UNIT 1

928G Wheel Loader

Machine Hydraulic Systems--
928G Wheel Loader

Unit Objectives:
Upon completion of this unit, the student will be able to:
1. Identify components in the 928G Wheel Loader pilot operated
implement hydraulic system and the LSPC with hand metering
unit steering system.
2. State the function of each component in the 928G Wheel Loader
pilot operated implement hydraulic system and the LSPC with
hand metering unit steering system.
3. Trace the oil flow in both the 928G Wheel Loader pilot operated
implement hydraulic system and the LSPC with hand metering
unit steering system.
4. Using the procedures in the Service Manual, test and adjust the
928G Wheel Loader implement hydraulic system and the LSPC
with hand metering unit steering system.
Unit 1 Machine Hydraulic Systems

Introduction
This unit will discuss the pilot operated hydraulic system and the load
sensing pressure compensated (LSPC) with hand metering unit
steering system on the 928G Wheel Loader.
On the manual operated construction equipment, the operator's lever
is attached through linkage or cable to the implement control. The
work required to move the implement control is performed by the
operator.
On the pilot operated equipment, the operator's lever is attached to a
pilot control valve that sends pilot oil to move the implement control.
The work required to move the implement control is performed by
the pilot oil. The pilot operated system gives the operator better
control with less effort which results in less operator fatigue, more
production and better safety.
The conventional steering system uses a variable (LSPC) pump and
shares the oil with the implement pilot system. The LSPC pump is
also used in the design of other implement hydraulic and steering
systems. However, the pump operation is basically the same.
Therefore, many of the concepts used in the LSPC steering system
may be transferred to any LSPC system.
The LSPC system differs from the fixed displacement pump system
in that the pump output is controlled primarily by the demand of the
system and not by the speed of the engine.
 Lesson 1: Implement Hydraulic System
Lesson 1: Implement Hydraulic System
(Pilot Operated System)

928G Wheel Loader

• Implement Hydraulic System
(Pilot Operated System)
• Steering System
(LSPC with Hand Metering Unit)

Introduction
The 928G Wheel Loader pilot operated implement hydraulic system
is simular to the implement hydraulic system used on other
Caterpillar machines. The information learned in this lesson will
allow students to understand the pilot operated hydraulic system used
on many Caterpillar machines.

Objectives
Upon completion of this lesson, the student will be able to:
1. Identify components of the 928G Wheel Loader pilot operated
implement hydraulic system.
2. State the function of the 928G Wheel Loader pilot operated
implement hydraulic system.
3. Trace the oil flow through the 928G Wheel Loader pilot
operated implement hydraulic system schematic in all
positions (hold, tiltback, lower, etc...).
4. Perform the testing and adjusting procedures as stated in the
928G Wheel Loader Service Manual Module
(Form No. SENR1226)
Unit 1 1-1-4 Machine Hydraulic Systems
Lesson 1

TO IMPLEMENT HYDRAULIC SYSTEM

STEERING
SYSTEM
ACCUMULATOR
PILOT AND CHECK
STEERING VALVES PILOT
PUMP LOCKOUT
VALVE

PRESSURE
REDUCING PILOT
VALVE CONTROL TILT
VALVES CYLINDER

SYSTEM RELIEF
VALVE

MAIN
PUMP

LIFT
CYLINDER

FILTER IMPLEMENT
CONTROL
VALVE

TANK

Fig. 1.1.1

IMPLEMENT HYDRAULIC SYSTEM

Figure 1.1.1 shows a simplified schematic of the implement hydraulic

system. The implement hydraulic system consists of a pilot system
and a main implement system.
The pilot system controls the functions of the main control valve.
Pilot system components are:
Pilot and steering pump: The pilot and steering pump supplies oil
to the implement pilot system and to the steering system when the
engine is ON.

Pressure reducing valve: The pressure reducing valve controls

maximum pilot system pressure.

Check valves: Prevent oil in the pilot and steering circuits from
flowing back to the pump when the pump is not pumping.

Accumulator: Maintains a constant pressure in the pilot system

when the engine in running. Also when the engine is not running, the
accumulator provides pressurized oil in the pilot system to lower the
bucket.

Pilot lockout valve: The pilot lockout valve shuts off pilot oil to the
pilot control valve.

Pilot control valve: The pilot control valve controls pilot oil flow to
the implement control valve.
Unit 1 1-1-5 Machine Hydraulic Systems
Lesson 1

The main implement hydraulic system components are:

Main system pump: The main system pump supplies oil to the lift
and tilt cylinders.

System relief valve: The main relief valve limits the maximum
pressure at the main system pump.

Implement control valve: The main control valve controls oil flow
to the implement cylinders.

Tilt cylinder: The tilt cylinder moves the bucket to the DUMP and
TILT positions.

Lift cylinders: The lift cylinders raise and lower the lift arms.

The hydraulic tank stores hydraulic oil for both the pilot and
implement systems.

INSTRUCTOR NOTE: At this time, take the students to the

928G Wheel Loader and point out the components of the
Implement Hydraulic System. The students will locate the
component on the928G Wheel Loader IT28G Integrated
Toolcarrier Hydraulic System Schematic (Form No. SENR1227).
Unit 1 1-1-6 Machine Hydraulic Systems
Lesson 1

2 4

Fig. 1.1.2

Hydraulic Tank

The hydraulic tank (1) is located behind the cab below the hood
access cover. The hydraulic tank supplies oil to the implement, the
steering, the brake and the fan drive systems.

Also shown are the hydraulic tank oil fill cap (2), the hydraulic tank
breather (3) and the radiator fill cap (4).
Unit 1 1-1-7 Machine Hydraulic Systems
Lesson 1

2 3
1

Fig. 1.1.3

Implement Pump

The implement pump (1) is located on the right side of the machine
above the transmission.

Oil flows from the tank to the implement pump. The implement
pump sends oil flow to the control valve on the front frame.

Also shown are the steering pump (2) and the steering pump control
valve (3).
Unit 1 1-1-8 Machine Hydraulic Systems
Lesson 1

3
5

Fig. 1.1.4

The pilot lockout valve lever (not visible, below 1) is located between
the operator's seat and the pilot control valves. When the pilot
lockout valve lever is in the LOCK position, the pilot oil is blocked to
the pilot control valves.
The tilt control lever (2) operates the tilt pilot valve. The tilt pilot
valve sends pilot oil to the tiltback and dump spool in the main
control valve. The lift control lever (3) operates the lift pilot valve.
The lift pilot valve sends pilot oil to the lift, lower and float spool in
the main control valve.

Also shown are the third function control lever (4), and the third
function lever lock (5).
Unit 1 1-1-9 Machine Hydraulic Systems
Lesson 1

PIVOT PLATE

UPPER PLUNGER UPPER PLUNGER

(Dump) (Tilt Back)

COIL ASSEMBLY
(Bucket Tilt Back kickout)

UPPER CENTERING
RETAINER SPRING

LOWER PLUNGER RETAINER

LOWER CENTERING
METERING SPRING SPRING

RETAINER
TO METERING STEM
TANK SPRING
METERING STEM
(Dump) METERING STEM
(Tilt Back)

PILOT OIL

TO MAIN CONTROL VALVE

Fig. 1.1.5

Tilt/Dump Pilot Control Valve

Figure 1.1.5 shows the major components in the tilt/dump pilot
control valve. Except for the coil assembly at the top of the dump
section (left side), the parts are the same for both sides of the valve.
With the engine running and the control lever in the HOLD position,
pilot oil enters the supply port (bottom center of valve body) and is
blocked by the metering stems. Any oil in the lines to the main
control valve is vented to the tank port through the center of the
metering stems.
Unit 1 1-1-10 Machine Hydraulic Systems
Lesson 1

DUMP TILT BACK

TO
TANK ORIFICE

MERERING
STEM

PILOT OIL

FROM MAIN TO MAIN

CONTROL VALVE CONTROL VALVE

Fig. 1.1.6
TILT BACK Position
When the operator moves the pilot control lever to the TILT BACK
position (Figure 1.1.6), the force causes the pivot plate to move the
upper plunger, the lower plunger, the metering spring, the metering
stem spring retainer, the metering stem spring and the metering stem
down. Oil from the pilot pump flows through the orifice and the
center of the metering stem to the main control valve. Return oil
from the main control valve flows through the dump metering stem
port, the center of the metering stem and to the tank port.
Unit 1 1-1-11 Machine Hydraulic Systems
Lesson 1

LOWER CENTERING
SPRING

METERING
SPRING
METERING STEM
SPRING

TO TO ORIFICE
TANK TANK

METERING STEM

FROM FROM
PUMP PUMP

FROM MAIN TO MAIN

CONTROL VALVE CONTROL VALVE

Fig. 1.1.7

Metering Stem
The job of the metering stem (Figure 1.1.7) is to allow movement of
the main valve spool relative to the movement of the pilot valve
lever. The metering stem and metering spring function as a pressure
reducing valve and control the oil pressure at the main control valve
spool.
When the tiltback metering stem moves down, pilot oil flows through
the orifice, the center of the metering stem and out to the main
control valve spool. The pilot oil is blocked at the main control valve
spool causing the pilot pressure to increase. The pressure increase is
also sensed against the metering stem (red arrows). When the
pressure increase overcomes the applied force, the metering stem
moves up and compresses the metering spring. The movement
restricts pilot oil flow through the metering stem orifice. Restricting
the oil flow controls the pressure at the main control valve spool.
The metering spring therefore adjusts the pressure at the main control
valve spool in proportion to the movement of the pilot valve lever.
The pressure moves the main control valve spool. The main control
valve spool directs the main system oil to the cylinder.
Unit 1 1-1-12 Machine Hydraulic Systems
Lesson 1

2
1
3

4
5

Fig. 1.1.8

The implement control valve (1) is located between the lift arms on
the front frame. Included in the implement control valve housing are:
the lift control valve (2), tilt control valve (3), main relief valve (4),
and the tilt cylinder rod end line relief valve (6).
Also shown are oil supply line (5),and return line (7).
The above control valve is from the 938G Wheel Loader. The valve
operation is the same as the 928G Wheel Loader.
Unit 1 1-1-13 Machine Hydraulic Systems
Lesson 1

TILT BACK DUMP

INLET MAIN CONTROL
PILOT
PASSAGE SPOOL

LINE RELIEF
AND MAKEUP
OUTLET
VALVE TO CHECK TO
TANK VALVE TANK

Fig. 1.1.9

Control Valve in HOLD Position

Figure 1.1.9 shows the 928G tilt back/dump control valve in the
HOLD position. The function of the valve shown is representative of
the tilt valve, lift valve, auxiliary valve or the fourth function valve.
The line valves (line relief, makeup, etc...) may change depending on
the particular control valve.
When in the HOLD position, pump supply oil enters the center
passage, flows around the control spool, and through the outlet
passages to the next valve. Supply oil also flows through the internal
passage to the check valve. Oil flows past the check valve to the the
main control spool. The main control spool blocks supply oil flow to
the work ports (tilt and dump passages). The main control spool also
blocks the work port oil passages from the tank oil passages.
Unit 1 1-1-14 Machine Hydraulic Systems
Lesson 1

HEAD ROD
END END

PILOT INLET
PASSAGE

CHECK OUTLET
TO VALVE TO
TANK TANK

Fig. 1.1.10

TILT BACK Position

When the operator moves the pilot control lever to the TILT BACK
position (Figure 1.1.10), pilot oil (orange) moves the main control
spool to the right. The control spool blocks the oil outlet passages,
opens the passage from the check valve to the tilt cylinder head end
and opens the passage from the tilt cylinder rod end to the tank
return. When the supply pressure is higher than the pressure in the
head end of the tilt cylinder, the supply oil opens the check valve and
flows past the control spool to the head end of the tilt cylinder. The
return oil flows from the rod end of the tilt cylinder, past the control
spool and to the tank. The bucket begins tilting back.
Unit 1 1-1-15 Machine Hydraulic Systems
Lesson 1

PILOT VALVE MAIN VALVE

ADJUSTMENT SPRING SPRING MAIN VALVE

ORIFICE

MAKEUP PILOT MAIN VALVE

VALVE VALVE SPRING CHAMBER

Fig. 1.1.11

Combination Line Relief and Makeup Valve

Figure 1.1.11 shows the combination line relief and makeup valve.
The line relief valve is simply a pilot operated relief valve. However,
the line relief valve is not designed to handle maximum implement
pump flow.
The oil in the cylinder is connected through lines to the right end of
the combination valve. The oil flows through the main valve orifice
to the main valve spring chamber. The oil pressure in the spring
chamber is the same as the oil pressure at the front (right) of the
valve. The oil pressure plus the force of the spring keeps the relief
valve closed.
Unit 1 1-1-16 Machine Hydraulic Systems
Lesson 1

MAKEUP MAKEUP VALVE

VALVE DUMP

PILOT VALVE MAIN VALVE MAKEUP VALVE

ORIFICE ORIFICE DUMP

Fig. 1.1.12

Line Relief in RELIEF Position

In Figure 1.1.12, the line relief is shown in the RELIEF position.
When the oil pressure overcomes the setting of the pilot valve, the
pilot valve moves to the left against the spring. The high pressure oil
in the spring chamber flows through the pilot valve to the pilot spring
chamber drain passage. The pressure in the main valve spring
chamber decreases. The higher pressure oil at the right side of the
main valve moves the main valve to the left. The high pressure oil
flows past the main valve, through the makeup valve dump openings
to the tank.
The makeup valve does not move when the line relief valve opens.
Unit 1 1-1-17 Machine Hydraulic Systems
Lesson 1

RELIEF VALVE
SPRING CHAMBER EFFECTIVE
AREA

MAIN VALVE EFFECTIVE

SPRING AREA

Fig. 1.1.13

Makeup Valve
Figure 1.1.13 shows the combination line relief and makeup valve in
the MAKEUP position. The tank pressure is sensed on the effective
area of the combination valve at all times.
When the oil pressure in the cylinder, the connecting line and the
relief valve spring chamber decreases to 13.78 kPa (2 psi) less than
the oil pressure in the tank, the tank pressure moves the makeup
valve and the main valve to the left against the main valve spring.
The tank oil flows through the newly opened passage to the
connecting line and cylinder.
Unit 1 1-1-18 Machine Hydraulic Systems
Lesson 1

HEAD ROD
END END
INLET
PILOT
PASSAGE

OUTLET MAKEUP
TO CHECK TO VALVE
TANK VALVE TANK

Fig. 1.1.14

Lift Control Valve in LOWER Position

Figure 1.1.14 shows the lift control valve in the LOWER position.
When the operator moves the lift/lower pilot control lever to the
LOWER position, pilot oil (orange) moves the main control spool to
the left. The control spool blocks the oil outlet passages, opens the
passage from the check valve to the lift cylinder rod end and opens
the passage from the lift cylinder head end to the tank return. When
the supply pressure is higher than the pressure in the rod end of the
tilt cylinder, the supply oil opens the check valve and flows past the
control spool to the rod end of the lift cylinder. The return oil flows
from the head end of the lift cylinder, past the control spool and to
the tank. The bucket begins to lower.
Unit 1 1-1-19 Machine Hydraulic Systems
Lesson 1

HEAD ROD
END END
INLET
PILOT
PASSAGE

OUTLET MAKEUP
TO CHECK TO VALVE
TANK VALVE TANK

Fig. 1.1.15

Lift Control Valve in FLOAT Position

Figure 1.1.15 shows the lift control valve in the FLOAT position.
When the operator moves the lift/lower pilot control lever to the
FLOAT position, pilot oil (orange) moves the main control spool
completely to the left. The control spool opens the passage from the
check valve to the left side outlet and opens the passage from the lift
cylinder head end to the tank return. The control spool also connects
the lift cylinder rod end to the tank return. When the pump and both
ends of the lift cylinder are connected to the tank, the lift cylinder
cannot be hydraulically raised of lowered.
When the machine is moved and the lift/lower control is in the
FLOAT position, the implement follows the curvature of the ground.
At this time, perform Lab 1.1.1.
Unit 1 1-1-20 Machine Hydraulic Systems
Lesson 1

LOWERING
VALVE

AUXILIARY TILT LIFT

CYLINDERS CYLINDER CYLINDERS

ACCUMULATOR

PRESSURE
REDUCING
VALVE
TO
STEERING
MAIN
RELIEF
VALVE

FROM
STEERING
MANIFOLD

AUX. TILT/DUMP LIFT/LOWER

VALVE VALVE VALVE

PUMPS

PILOT SHUTOFF
VALVE

AUX. TILT/DUMP LIFT/LOWER

PILOT VALVE PILOT VALVE PILOT VALVE

TANK

Fig. 1.1.16

Implement Hydraulic Schematic

Figure 1.1.16 shows the implement hydraulic system with the engine
running and all control levers in the HOLD position. The pilot
system is a closed center system and the main system is an open
center system.
The steering and pilot pump draws oil from the tank and sends supply
oil to the steering system and to the pilot system pressure reducing
valve. The pressure reducing valve maintains a constant pressure in
the pilot system. Oil from the pressure reducing valve flows through
the check valve to the accumulator and the pilot lockout valve.
When the pilot lockout valve lever is in the LOCK position, the pilot
oil is blocked to the pilot control valves. When the pilot lockout
valve lever is in the UN-LOCK position, oil flows to the pilot control
valves. When the pilot control valves are in the HOLD position, pilot
oil is blocked to the main control valve.
The main implement pump draws oil from the tank and sends supply
oil past the main relief valve to the auxiliary, tilt/dump and lift/lower
control valve spools inside the main implement control valve body.
In the HOLD position, oil flows through the center of the auxiliary,
tilt and lift control valve spools and returns to the tank.
Unit 1 1-1-21 Machine Hydraulic Systems
Lesson 1

LOWERING
VALVE

LIFT
AUXILIARY TILT CYLINDERS
CYLINDERS CYLINDER

ACCUMULATOR

PRESSURE
REDUCING
VALVE
TO
STEERING
MAIN
RELIEF
VALVE

FROM
STEERING
MANIFOLD

AUX. TILT/DUMP LIFT/LOWER

VALVE VALVE VALVE

PUMPS

PILOT SHUTOFF
VALVE

AUX. TILT/DUMP LIFT/LOWER

PILOT VALVE PILOT VALVE PILOT VALVE

TANK

Fig. 1.1.17

Figure 1.1.17 shows the flow through the hydraulic system with the
tilt/dump pilot valve control lever in the TILT BACK position.
When the tilt/dump pilot valve control lever is moved to the TILT
BACK position, pilot oil is sent to the end of the tilt/dump control
spool in the main implement control valve. Pilot oil moves the
tilt/dump control spool to the TILT BACK position. Oil from the
opposite end of the tilt/dump control spool flows through the
tilt/dump pilot valve to the tank.
Movement of the tilt/dump control spool to the TILT BACK position
blocks the flow of implement pump (supply) oil to the tank and
directs supply oil to the head end of the tilt cylinder. Oil in the rod
end of the tilt cylinder is forced back past the tilt/dump control spool
to the tank.
Unit 1 1-1-22 Machine Hydraulic Systems
Lesson 1

LOWERING
VALVE

LIFT
AUXILIARY TILT CYLINDERS
CYLINDERS CYLINDER

ACCUMULATOR

PRESSURE
REDUCING
VALVE
TO
STEERING
MAIN
RELIEF
VALVE

FROM
STEERING
MANIFOLD

AUX. TILT/DUMP LIFT/LOWER

VALVE VALVE VALVE

PUMPS

PILOT SHUTOFF
VALVE

AUX. TILT/DUMP LIFT/LOWER

PILOT VALVE PILOT VALVE PILOT VALVE

TANK

Fig. 1.1.18

Figure 1.1.18 shows the flow through the hydraulic system with the
lift/lower pilot valve control lever in the LOWER position.
When the lift/lower pilot control lever is moved to the LOWER
position, pilot oil is sent to the lift/lower control spool. Pilot oil
moves the lift/lower control spool to the LOWER position. Oil from
the opposite end of the lift/lower control spool flows back through the
lift/lower pilot control valve to the tank.
Movement of the lift/lower control spool to the LOWER position
blocks the flow of supply oil to the tank. Supply oil is directed to the
rod end of the lift cylinders. Oil in the head end of the cylinders is
forced past the lift/lower control spool to the tank.
Unit 1 1-1-23 Machine Hydraulic Systems
Lesson 1

LOWERING
VALVE

LIFT
AUXILIARY TILT CYLINDERS
CYLINDERS CYLINDER

ACCUMULATOR

PRESSURE
REDUCING
VALVE
TO
STEERING
MAIN
RELIEF
VALVE

FROM
STEERING
MANIFOLD

AUX. TILT/DUMP LIFT/LOWER

VALVE VALVE VALVE

PUMPS

PILOT SHUTOFF
VALVE

AUX. TILT/DUMP LIFT/LOWER

PILOT VALVE PILOT VALVE PILOT VALVE

TANK

Fig. 1.1.19

In Figure 1.1.19, the lift/lower pilot valve control lever has been
moved to the FLOAT position.
When the lift/lower pilot valve control lever is moved to the FLOAT
position, the control valve is held in place by an electromagnet in the
float position coil assembly. Pilot oil is sent to the lift/lower control
spool .Pilot oil moves the lift/lower control spool to the FLOAT
position. Oil from the opposite end of the lift/lower control spool
flows back through the lift/lower pilot valve to the tank.
In the FLOAT position, supply oil is directed to the rod end of the lift
cylinders and to the tank. Both ends of the lift cylinders are open to
the tank allowing the bucket to float along the ground (follow the
contour of the ground).
Unit 1 1-1-24 Machine Hydraulic Systems
Lesson 1

LOWERING
VALVE

LIFT
AUXILIARY TILT CYLINDERS
CYLINDERS CYLINDER
ORIFICE

ACCUMULATOR

PRESSURE
REDUCING
VALVE
LIFT CYLINDER
TO MAKE-UP VALVE
TEERING
MAIN
RELIEF
VALVE

FROM
STEERING
MANIFOLD

AUX. TILT/DUMP LIFT/LOWER

VALVE VALVE VALVE

PUMPS

PILOT SHUTOFF
VALVE

AUX. TILT/DUMP LIFT/LOWER

PILOT VALVE PILOT VALVE PILOT VALVE

TANK

Fig. 1.1.20

In Figure 1.1.20 the bucket is being LOWERED with the ENGINE

OFF.
When the bucket is in the RAISED position and the engine is OFF,
the weight of the bucket acts on the lift cylinder pistons and
pressurizes the oil in the head end of the lift cylinders. When the
lowering valve is moved to the OPEN position, a passage is open for
the pressurized oil to flow from the head end of the lift cylinders.
The weight of the bucket moves the pistons and displaces the
pressurized oil. The movement of the pistons causes a vacuum in the
rod end of the lift cylinders. Most of the head end oil is forced
through the orifice, the lowering valve and the lift cylinder rod end
makeup valve into the rod end of the lift cylinders. The excessive oil
flows to the tank. The oil flow through the rod end makeup valve
prevents cavitation in the lift cylinders.
At this time, perform Lab 1.1.2 and Lab 1.1.3.
Unit 1 -1- Machine Hydraulic Systems
Instructor Copy Lab 1.1.1

Instructor Copy: Lab 1.1.1

Lab 1.1.1: Implement Hydraulic System Component Identification
Shop Lab Exercise
Instructor attaches tags containing letters or numbers to the Implement Hydraulic System components.
Students identify the Implement Hydraulic System components by matching the lettered or numbered
tags on the components with the names on the worksheets. After locating the components on the
machine, the students locate and record the appropriate schematic item number (from the schematic)
for each component.
NOTE: Tags containing letters or numbers should be attached to the Implement Hydraulic
System components in advance. Record the tag information in the space provided on the
instructor's copy of the "Lab A: Implement Hydraulic System Components Worksheets."

Procedure:
Explain the process for filling out the worksheets
Inform the students that they may refer to the Service Manual or class notes during the lab exercise.
After the Lab, discuss the completed lab worksheets with class.
Materials Needed
Lab 1.1.1 Worksheets
Pen or pencil
Service Manual module "928G Wheel Loader, IT28G Integrated Toolcarrier Hydraulic System
Operation, Testing & Adjusting" (Form SENR1226)
Service Manual module "928G Wheel Loader, IT28G Integrated Toolcarrier Hydraulic System
Schematic" (Form SENR1227)
928G Wheel Loader or IT28G Integrated Toolcarrier
Mechanic's tool box with hand tools
Unit 1 -2- Machine Hydraulic Systems
Instructor Copy Lab 1.1.1

LAB 1.1.1: Implement Hydraulic System Component Identification

Worksheet 1
Directions: The Service Manual may be used when performing this lab. Write the letter or number
attached to the component in the space provided next to the correct name. Record the components
location, function and item number.
INSTRUCTOR'S NOTE: Item numbers are for the 928G Wheel Loader

Pressure Reducing Valve

Location: Attached to the inside of the right frame below the cab
Function: Controls pilot system oil pressure
Item Number 6

Pilot and Steering Pump

Location: Below the cab on the left side of the machine
Function: Supplies oil flow to the steering and pilot systems
Item Number 18

Main Control Valve

Location: Front end frame between the lift arms
Function: Controls the oil flow to the implement (attachment) cylinders
Item Number 16

Control Levers
Location: Console in front of the right armrest
Function: Operate the pilot control valves
Item Number 21 - 22
Unit 1 -3- Machine Hydraulic Systems
Instructor Copy Lab 1.1.1

Lab 1.1.1: Implement Hydraulic System Component Identification

Worksheet 1 (continued)

Main System Pump

Location: Below the cab on the left side of the machine
Function: Supplies oil flow to the implement cylinders
Item Number 18

Auxiliary Cylinders (if equipped)

Location: Front frame
Function: Move auxiliary implements
Item Number 8

Tilt Cylinder
Location: Front frame
Function: Dump and tilt back bucket
Item Number 9

Lift Cylinders

Location: Front frame

Function: Raise and lower bucket

Item Number 10

Main Relief Valve

Location: On the inlet section of the main control valve
Function: Limits the main system pump maximum pressure
Item Number 16
Unit 1 -1- Machine Hydraulic Systems
Student Copy Lab 1.1.1

Student Copy: Lab 1.1.1

LAB 1.1.1: Implement Hydraulic System Component Identification
Shop Lab Exercise
Procedure:
Students will identify the Implement Hydraulic System components by matching the lettered or
numbered tags on the components with the names on the worksheets.
After locating the components on the machine, the students will locate the component on the hydraulic
system schematic and record the appropriate schematic item number for each component.
Materials Needed
Lab 1.1.1 Worksheets
Pen or pencil
Service Manual module "928G Wheel Loader, IT28G Integrated Toolcarrier Hydraulic System
Operation, Testing & Adjusting" (Form SENR1226)
Service Manual module "928G Wheel Loader, IT28G Integrated Toolcarrier Hydraulic System
Schematic" (Form SENR1227)
928G Wheel Loader or IT28G Integrated Toolcarrier
Mechanic's tool box with hand tools
Unit 1 -2- Machine Hydraulic Systems
Student Copy Lab 1.1.1

LAB 1.1.1: Implement Hydraulic System Component Identification

Worksheet 1
Directions: The Service Manual may be used when performing this lab. Write the letter or number
attached to the component in the space provided next to the correct name. Record the components
location, function and item number.
INSTRUCTOR'S NOTE: Item numbers are for the 928G Wheel Loader

Pressure Reducing Valve

Location: _____________________________________________________________________
Function: ____________________________________________________________________
Item Number ___________________________

Pilot and Steering Pump

Location: ____________________________________________________________________
Function: ____________________________________________________________________
Item Number __________________

Main Control Valve

Location: ____________________________________________________________________
Function: ____________________________________________________________________
Item Number __________________

Control Levers
Location: ____________________________________________________________________
Function: ____________________________________________________________________
Item Number __________________
Unit 1 -3- Machine Hydraulic Systems
Student Copy Lab 1.1.1

LAB 1.1.1: Implement Hydraulic System Component Identification

Worksheet 1 (continued)

Main System Pump

Location: ________________________________________________________________
Function: ________________________________________________________________
Item Number ____________________

Auxiliary Cylinders (if equipped)

Location: ________________________________________________________________
Function: ________________________________________________________________
Item Number ____________________

Tilt Cylinder
Location: ________________________________________________________________
Function: ________________________________________________________________
Item Number ____________________

Lift Cylinders

Location: ________________________________________________________________

Function: ________________________________________________________________

Item Number ____________________

Main Relief Valve

Location: ________________________________________________________________
Function: ________________________________________________________________
Item Number ____________________
Unit 1 -1- Machine Hydraulic Systems
Instructor Copy Lab 1.1.2

Instructor Copy: Lab 1.1.2

Lab 1.1.2: Implement Hydraulic System Testing and Adjusting
Shop Lab Exercise

Following the procedures in the Service Manual module "928G Wheel Loaders IT28G Integrated
Toolcarrier Hydraulic System, Systems Operation Testing and Adjusting" (Form SENR1226), perform
the following tasks:

1. Visual Inspection
2. Check Lift and Tilt Cylinder Drift with Engine On
3. Check Lift and Tilt Cylinder Drift with Engine Off, Key Off
4. Check Lift and Tilt Cylinder Speed

After the Lab, discuss the completed lab worksheets with class.

To avoid possible personal injury, follow all warnings listed in the Service Manual module "928G
Wheel Loaders IT28G Integrated Toolcarrier Hydraulic System, Systems Operation Testing and
Adjusting" (Form SENR1226).

WARNING

Materials Needed
Lab 1.1.2 Worksheets
Pen or pencil
Service Manual module "928G Wheel Loader, IT28G Integrated Toolcarrier Hydraulic System
Operation, Testing & Adjusting" (Form SENR1226)
Service Manual module "928G Wheel Loader, IT28G Integrated Toolcarrier Hydraulic System
Schematic" (Form SENR1227)
928G Wheel Loader or IT28G Integrated Toolcarrier
6 in. ruler
Felt tip pen
Stop watch
Mechanic's tool box with hand tools
Unit 1 -2- Machine Hydraulic Systems
Instructor Copy Lab 1.1.2

Lab 1.1.2: Implement Hydraulic System Testing and Adjusting Worksheet 1

VISUAL INSPECTION

Check the oil level in the hydraulic tank sight gauge.

Oil Level
Comments:

Check for air in the hydraulic oil.

Comments:

Check oil lines for damage or leaks.

Comments:

Check for restrictions to flow.

Comments:

Remove and check filter elements.

Comments:

Inspect control linkage.

Comments:
Unit 1 -3- Machine Hydraulic Systems
Instructor Copy Lab 1.1.2

Lab 1.1.2: Implement Hydraulic System Testing and Adjusting Worksheet 2

Directions: Write the specifications from the service manual in the appropriate area of the worksheet
for each test. Perform the tests and record the actual machine readings on the worksheet.

Lift and Tilt Cylinder Drift Tests

LIFT CYLINDERS DRIFT

Maximum Drift Oil Temperature Time In Minute

Specifications
Actual

TILT CYLINDER DRIFT

Maximum Drift Oil Temperature Time In Minutes

Specifications
Actual

Lift and Tilt Cylinder Speed Tests

LIFT CIRCUIT SPEED TESTS

Function Distance Specifications
Ground level to maximum height
RAISE
Empty bucket
Maximum height to ground level
LOWER
Empty bucket
Maximum height to ground level
FLOAT Empty bucket
Unit 1 -4- Machine Hydraulic Systems
Instructor Copy Lab 1.1.2

Lab 1.1.2: Implement Hydraulic System Testing and Adjusting Worksheet 3

LIFT CIRCUIT RAISE

Oil Temp ____°F 1st Test 2nd Test 3rd Test Average
Cycle Time
Is the average cycle time within machine specification? ___Yes ___No
LIFT CIRCUIT LOWER

Oil Temp ____°F 1st Test 2nd Test 3rd Test Average
Cycle Time
Is the average cycle time within machine specification? ___Yes ___No
LIFT CIRCUIT FLOAT

Oil Temp ____°F 1st Test 2nd Test 3rd Test Average
Cycle Time
Is the average cycle time within machine specification? ___Yes ___No

SPEED TESTS FOR TILT CIRCUIT

Function Distance Specifications
Full Dump Position to Full Tilt
TILT BACK Back Position-Empty Bucket
Full Tilt Back Position to Full
DUMP
Dump Position-Empty Bucket

TILT CIRCUIT TILTBACK

Oil Temp ____°F 1st Test 2nd Test 3rd Test Average
Cycle Time
Is the average cycle time within machine specification? ___Yes ___No

TILT CIRCUIT DUMP

Oil Temp ____°F 1st Test 2nd Test 3rd Test Average
Cycle Time
Is the average cycle time within machine specification? ___Yes ___No
Unit 1 -1- Machine Hydraulic Systems
Student Copy Lab 1.1.2

Student Copy: Lab 1.1.2

Lab 1.1.2: Implement Hydraulic System Testing and Adjusting
Shop Lab Exercise
Following the procedures in the Service Manual module "928G Wheel Loaders IT28G Integrated
Toolcarrier Hydraulic System, Systems Operation Testing and Adjusting" (Form SENR1226), perform
the following tasks:
1. Visual Inspection
2. Check Lift and Tilt Cylinder Drift with Engine On
3. Check Lift and Tilt Cylinder Drift with Engine Off, Key Off
4. Check Lift and Tilt Cylinder Speed

After the Lab, discuss the completed lab worksheets with class.

To avoid possible personal injury, follow all warnings listed in the Service Manual module "928G
Wheel Loaders IT28G Integrated Toolcarrier Hydraulic System, Systems Operation Testing and
Adjusting" (Form SENR1226).

WARNING

Materials Needed
Lab 1.1.2 Worksheets
Pen or pencil
Service Manual module "928G Wheel Loader, IT28G Integrated Toolcarrier Hydraulic System
Operation, Testing & Adjusting" (Form SENR1226)
Service Manual module "928G Wheel Loader, IT28G Integrated Toolcarrier Hydraulic System
Schematic" (Form SENR1227)
928G Wheel Loader or IT28G Integrated Toolcarrier
6 in. ruler
Felt tip pen
Stop watch
Mechanic's tool box with hand tools
Unit 1 -2- Machine Hydraulic Systems
Student Copy Lab 1.1.2

Lab 1.1.2: Implement Hydraulic System Testing and Adjusting Worksheet 1

VISUAL INSPECTION

Check the oil level in the hydraulic tank sight gauge.

Oil Level
Comments:

Check for air in the hydraulic oil.

Comments:

Check oil lines for damage or leaks.

Comments:

Check for restrictions to flow.

Comments:

Remove and check filter elements.

Comments:

Inspect control linkage.

Comments:
Unit 1 -3- Machine Hydraulic Systems
Student Copy Lab 1.1.2

Lab 1.1.2: Implement Hydraulic System Testing and Adjusting Worksheet 2

Directions: Write the specifications from the service manual in the appropriate area of the worksheet
for each test. Perform the tests and record the actual machine readings on the worksheet.

Cylinder Drift Tests

Lift and Tilt Cylinder Drift Tests

LIFT CYLINDERS DRIFT

Maximum Drift Oil Temperature Time In Minute

Specifications
Actual

TILT CYLINDER DRIFT

Maximum Drift Oil Temperature Time In Minutes

Specifications
Actual

Lift and Tilt Cylinder Speed Tests

LIFT CIRCUIT SPEED TESTS

Function Distance Specifications
Ground level to maximum height
RAISE
Empty bucket
Maximum height to ground level
LOWER
Empty bucket
Maximum height to ground level
FLOAT Empty bucket
Unit 1 -4- Machine Hydraulic Systems
Student Copy Lab 1.1.2

Lab 1.1.2: Implement Hydraulic System Testing and Adjusting Worksheet 3

LIFT CIRCUIT RAISE

Oil Temp ____°F 1st Test 2nd Test 3rd Test Average
Cycle Time
Is the average cycle time within machine specification? ___Yes ___No
LIFT CIRCUIT LOWER

Oil Temp ____°F 1st Test 2nd Test 3rd Test Average
Cycle Time
Is the average cycle time within machine specification? ___Yes ___No
LIFT CIRCUIT FLOAT

Oil Temp ____°F 1st Test 2nd Test 3rd Test Average
Cycle Time
Is the average cycle time within machine specification? ___Yes ___No

SPEED TESTS FOR TILT CIRCUIT

Function Distance Specifications
Full Dump Position to Full Tilt
TILT BACK Back Position-Empty Bucket
Full Tilt Back Position to Full
DUMP
Dump Position-Empty Bucket

TILT CIRCUIT TILTBACK

Oil Temp ____°F 1st Test 2nd Test 3rd Test Average
Cycle Time
Is the average cycle time within machine specification? ___Yes ___No

TILT CIRCUIT DUMP

Oil Temp ____°F 1st Test 2nd Test 3rd Test Average
Cycle Time
Is the average cycle time within machine specification? ___Yes ___No
Unit 1 -1- Machine Hydraulic Systems
Instructor Copy Lab 1.1.3

Lab 1.1.3: Implement Hydraulic System Testing and

Adjusting
Shop Lab Exercise

Instructor Copy: Lab 1.13

Students will perform various testing and adjusting procedures on the
implement hydraulic system.

Procedure:

Explain the process for filling out the worksheets (distributed prior to the
slide presentation).

Inform the students that they may refer to the Service Manual or class
notes during the lab exercise.

Discuss the completed lab worksheets with the class.

Materials Needed

Lab 1.1.3 Worksheets

Pen or pencil

Service Manual module "928G Wheel Loader, IT28G Integrated

Toolcarrier Hydraulic System Operation, Testing & Adjusting" (Form
SENR1226)
1 - 8T-0857 Pressure Gauge

1 - 8T-0852 Pressure Gauge

1 - 6V-3014 Hose Assembly

1 - 6V-4143 Quick Disconnect Fitting

1 - 3S-6224 Hydraulic Pump Group

1 - 7S-5437 Nitrogen Charging Group

Mechanic's tool box with hand tools

Unit 1 -2- Machine Hydraulic Systems
Instructor Copy Lab 1.1.3

Lab 1.1.3: Implement Hydraulic System

Testing and Adjusting Worksheet 1
Following the procedure in Service Manual module "928G Wheel
Loader, IT28G Integrated Toolcarrier Hydraulic System Operation,
Testing & Adjusting" (Form SENR1226), perform the following tasks:
1. Test Pilot System Pressure (Pressure Reducing Valve)
2. Test and Adjust Main Relief Valve
3. Test Tilt Cylinder Rod End Relief Valve
4. Test Tilt Cylinder Head End Relief Valve
5. Pilot Oil Accumulator Recharging Procedure

WARNING

To avoid possible personal injury, follow all warnings listed in the

Service Manual module "950G/962G Wheel Loaders Electro-
Hydraulic System Testing and Adjusting" (Form RENR2146).
Unit 1 -3- Machine Hydraulic Systems
Instructor Copy Lab 1.1.3

Lab 1.1.3: Implement Hydraulic System Testing and Adjusting Worksheet 2

Directions: Locate and enter the specifications from the service manual in the spaces provided.
Perform the tests and compare the machine readings to the specifications.

IMPLEMENT HYDRAULIC SYSTEM PRESSURE TESTS

Pressure Reducing Valve Main Relief Valve
Specifications
Machine Pressure

TILT RELIEF VALVE PRESSURE TEST

Tilt Cylinder Head End Tilt Cylinder Rod End
Relief Valve Relief Valve
Specifications
Machine Pressure
Unit 1 -1- Machine Hydraulic Systems
Student Copy Lab 1.1.3

Lab 1.1.3: Implement Hydraulic System Testing and

Adjusting
Shop Lab Exercise

Student Copy: Lab 1.1.3

When testing and adjusting the steering system, use the Service Manual
module "928G Wheel Loader, IT28G Integrated Toolcarrier Hydraulic
System Operation, Testing & Adjusting" (Form SENR1226)

Procedure:

Following the procedure in Service Manual module "928G Wheel

Loader, IT28G Integrated Toolcarrier Hydraulic System Operation,
Testing & Adjusting" (Form SENR1226), perform the following tasks:
1. Test Pilot System Pressure (Pressure Reducing Valve)
2. Test and Adjust Main Relief Valve
3. Test Tilt Cylinder Rod End Relief Valve
4. Test Tilt Cylinder Head End Relief Valve
5. Pilot Oil Accumulator Recharging Procedure

WARNING

To avoid possible personal injury, follow all warnings listed in the

Service Manual module "950G/962G Wheel Loaders Electro-
Hydraulic System Testing and Adjusting" (Form RENR2146).
Unit 1 -2- Machine Hydraulic Systems
Student Copy Lab 1.1.3

Materials Needed

Lab 1.1.3 Worksheets

Pen or pencil

Service Manual module "928G Wheel Loader, IT28G Integrated

Toolcarrier Hydraulic System Operation, Testing & Adjusting" (Form
SENR1226)
1 - 8T-0857 Pressure Gauge

1 - 8T-0852 Pressure Gauge

1 - 6V-3014 Hose Assembly

1 - 6V-4143 Quick Disconnect Fitting

1 - 3S-6224 Hydraulic Pump Group

1 - 7S-5437 Nitrogen Charging Group

Mechanic's tool box with hand tools

Unit 1 -3- Machine Hydraulic Systems
Student Copy Lab 1.1.3

Lab 1.1.3: Implement Hydraulic System Testing and Adjusting Worksheet 2

Directions: Locate and enter the specifications from the service manual in the spaces provided.
Perform the tests and compare the machine readings to the specifications.

IMPLEMENT HYDRAULIC SYSTEM PRESSURE TESTS

Pressure Reducing Valve Main Relief Valve
Specifications
Machine Pressure

TILT RELIEF VALVE PRESSURE TEST

Tilt Cylinder Head End Tilt Cylinder Rod End
Relief Valve Relief Valve
Specifications
Machine Pressure
Unit 1 -1- Machine Hydraulic Systems
Instructor Copy Test 1.1.1

TEST 1.1.1

The following test is a paper test designed to measure the student's

knowledge of the 928G Wheel Loader Implement Hydraulic System.
The answers are provided on the following pages. The actual student
tests are provided in the Student Materials section.

The lab exercises measure the student's ability to satisfy the course
performance objectives.
Unit 1 -2- Machine Hydraulic Systems
Instructor Copy Test 1.1.1

928G Wheel Loader Implement Hydraulic System Test

Instructor Copy: Test 1.1.1

Classroom Test 1.1.1
Students may refer to their course materials and class notes when taking
the test.

Students may not consult with others during the posttest.

Trace the implement hydraulic system oil flow when the system is in the
TILTBACK, DUMP, RAISE, LOWER or FLOAT condition.

Implement hydraulic system color codes:

Red - System or high pressure

Red and White Stripes - Reduced pressure

Orange - Pilot oil pressure

Blue - Blocked oil

Green - Tank or return oil

Procedure:

Give the students a copy of the "928G Wheel Loader Implement

Hydraulic System Posttest" and a set of color pencils.

Explain the posttest.

Refer to the proper slide in the Slide/Text Reference to check the

posttest.

Materials Needed

928G Wheel Loaders Implement Hydraulic System Test 1.1.1

Set of color pencils

Unit 1 -1- Machine Hydraulic Systems
Student Copy Test 1.1.1

TEST 1.1.1

The following test is a paper test designed to measure your knowledge of

the 928G Wheel Loader Implement Hydraulic System.
Unit 1 -2- Machine Hydraulic Systems
Student Copy Test 1.1.1

928G Wheel Loader Implement Hydraulic System Test

Student Copy: Test 1.1.1

Classroom Test
Students may refer to their course materials and class notes when taking
the test.

Students may not consult with others during the posttest.

Implement hydraulic system color codes:

Red - System or high pressure

Red and White Stripes - Reduced pressure

Orange - Pilot oil pressure

Blue - Blocked oil

Green - Tank or return oil

Procedure:

Trace the implement hydraulic system oil flow when the system is in the
the condition asked for on the test.

Materials Needed

928G Wheel Loaders Implement Hydraulic System Test 1.1.1

Set of color pencils

 Unit 1

LOWERING
VALVE

AUXILIARY LIFT
TILT
CYLINDERS CYLINDERS
CYLINDER
Student Copy Test 1.1.1

TILT BACK POSITION

ACCUMULATOR

PRESSURE
REDUCING
VALVE
TO
STEERING
MAIN
RELIEF
VALVE

FROM
-3-

STEERING
MANIFOLD

AUX. TILT/DUMP LIFT/LOWER

VALVE VALVE VALVE

PUMPS

PILOT SHUTOFF
VALVE

AUX. TILT/DUMP LIFT/LOWER

PILOT VALVE PILOT VALVE PILOT VALVE
Machine Hydraulic Systems

TANK