENR1455&infoType=-1&hideDocumentStructure=false

Illustration 1 g06141647
Schematic for the hydraulic system
(1) Main control valve
(2) Line relief valve for rod end of auxiliary cylinders
(3) Line relief valve for head end of auxiliary cylinders
(4) Auxiliary cylinders
(5) Line relief valve for rod end of tilt cylinder
(6) Line relief valve for head end of tilt cylinder
(7) Pressure tap for rod end of tilt cylinder
(8) Tilt cylinder
(9) Pressure tap for head end of tilt cylinder
(10) Lift circuit relief valve
(11) Ride control accumulator
(12) Ride control solenoid valve
(13) Lift cylinders
(14) Pressure tap for the main hydraulic system
(15) Ride control solenoid valve
(16) Line to the parking brake circuit
(17) Line to the parking brake circuit
(18) Main relief valve
(19) Pilot diverter solenoid valve
(20) Pilot diverter solenoid valve
(21) Line to the pilot circuit
(22) Pilot and braking pump
(23) Steering pump
(24) Lift arm positioner valve
(25) Float sequence valve
(26) Breaker relief valve
(27) Pilot control valve
(28) Check valve
(29) Line from the steering valve
(30) Implement pump
(31) Selector and pressure control valve
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 (32) Hydraulic oil temperature sensor
(33) Line to the braking system
(34) Hydraulic oil level sensor
(35) Hydraulic tank
(36) Hydraulic oil filters
(37) Check valve
(38) Pilot oil pressure reducing valve
(39) Check valve
(40) Implement and steering solenoid valve
(41) Parking brake control valve

Tilt Circuit
Line relief valves (5) and (6) protect tilt cylinder (8) from external shocks. When pressure in tilt cylinder exceeds the setting of either
line relief valve, the valves open to vent excess pressure to hydraulic tank (34).

TILT BACK Operation

With engine running and joystick control lever in HOLD position, pilot, and braking pump takes oil from hydraulic tank (35). The
oil is sent through check valve (37) to pilot oil pressure reducing valve (38) and the braking system. Pilot oil pressure reducing
valve (38) maintains a constant pressure in the pilot system. The pilot oil then flows through check valve (39) to selector and
pressure control valve (31), implement and steering solenoid valve (40), pilot control valve (27) and to the steering system. The
valve stems in pilot control valve (27) stop the flow of oil through the valve in the HOLD position. Excess oil flows from pilot oil
pressure reducing valve (38) and returns to hydraulic tank (35).

At the same time, the steering pump sends oil to the steering control valve of the steering system. Also, implement pump (30)
sends oil to main relief valve (18) which controls the maximum pressure in the implement oil system.

With both valve spools of main control valve (1) in HOLD positions, oil flows through main control valve (1), hydraulic oil filters (36)
and back to hydraulic tank (35). If oil filters get full of foreign material (debris), the filter bypass valve (in filter) opens, letting return
oil directly into the hydraulic tank.

When the joystick control lever is moved to the TILT BACK position, pilot control valve (27) tilt back stem moves to the TILT BACK
position. Pilot oil is now free to flow through pilot control valve (27) to the tilt back end of the tilt control valve spool. The tilt
control valve spool moves. Pilot oil at dump end of tilt control valve spool flows back to pilot control valve (27). The oil flows
through pilot valve dump stem to hydraulic tank (35).

The movement of the tilt control valve spool stops the flow of oil through main control valve (1). Implement pump pressure
increases and opens the load check valve. The oil from implement pump (30) now flows to the head end of tilt cylinder (8) and
causes the cylinder rod to extend. The tilt linkage causes the bucket to tilt back. The movement of the cylinder piston and rod
pushes the oil out of the rod end of the tilt cylinder. This oil flows into main control valve (1) and returns to hydraulic tank (35).

When released, the joystick control lever and the dump stem returns to the HOLD position causing the flow of pilot oil to be
stopped. The springs on the tilt control valve spool move the valve spool back to HOLD position. Pilot oil at tilt back end of tilt
control valve spool goes back to pilot control valve (27). The oil flows through tilt back stem returning to hydraulic tank (35).

The implement oil in tilt cylinder (8) is held by the tilt control valve spool and movement of the cylinder piston and rod stops. The
bucket will stay at that angle until the joystick control lever is moved again.

DUMP Operation
When the joystick control lever is moved to the DUMP position, pilot control valve (27) dump stem moves to the DUMP position.
Pilot oil is now free to flow through pilot control valve (27) to the dump end of the tilt control valve spool. The tilt control valve
spool moves. Pilot oil at tilt back end of tilt control valve spool flows back to tilt back stem of pilot control valve (27). The oil
returns to hydraulic tank (35).
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 The movement of the tilt control valve spool stops the flow of oil through main control valve (1). Implement pump pressure
increases and opens the load check valve. The oil from implement pump (30) now flows to the rod end of tilt cylinder (8) and
causes the cylinder rod to retract. The tilt linkage causes the bucket to dump.

The movement of the cylinder piston and rod pushes the oil out of the head end of the tilt cylinder. This oil flows into main control
valve (1) and returns to hydraulic tank (35).

When released, the joystick control lever and the dump stem returns to the HOLD position causing the flow of pilot oil to be
stopped. The springs on the tilt control valve spool move the valve spool back to the HOLD position. Pilot oil at dump end of tilt
control valve spool flows back to dump stem in pilot control valve (27) returning to hydraulic tank (35).

The implement oil in tilt cylinder (8) 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.

DUMP Operation with engine off

When the lift arms are raised and the engine is off, the bucket can be dumped. The pilot oil supply comes from the head end of
the lift cylinders. This oil flows through check valve (28) to selector and pressure control valve (31) which decreases the pressure of
the oil to pilot oil pressure. The oil flows to implement and steering solenoid valve (40) and then to pilot control valve (27). When
the joystick control lever is moved to DUMP position, oil flows to tilt control valve spool moving the spool to the DUMP position.
The head end of tilt cylinder (8) is now open to hydraulic tank (35). The make-up valve in main control valve (1) opens so that the
rod end of tilt cylinder (8) is also open to hydraulic tank (35). The weight of the bucket causes the bucket to dump.

Note: When the engine is off and the lift arms are raised, the bucket can also be lowered.

Lift Circuit
Lift circuit relief valve (10) protects lift cylinders (13) from external shocks when the lift control valve spool is in the HOLD position.
When pressure in lift cylinders (13) exceeds the setting of lift circuit relief valve (10), the relief valve opens. The relief valve permits
movement of lift cylinders and allows high-pressure oil to return to hydraulic tank (35), preventing damage to machine
components.

RAISE Operation
With engine running and the joystick control lever in HOLD position, pilot, and braking pump (22) takes oil from hydraulic tank
(35). The oil is sent through check valve (37) to pilot oil pressure reducing valve (38) and the braking system. Pilot oil pressure
reducing valve (38) maintains a constant pressure in the pilot system. The pilot oil then flows through check valve (39), to selector
and pressure control valve (31), implement and steering solenoid valve (40), pilot control valve (27) and to the steering system.
The valve stems in pilot control valve (27) stop the flow of oil through the valve in the HOLD position. Excess oil flows from pilot
oil pressure reducing valve (38) and returns hydraulic tank (35).

With both control valve spools of main control valve (1) in HOLD position, oil flows through main control valve, hydraulic oil filters
(36) and returns to hydraulic tank (35). If oil filters get full of foreign material (debris), the filter bypass valve (in filter) opens,
returning oil directly into hydraulic tank.

When the joystick control lever is moved to the RAISE position, the lift stem in pilot control valve (27) moves to the RAISE
position. Pilot oil is now free to flow through pilot control valve (27) to the lift end of the lift control valve spool. The lift control
valve spool moves. Pilot oil at lower end of lift control valve spool flows back to lower stem in pilot control valve (27), returning to
hydraulic tank (35).

The movement of the lift control valve spool stops the flow of oil through main control valve (1). The implement pump (30)
pressure increases and opens the load check valve in main control valve (1). The oil from implement pump (30) now flows to the
head end of lift cylinders (13) and causes the cylinder rods to extend. The lift arms cause the bucket to lift.

The movement of the cylinder pistons and rods pushes the oil out of the rod end of the lift cylinders. The oil flows into main
control valve (1) and returns to hydraulic tank (35).
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 When released, the joystick control lever and the dump stem returns to the HOLD position causing the flow of pilot oil to be
stopped. The lift control valve spool springs, move the valve spool to the HOLD position. The pilot oil at lift end of lift control
valve spool flows back through pilot control valve (27) and returns to hydraulic tank (35). The implement oil in lift cylinders (13) 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.

LOWER Operation
When the joystick control lever is moved to the LOWER position, pilot control valve (27) lower stem moves to the LOWER
position. Pilot oil is now free to flow through pilot control valve (27) to the lower end of the lift control valve spool. The lift control
valve spool to moves. Pilot oil at lift end of lift control valve spool flows back to pilot control valve (27) lift stem, returning to
hydraulic tank (35).

The movement of the lift control valve spool stops the flow of oil through main control valve (1). Implement pump (30) pressure
increases and opens the load check valve. The oil from implement pump (30) now flows to the rod end of lift cylinders (13) and
causes the cylinder rods to retract. The lift arms cause the bucket to lower. The movement of the cylinder pistons and rods pushes
the oil out of the head end of the lift cylinders. This oil flows into main control valve (1) and returns to hydraulic tank (35).

When released, the joystick control lever and the lower stem returns to the HOLD position. The flow of pilot oil through pilot
control valve (27) is stopped. The springs on the lift control valve spool move the valve spool back to the HOLD position. The
pilot oil at lower end of lift control valve spool flows back to pilot control valve (27) and returns to hydraulic tank (35). The
implement oil in lift cylinders (13) 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.

FLOAT Operation
When the joystick control lever is moved to the FLOAT position, pilot control valve (27) lower stem moves to the FLOAT position.
The flow of oil to the lift control valve spool is the same as in the LOWER position. The extra movement of the lower stem allows
greater pilot pump oil pressure into the line to the lift control valve spool. This pressure is also felt in float sequence valve (25).
The float sequence valve (25) spool moves. Oil in spring chamber of the make-up valve in main control valve (1), vents (drains) to
hydraulic tank (35). The make-up valve opens and lets implement oil flow directly to hydraulic tank (35). The head end and rod
end of lift cylinders (13) are also open to hydraulic tank (35). Outside forces on the bucket will control the movement of the
cylinder pistons and rods.

The joystick control lever returns to the HOLD position when released.

LOWER Operation with engine off

With the engine off, the bucket can be lowered . The pilot oil supply comes from the head end of the lift cylinders. This oil flows
through check valve (28) to selector and pressure control valve (31) which decreases the pressure of the oil to pilot oil pressure.
The oil flows to implement and steering solenoid valve (40) and then flows to pilot control valve (27). When the joystick control
lever is moved through the LOWER position and on to the FLOAT position, the lower stem moves to FLOAT position. Pilot oil
flows to the lift control valve spool and moves the spool to the (LOWER) position. The head end of lift cylinders (13) is now open
to hydraulic tank (35). The make-up valve in main control valve (1) opens so that the rod ends of lift cylinders (13) are also open to
hydraulic tank (35). The weight of the bucket and lift arms causes the bucket to lower to the ground.

Note: When the engine is off and the lift arms are raised, the bucket can also be dumped.

Auxiliary Circuit
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 Illustration 2 g02995876
Location of the switch to activate the auxiliary system
The flow of oil from implement pump (30) changes when the machine has an auxiliary control valve. Implement oil flows first to
the auxiliary control valve spool before flowing to tilt control valve spool and lift control valve spool.

Auxiliary line relief valves (2) and (3) protect auxiliary cylinders (4) from external shocks. When auxiliary cylinder pressures exceed
the setting of either auxiliary line relief valve, the relief valves open, venting excess pressure to hydraulic tank (35).

EJECT Operation
When the engine is running, press and hold the switch to activate the auxiliary system. Move pilot control valve (27) to the EJECT
position. Pilot oil flows through pilot diverter solenoid valves (19) and (20) to the eject end of the auxiliary control valve spool. The
auxiliary control valve spool moves.

The movement of the auxiliary control valve spool stops the flow of oil through the tilt control valve spool. Implement pump (30)
pressure increases and opens the check valve. The oil from implement pump (30) now flows to the head end of auxiliary cylinders
(4) and causes the cylinder rods to extend.

RETRACT Operation
When the engine is running, press and hold the switch to activate the auxiliary system. Move pilot control valve (27) to the
RETRACT position. Pilot oil flows through pilot diverter solenoid valves (19) and (20) to the retract end of the auxiliary control
valve spool. The auxiliary control valve spool moves.

The movement of the auxiliary control valve spool stops the flow of oil through the tilt control valve spool. Implement pump (30)
pressure increases and opens the check valve. The oil from implement pump (30) now flows to the rod end of auxiliary cylinders
(4) and causes the cylinder rods to retract.
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PIP-11078960
2021/03/30
01:23:06-03:00
i06852155
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