938G SERIES II WHEEL LOADER

IT38G SERIES II
I N T E G R AT E D T O O L C A R R I E R

© 2003 Caterpillar Inc.

 KEY NEW FEATURES
• ECPC Controlled Transmission
• Electronic On Demand Fan
• 3126B ATAAC Electronic Engine
• Integrated Brake System
• Variable Shift Control
• New Cab Features
• Low Effort Hydraulic Pilot Valve
• Remote Pressure Taps (Option)
 SIMILARITIES AND DIFFERENCES
FEATURES DIFFERENT SIMILAR SAME
Instrument Cluster X
Engine/Engine ECM X
Fuel Pump X
Cooling Fan X
ECPC Controlled Transmission X
Hydraulic Fan Pump X
Machine ECM X
Nomenclature X
Appearance X
Steering System X
Ride Control X
Quick Coupler X
Implement Hydraulic System X
Traction Control System X
 Hydraulic Schematic Color Palette
Black - Mechanical connection. Seal Red - High pressure oil

Dark Gray - Cutaway section Red/White Stripes - 1st pressure reduction

Light Gray - Surface color Red Crosshatch - 2nd reduction in pressure

White - Atmosphere OR Pink - 3rd reduction in pressure

Air (no pressure)

Purple - Pneumatic pressure Red/Pink Stripes - Secondary source oil pressure

Yellow - Moving or activated components Orange - Pilot, signal or Torque Converter oil

Cat Yellow - (restricted usage) Orange/White Stripes -

Identification of components Reduced pilot, signal or TC oil pressure
within a moving group
Orange Crosshatch - 2nd reduction in
Green - Tank, sump, or return oil pilot, signal or TC oil pressure.

Green/White Stripes - Scavenge oil Blue - Trapped oil

or hydraulic void

Brown - Lubricating oil

 ELECTRONIC AND HYDRAULIC POWER TRAIN CONTROL SYSTEMS
NEUTRAL
MACHINE
ECM
OPERATOR STATION INPUTS
DASH ENGINE
INSTRUMENT ECM
RIDE CONTROL CLUSTER
DOWNSHIFT SWITCH
SWITCH
ENGINE SPEED
SENSOR
CAN DATA LINK
F-N-R SWITCH
SHIFT LEVER

MAIN RELIEF VALVE TORQUE

PARKING BRAKE CONVERTER
NEUTRALIZER SWITCH
OVERRIDE SWITCH
T/C OUTLET TO
KEY START SWITCH RELIEF VALVE LUBRICATION
COOLER
MANUAL/AUTO/ECON BRAKE ACCUMULATOR
SWITCH PRESSURE SENSOR
FWD LOW 2ND SPEED
SOLENOID
VARIABLE SHIFT ECM OUTPUTS VALVE
CONTROL SWITCH T/C INLET
RELIEF
VALVE 2
4
TRANSMISSION INPUTS
FWD HIGH 3RD SPEED

FILTER
TORQUE CONVERTER OIL
TORQUE CONVERTER TEMPERATURE SENSOR .
OUTPUT SPEED SENSOR
1 5
PUMP
TRANSMISSION INTERMEDIATE
TRANSMISSION INTERMEDIATE SPEED SENSOR NO. 2 1ST SPEED
SPEED SENSOR NO. 1 REV

TRANSMISSION OUTPUT TANK

TRANSMISSION OUTPUT SPEED SENSOR NO. 2
SPEED SENSOR NO. 1
3 6
TRANSMISSION OIL
TEMPERATURE SENSOR
TRANSMISSION PROPORTIONAL SOLENOID VALVE
CLUTCH RELEASED
TEST PORT

SPOOL VALVE
BALL
ORIFICE SPOOL SPRING

SOLENOID PIN DRAIN FROM

ORIFICE PUMP

CLUTCH
TRANSMISSION PROPORTIONAL SOLENOID VALVE
MODULATION
TEST PORT

VALVE
BALL
SPOOL SPRING

SOLENOID PIN DRAIN FROM

ORIFICE PUMP

CLUTCH
TRANSMISSION PROPORTIONAL SOLENOID VALVE
MAXIMUM CLUTCH PRESSURE
TEST PORT

SPOOL VALVE
BALL
ORIFICE SPOOL SPRING

SOLENOID PIN DRAIN FROM

ORIFICE PUMP

CLUTCH
 938G SERIES II IMPLEMENT HYDRAULIC SYSTEM
HOLD RIDE
CONTROL

MAIN
RELIEF
VALVE

AUX TILT LIFT

VALVE VALVE
TO
SELECTOR
STEERING
REDUCING VALVE

FROM
STEERING

PILOT
HYDRAULIC VALVE
LOCKOUT
VALVE
 IT38G SERIES II IMPLEMENT HYDRAULIC SYSTEM
HOLD
RIDE
TO FOURTH TO AUX TO AUX
CONTROL
FUNCTION FUNCTION FUNCTION

MAIN
RELIEF
VALVE

AUX. COUPLER TILT LIFT

VALVE VALVE VALVE VALVE
TO REDUCING SELECTOR
STEERING VALVE

FROM
STEERING

PILOT
PILOT SHUTOFF VALVE
VALVE
 938G SERIES II RIDE CONTROL SYSTEM
RIDE CONTROL
ON
LIFT SOLENOID
CYLINDERS VALVES

DIVERTER
VALVE

TO LIFT
STEERING VALVE
SELECTOR
REDUCING VALVE

FROM
STEERING

PILOT SHUTOFF
VALVE PILOT
VALVE
 LEVER
PILOT VALVE
SHIFT DETENT PLUNGER

ADJUSTMENT PIN PLATE

RETAINER PLUNGER

DETENT COIL

SPOOL

ORIFICE
PILOT
SUPPLY

FROM TO TO
CONTROL VALVE TANK CONTROL VALVE
 CONTROL VALVE
HOLD

PORT A INLET PORT B MAIN CONTROL

PILOT SPOOL
PASSAGE

LINE RELIEF BRIDGE OUTLET

AND MAKEUP PASSAGE
VALVE SERIES FEEDER CHECK
PASSAGE VALVE
 CONTROL VALVE
SHIFT RIGHT
PORT A INLET PORT B
PILOT
PASSAGE

LINE RELIEF BRIDGE LINE RELIEF

OUTLET
AND MAKEUP PASSAGE AND MAKEUP
VALVE SERIES FEEDER CHECK VALVE
PASSAGE VALVE
 IT38GII TILT CONTROL VALVE
REGENERATIVE
HEAD END ROD END
INLET
LAND
PILOT
PASSAGE

BRIDGE CHECK OUTLET LINE RELIEF

PASSAGE VALVE VALVE
LIFT CONTROL VALVE
HOLD

PORT INLET PORT

A B

MAKEUP
OUTLET VALVE
 LIFT CONTROL VALVE
FLOAT
HEAD INLET ROD
PILOT END END
PASSAGE

OUTLET MAKEUP
BRIDGE
VALVE
PASSAGE
SERIES FEEDER CHECK
PASSAGE VALVE
 STEERING STEERING SYSTEM
CYLINDERS
HOLD / LOW PRESSURE STANDBY

STEERING BIAS SPRING

CONTROL
VALVE

CONTROL ACTUATOR
SPOOL TO PILOT SYSTEM PISTON

SELECTOR
SPOOL

CHECK
STEERING VALVE PRESSURE AND FLOW
METERING COMPENSATOR VALVE
UNIT (SMU)

MARGIN PRESSURE
SPOOL CUTOFF SPOOL
 STEERING
STEERING SYSTEM
CYLINDERS LEFT TURN / CONSTANT FLOW

STEERING
CONTROL BIAS SPRING
VALVE

ACTUATOR
CONTROL TO PILOT SYSTEM PISTON
SPOOL

SELECTOR
SPOOL

CHECK
STEERING VALVE PRESSURE AND FLOW
METERING COMPENSATOR VALVE
UNIT (SMU)

MARGIN PRESSURE
SPOOL CUTOFF SPOOL
 BRAKE SYSTEM
CUT-OUT/BRAKES ENGAGED
LEFT BRAKE RIGHT BRAKE ACCUMULATOR
PEDAL PEDAL CHARGING VALVE
INVERSE
BRAKE LIGHTS SHUTTLE
VALVE BRAKE
TANDEM
BRAKE PRESSURE
VALVE SWITCH
REAR AXLE
BRAKES
REAR CUT-IN/
BRAKE CUT-OUT
ACCUMULATOR SPOOL

FRONT AXLE
BRAKES

UNLOADING
FRONT
VALVE
BRAKE
ACCUMULATOR
TO IMPLEMENT
TO STEERING SYSTEM
SYSTEM MAIN
IMPLEMENT
PUMP RELIEF VALVE

STEERING
PUMP
BRAKE
PUMP
 BRAKE CONTROL VALVE
BRAKES BRAKES
RELEASED ENGAGED

SPRINGS

REAR
BRAKE
SPOOL
FROM REAR TO REAR
BRAKES BRAKES

FRONT
FROM
BRAKE
ACCUMULATOR
SPOOL

FROM FRONT TO FRONT

BRAKES BRAKES

FROM
ACCUMULATOR

SPRING
 HYDRAULIC FAN SYSTEM

TRANSMISSION OIL
SOLENOID TEMPERATURE SENSOR
FAN VALVE
OIL BYPASS MOTOR
COOLER VALVE

FAN
POWER TRAIN
ECM

FLOW
CONTROL
SPOOL

PRESSURE PRESSURE AND FLOW CAT DATA

CUTOFF COMPENSATOR VALVE LINK
SPOOL

ENGINE
ECM
FAN
ACTUATOR PISTON
PUMP

HYDRAULIC OIL COOLANT AIR INLET

TEMPERATURE SENSOR TEMPERATURE SENSOR TEMPERATURE SENSOR
 HYDRAULIC FAN SYSTEM
MINIMUM FAN SPEED

BYPASS
VALVE TRANSMISSION OIL
SOLENOID TEMPERATURE SENSOR
FAN VALVE
MOTOR

OIL FAN PRESSURE AND FLOW POWER TRAIN

COOLER COMPENSATOR VALVE ECM

FLOW
CONTROL
SPOOL

PRESSURE CAT DATA

CUTOFF LINK
SPOOL

ENGINE
FAN ECM
PUMP
ACTUATOR PISTON

HYDRAULIC OIL COOLANT AIR INLET

TEMPERATURE SENSOR TEMPERATURE SENSOR TEMPERATURE SENSOR
 HYDRAULIC FAN SYSTEM
MAXIMUM FAN SPEED

BYPASS
VALVE TRANSMISSION OIL
SOLENOID TEMPERATURE SENSOR
FAN VALVE
MOTOR

OIL FAN PRESSURE AND FLOW POWER TRAIN

COOLER COMPENSATOR VALVE ECM

FLOW
CONTROL
SPOOL

PRESSURE CAT DATA

CUTOFF LINK
SPOOL

ENGINE
FAN ECM
PUMP
ACTUATOR PISTON

HYDRAULIC OIL COOLANT AIR INLET

TEMPERATURE SENSOR TEMPERATURE SENSOR TEMPERATURE SENSOR
 FAN PUMP
ENGINE OFF
MARGIN
SPRING FROM
ACTUATOR
PISTON PUMP
BIAS SOLENOID
SPRING VALVE

ORIFICE

ORIFICES

SHAFT

ENGINE
ECM
FLOW CONTROL
PISTON AND TO FAN PRESSURE SPOOL
SWASHPLATE BARREL ASSEMBLY
MOTOR CUTOFF SPOOL
 FAN PUMP
MINIMUM FAN SPEED
MARGIN
SPRING
FROM
ACTUATOR
PUMP
PISTON
PASSAGE
BIAS SOLENOID
SPRING VALVE

ORIFICE

ORIFICES

ENGINE
ECM
FLOW CONTROL
SWASHPLATE TO FAN SPOOL
PRESSURE
MOTOR
CUTOFF SPOOL
 FAN PUMP
CONSTANT FAN SPEED
MARGIN
SPRING
FROM
ACTUATOR PUMP
PISTON
SOLENOID
BIAS VALVE
SPRING ORIFICE

ORIFICES

ENGINE
ECM
FLOW CONTROL
TO FAN SPOOL
SWASHPLATE MOTOR PRESSURE
CUTOFF SPOOL
 FAN PUMP
MAXIMUM FAN SPEED
MARGIN
SPRING FROM
ACTUATOR PUMP
PISTON
SOLENOID
BIAS VALVE
SPRING

ORIFICE

ORIFICES

ENGINE
ECM
FLOW CONTROL
TO FAN SPOOL
SWASHPLATE MOTOR PRESSURE
CUTOFF SPOOL
SIGNIFICANT MAINTENANCE CHANGES
• ECPC TRANSMISSION
• INSTRUMENT CLUSTER
• ELECTRONIC ENGINE
 NEW TOOLING

• CATERPILLAR ELECTRONIC TECHNICIAN