INTERACTIVE SCHEMATIC

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 SENR6797-01
January 2012

938G Wheel Loader And

IT38G Integrated Toolcarrier
Hydraulic System
938G: IT38G:
4YS1-UP 7BS1-UP
6WS1-UP 1CW1-UP
8RS1-UP
9HS1-UP

© 2012 Caterpillar, All Rights Reserved Printed in U.S.A.

COMPONENT LOCATION
Part Part
Machine Schematic
Description Number Number
Location Location
For IT38 G For 938G
Accumulator Atch 124-9439 124-9439 1 E-3
Accumulator Atch (Alternate Rid e Control) 124-9439 124-9439 1 E-3
Accumulator Hydraulic 213-8773 213-8773 2 D-8, D-7
Core As. (Hydraulic Oil Cooler) 135-5327 135-5327 3 C-4
Cylinder Gp - Lift 114-8131 128-7678 4 E-4
105-0094 105-0094
Cylinder Gp - Steering 5 F-1
139-3312 139-3312
Cylinder Gp - Tilt 115-6963 9T-7161 6 F-4
Cylinder Gp (Coupler) 9T-8823 - 7 F-5
Filter Element 9J-5461 9J-5461 8 A-4
HMU (Hand Metering Unit) 113-0061 113-0061 9 D-1
Housing 101-2704 - 10 D-3
Manifold 9U-3862 9U-3862 10 E-3
Motot Gp (Fan Drive) 159-7986 159-7986 11 C-5
Pump Gp 105-2140 105-2140 12 B-7
Pump Gp - Piston (Hydraulic Fan) 139-6084 139-6084 13 B-5
Pump Gp - Supplemental Steering (Atch) 139-2327 123-8915 14 B-2
Tank Gp - Hydraulic 154-2140 160-3408 15 A-4
Valve - Bypass (Hydraulic Oil Cooler) 130-5202 130-5202 3 C-4
Valve - Check (Pilot) 9T-3096 9T-3096 12 C-7
Valve - Check (Ride Control) 9T-3096 9T-3096 1 E-4
Valve Gp - Accumulator Charge 134-5106 134-5106 16 D-7
Valve Gp - Breaker Relief 9T-0818 9T-0818 15 B-4
Valve Gp - Diverter (Supplemental Steering) (Atch) 141-2597 141-2597 17 C-2
Valve Gp - Main Control 133-4240 133-4238
18 E-4
Valve Gp - Main Control (Atch) 133-4241 133-4239
Valve Gp - Main Implement Relief 108-6428 108-6428 19 E-6
Valve Gp - Manual Hydraulic Lockout 112-1817 112-1817 18 D-6
Valve Gp - Pilot 122-6346 122-6344
19 C-4
Valve Gp - Pilot (Atch) 122-6347 122-6239
Valve Gp - Relief 4T-2764 4T-2764 10 D-3
122-6842 105-7715
Valve Gp - Relief (Line) 19 E-4
105-7715 -
Valve Gp - Relief (Line) (Coupler Cylinder) 105-7715 105-7715 19 E-5
Valve Gp - Relief (Line) (To fourth Function) 105-7715 - 20 E-6
Valve Gp - Relief (Line,Tilt Cyl Head End Port) 106-8528 106-8528 19 E-4
Valve Gp - Relief (Steering Backup) 6E-3447 6E-3447 21 E-2
Valve Gp - Relief Steering Control 9T-7420 9T-7420 21 E-1
Valve Gp - Relief Steering Crossover 9T-7419 9T-7419 21 E-1
Valve Gp - Selector And Press Cont (Pilot) 6E-3078 6E-3078 22 D-6
Valve Gp - Shutoff 6W-8221 - 7 E-5
Valve Gp - Solenoid 8T-8808 - 18 D-4, D-5
Valve Gp - Solenoid (Ride Control) (Atch) 149-2658 149-2658 1 E-3, D-3
Valve Gp - Tandem Brake 215-3687 215-3687 23 E-7
Valve Gp (Atch) (To Fourth Function) 6E-5958 6E-5958 20 E-6
Valve Gp (Atch) (Coupler) 6E-5958 6E-5958 20 E-5
TAP LOCATION

Tap Schematic
Description
Number Location
GG Steering Pump Pressure C-8
JJ Implement Pump Pressure B-7
BB Pilot Pump Pressure D-6
HH Hand Metering Unit Supply C-1
FLUID POWER SYMBOLS
BASIC COMPONENT SYMBOLS

MAIN AUX.
PUMP: VARIABLE and
PUMP or MOTOR FLUID CONDITIONER SPRING CONTROL VALVES RESTRICTION LINE RESTRICTION 2-SECTION PUMP PRESSURE COMPENSATED
(FIXED)

VARIABILITY SPRING LINE RESTRICTION PRESSURE HYDRAULIC PNEUMATIC LINE RESTRICTION ATTACHMENT
(ADJUSTABLE) (VARIABLE) COMPENSATION ENERGY TRIANGLES VARIABLE and PRESSURE
COMPENSATED

VALVE ENVELOPES
VALVES
VALVE PORTS

ONE POSITION TWO POSITION THREE POSITION TWO-WAY THREE-WAY FOUR-WAY

CONTROL VALVES CHECK VALVES

AB AB

P T P T
BASIC SPRING SHUTTLE PILOT
NORMAL POSITION SHIFTED POSITION INFINITE POSITION
SYMBOL LOADED CONTROLLED

FLUID STORAGE RESERVOIRS

VENTED PRESSURIZED RETURN ABOVE FLUID LEVEL RETURN BELOW FLUID LEVEL

MEASUREMENT ROTATING SHAFTS

PRESSURE TEMPERATURE FLOW UNIDIRECTIONAL BIDIRECTIONAL

COMBINATION CONTROLS

SOLENOID SOLENOID SOLENOID SOLENOID and SERVO THERMAL DETENT

or MANUAL and PILOT PILOT or MANUAL

MANUAL CONTROL SYMBOLS

PUSH-PULL LEVER MANUAL SHUTOFF GENERAL MANUAL PUSH BUTTON PEDAL SPRING

RELEASED PRESSURE PILOT CONTROL SYMBOLS

REMOTE SUPPLY PRESSURE

EXTERNAL RETURN INTERNAL RETURN SIMPLIFIED COMPLETE INTERNAL

SUPPLY PRESSURE

ACCUMULATORS CROSSING AND JOINING LINES HYDRAULIC AND PNEUMATIC CYLINDERS

SPRING LOADED GAS CHARGED LINES CROSSING LINES JOINING SINGLE ACTING DOUBLE ACTING

HYDRAULIC PUMPS HYDRAULIC MOTORS INTERNAL PASSAGEWAYS

FIXED VARIABLE DISPLACEMENT FIXED VARIABLE DISPLACEMENT INFINITE THREE TWO

DISPLACEMENT NON-COMPENSATED DISPLACEMENT NON-COMPENSATED POSITIONING POSITION POSITION

UNIDIRECTIONAL UNIDIRECTIONAL

FLOW IN ONE PARALLEL CROSS FLOW ALLOWED IN

BIDIRECTIONAL BIDIRECTIONAL DIRECTION FLOW FLOW EITHER DIRECTION
ELECTRICAL SYMBOLS
Hydraulic Symbols (Electrical)

G M
Transducer Transducer Generator Electric Motor
(Fluid) (Gas / Air)

Pressure Switch Pressure Switch Temperature Switch Electrical Wire

(Adjustable)

Electrical Symbols (Electrical)

Pressure Temperature Level Flow

Symbol Symbol Symbol Symbol

Wire Number Identification Codes

Electrical Schematic Example Hydraulic Schematic Example

Current Standard Current Standard

Harness identification code
This example indicates
wire 135 in harness "AG". Wire
Circuit Number Wire Color
Identification

325-AG135 PK-14
325-PK
Circuit Identification Wire Color Wire Gauge
Number

Previous Standard
Wire Color
Wire

325-PK-14
B A
Circuit Number Wire Gauge
Identification (EXAMPLE VALVE)
 8 7 6 5 4 3 2 1
(6) CYLINDER GP
(TILT) STEERING
115-6963

(5) CYLINDER GP
(STEERING)
139-3312
105-0094
FIXED FRONT AXLE
F F

RACKBACK

DUMP
CYLINDER GP CYLINDER GP
(AUX) (AUX)
(ATCH) (ATCH)
(6) CYLINDER GP
(4) CYLINDER GP
(7) CYLINDER GP (TILT)
(LIFT)
(COUPLER) 9T-7161
128-7678
9T-8823
114-8131
TO XMISSON
CONTROL (7) VALVE GP (1) ACCUMULATOR
TO STOP LAMP (19) VALVE GP (ATCH)
(19) RELIEF (1) CHECK

DUMP
RACKBACK
SWITCH (NC) SHUTOFF (10) MANIFOLD
(MAIN IMPL VALVE 6W-8221 VALVE 124-9439
9U-3862
RELIEF) (LINE) 9T-3096 C1
108-6428 105-7715
C2

TO FOURTH FUNCTION C3 (1) VALVE

LEFT AND RIGHT SOLENOID (21) RELIEF VALVE
PEDAL ASSEMBLY (RIDE CONTROL) (STEERING
E NO T1 (ATCH) (21) RELIEF CROSSOVER) E
149-2658 VALVE 9T-7419

RAISE

LOWER
(1) ACCUMULATOR (STEERING
NC (23) TANDEM (19) RELIEF (ATCH ALTERNATE BACKUP)
C
BRAKE VALVE RIDE) 6E-3447
VALVE (19) RELIEF 124-9439
(LINE)
215-3687 VALVE 106-8528 (21) VALVE GP
(20) RELIEF (LINE) (STEERING
ALTERNATE RIDE CONTROL
VALVE 105-7715 CONTROL)
(LINE) 122-6842 9T-7420
(10) HOUSING
105-7715
101-2704
C1
T2
C2
(2) HYDRAULIC
C3 (1) VALVE
ACCUMULATOR TO AUDIBLE
AND VISUAL SOLENOID
213-8773 SIGNLS SWITCH (18) VALVE GP (9) HMU
IS NORMALLY MAIN CONTROL T1 (RIDE CONTROL) 113-0061
CLOSED
133-4238 (ATCH)
175-3244
133-4240 149-2658
(20) VALVE GP (18) VALVE GP (18) VALVE GP
(20) VALVE GP (ATCH) SOLENOID (18) VALVE GP
D MAIN CONTROL D
(ATCH) 6E-5958 8T-8808 SOLENOID (ATCH)
(16) DUAL ACCUMULATOR (2) HYDRAULIC
CHARGE VALVE 6E-5958 8T-8808 133-4239 (1) VALVE GP
ACCUMULATOR (10) VALVE GP
134-5106 133-4241 SOLENOID RELIEF
213-8773 149-2658 4T-2764

(22) VALVE GP BB
6E-3078 T2

OSCILLATING REAR AXLE

(18) VALVE GP (19) VALVE GP
112-1817 (PILOT)
122-6344
BRAKES 122-6346
HYDRAULIC COOLING (19) VALVE GP HH
(ATCH)
122-6239
(3) CORE AS. 122-6347
C (HYD OIL C
COOLER)
135-5327 (17) DIVERTER
VALVE GP
(12) CHECK (SUPPLEMENTAL
VALVE STEERING)
GG 9T-3096 (ATCH)
(3) BYPASS VALVE 141-2597
(HYD OIL COOLER)
130-5202
JJ
(11) MOTOR GP
(FAN DRIVE)
159-7986 (14) PUMP GP
(SUPPLEMENTAL
STEERING)
(13) PISTON (ATCH)
PUMP GP 123-8915
(12) PUMP GP (HYD FAN) 139-2327
105-2140 139-6084

B B

(15) BREAKER
RELIEF
LINE PATTERNS
VALVE GP
9T-0818 Pressure Line
(8) FILTER Pilot / Load Sensing Pressure
ELEMENT
Drain / Return Lines
9J-5461
Component Group
(15) HYD TANK GP Attachment
160-3408
154-9037 Air Line

CALLOUTS
YY Taps (Pressure, Sampling, Sensor - by letter)

52 Components (By number)

A A
HYDRAULIC CIRCUIT COLOR DESCRIPTIONS
PILOT PUMP OUTPUT
MAIN PUMP OUTPUT THIS SCHEMATIC IS FOR THE 938G WHEEL LOADER AND IT38G
SUPPLEMENTAL STEERING PUMP OUTPUT
STEERING CIRCUIT
INTEGRATED TOOLCARRIER HYDRAULIC SYSTEM
SCAVENGE PUMP MEDIA NUMBER: SENR6797-01
SUPPLY LINE
BRAKE CIRCUIT SCHEMATIC PART NUMBER: 135-1807, CHANGE: 02, VERSION: -
LIFT CIRCUIT PART NUMBER: 127-9648, CHANGE: 02, VERSION: -
DRAIN / RETURN LINE
IT38G ONLY AUXILARY CIRCUIT PART NUMBER: 143-9472, CHANGE 02, VERSION --
TILT CIRCUIT Components are shown installed on a fully operable machine with the key and engine off, transmission shifter
FOURTH FUNCTION CIRCUIT in neutral and with parking brake set.
Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations.

8 7 6 5 4 3 2 1
MACHINE HARNESS CONNECTOR AND
COMPONENT LOCATIONS
VIEW ALL CALLOUTS

22 BB HH 9 5 1 10 19 20 4 6 7
3

13

11

12

GG

JJ 21 14 17 5

15 8 14 9 18 HH 5 4 1 10 19 20 6 7

BB

22

11

13

JJ 12 GG 21 17
BRAKES
VIEW ALL CALLOUTS

C
D

C
D

23
16

SECTION D-D SECTION C-C