Caterpillar IT38F
Caterpillarintegrated toolcarrier(no series)

Caterpillar IT38F

Maintenance schedule, common problems & OEM parts breakdown

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The Caterpillar IT38F is a medium-sized integrated toolcarrier designed for material handling, loading, and general construction applications. It is part of the IT38 series lineage, succeeding the IT38E and preceding the IT38G. The machine is powered by a Cat C6.6 ACERT diesel engine producing 147 kW (197 hp) gross power. Operating weight ranges from approximately 16,681 lb (7,566 kg) depending on configuration. Production years span from 1996 to 2026. Configurations offered include various tire options, bucket capacities ranging from 2.3 to 3.0 m3 (3.0 to 4.0 yd3), and oscillating rear axle options.

Across the IT38 series generations, key changes include the transition to the C6.6 ACERT engine for improved emissions compliance and efficiency, updates to the hydraulic system for better flow and response, and enhancements to the operator station for comfort and safety. The IT38F remains significant in the used and parts market due to its widespread use in aggregate yards, roadwork, and industrial sites. Its durable powertrain and undercarriage design ensure long service life, making it a reliable choice for fleet operators seeking cost-effective maintenance and high availability.

Below: full specifications, fluids & capacities, the factory service schedule, common service parts, verified fault codes, what owners discuss, attachment guidance, the complete assembly directory, and a serial-number reference. Complete parts lists with full OEM part numbers, exploded diagrams, quantities, and fitment data are available free in Heavy Parts AI.

Caterpillar IT38F specifications

Engine

ModelCat® 6.6 ACERT™
Gross Power147 kW (197 hp)
Net Power134 kW (180 hp)
Displacement6.6 L (402.8 cu in)
Cylinders6
Emissions TierTier 4 Final / EU Stage V

Weights

Operating Weight15,964 kg (35,200 lb)
Shipping Weightnot documented for this exact serial range — verify with your dealer
Ground Pressurenot documented for this exact serial range — verify with your dealer

Dimensions

Transport Length7.93 m (26.0 ft)
Transport Width2.64 m (8.7 ft)
Transport Height3.35 m (11.0 ft)
Wheelbase3.02 m (9.9 ft)
Ground Clearance0.40 m (1.3 ft)
Hinge Pin Max Height3.93 m (12.9 ft)
Dump Clearance at Max Lift2.81 m (9.2 ft)

Performance

Travel Speed Forward43.2 km/h (26.8 mph)
Travel Speed Reverse25.6 km/h (15.9 mph)
Bucket Breakout Force126 kN (28,326 lbf)
Static Tipping Load (Bucket)10,850 kg (23,918 lb)
Gradeabilitynot documented for this exact serial range — verify with your dealer

Service capacities (summary)

Fuel Tank247 L (65.3 gal)
Hydraulic System89 L (23.6 gal)
Engine Oil17.4 L (4.6 gal)
Cooling System36.3 L (9.6 gal)

Values vary by configuration, region, and serial range — confirm against your machine before planning transport or lifts.

Caterpillar IT38F maintenance schedule

Service intervalTasks
Every 10 h
  • Check engine oil level and condition.
  • Check hydraulic fluid level at sight glass.
  • Check coolant level and inspect radiator cap.
  • Drain water from fuel separator.
  • Check air filter restriction indicator.
  • Inspect for fluid leaks under machine.
Every 250 h
  • Change engine oil and filter.
  • Grease all pivot points on linkage and undercarriage.
  • Check hydraulic fluid level.
  • Inspect belts and hoses for wear.
  • Check tire inflation and condition.
  • Inspect radiator and oil cooler fins for debris.
Every 500 h
  • Replace fuel filter element.
  • Replace hydraulic return filter.
  • Test battery load and clean terminals.
  • Inspect undercarriage for wear and track tension.
  • Test coolant with SCA kit.
  • Check transmission oil level.
Every 1,000 h
  • Collect hydraulic oil sample for S.O.S analysis.
  • Change final drive oil.
  • Inspect turbocharger for shaft play.
  • Torque ROPS mounting bolts.
  • Measure undercarriage wear dimensions.
  • Replace air filter primary element if restricted.
Every 2,000 h
  • Change hydraulic system oil.
  • Flush and replace coolant.
  • Change transmission oil and filter.
  • Perform comprehensive structural inspection.
  • Evaluate major component wear.
  • Inspect and replace worn belts and clamps.

Servicing the IT38F beyond the schedule

Predictive Maintenance & Fluid Analysis

Utilize S.O.S fluid analysis at 1,000-hour intervals to monitor engine oil, hydraulic fluid, and coolant for wear metals and contamination. Check hydraulic oil particle count and viscosity to detect pump or valve wear early. Inspect coolant SCA levels to prevent liner pitting and corrosion. Monitor transmission oil for gear wear indicators. Use Cat DEO engine oil and HYDO Advanced hydraulic oil to maintain system integrity. Analyze fuel samples for water content to prevent injector issues. Track coolant pH and glycol content to ensure proper freeze protection and heat transfer.

Corrective & Common Repairs

Address frequent issues with the C6.6 ACERT engine by inspecting turbocharger shaft play and replacing worn seals. Check hydraulic return filter for blockage causing pump cavitation. Inspect undercarriage rollers and idlers for premature wear due to heavy loading. Replace worn track shoes or tires to maintain traction and reduce ground pressure damage. Check articulation joint pins and bushings for play causing steering instability. Inspect brake pads and discs for wear. Replace fuel filter elements to prevent engine stalling and power loss. Check electrical connectors for corrosion in the Product Link 300 system.

Overhaul & Rebuild Points

Plan major overhauls for the C6.6 ACERT engine at 10,000 to 15,000 hours based on S.O.S analysis results. Rebuild hydraulic pumps and motors when flow rates drop below specifications or internal leakage is detected. Inspect final drive gears and bearings for pitting or spalling. Check transmission clutches for wear and replace friction elements as needed. Evaluate undercarriage components for wear limits; replace sprockets, tracks, and rollers when dimensions fall below OEM tolerances. Inspect the oscillating rear axle for seal leaks and bearing wear. Check the radiator and oil cooler cores for blockage requiring cleaning or replacement.

Seasonal & Environment Servicing

In dusty environments, check air filter restriction daily and replace elements more frequently. Clean radiator and oil cooler fins daily to prevent overheating. Use Cat HYDO Advanced hydraulic oil for extended drain intervals in hot climates. In cold weather, use Cat DEO-ULS Cold Weather engine oil and ensure coolant freeze protection is adequate. Check battery condition and charge level in low temperatures. Inspect fuel lines for waxing or gelling. Use Arctic Platinum grease for pivot points in freezing conditions. Monitor tire pressure changes due to temperature fluctuations. Store machine in a sheltered area to protect hydraulic hoses from UV degradation.

IT38F fault codes & troubleshooting

CodeMeaningLikely causeWhat to do
CID 0110 FMI 03Engine Coolant Temperature Sensor — Voltage Above NormalOpen circuit in sensor wiring harness or failed sensor elementInspect wiring for damage; replace sensor if circuit integrity is confirmed
CID 0190 FMI 08Engine Speed Sensor — Abnormal FrequencyIncorrect sensor air gap, damaged tone ring, or failing sensorCheck sensor mounting gap; inspect tone ring for damage
CID 0041 FMI 038-Volt DC Supply — Voltage Above NormalShort to power on the 8-volt reference circuitIsolate sensors sharing the 8V supply to locate the short
CID 0041 FMI 048-Volt DC Supply — Voltage Below NormalShort to ground on the 8-volt reference circuitDisconnect sensors one at a time to identify the grounded circuit
CID 0262 FMI 045-Volt Supply — Voltage Below NormalShort to ground on the 5-volt reference circuitDisconnect sensors sharing the 5V supply to isolate the fault
CID 0248 FMI 09CAT Data Link — Abnormal Update RateCAN bus wiring damage or termination resistor failureCheck CAN wiring integrity and measure termination resistance
CID 0091 FMI 02Throttle Position Sensor — Erratic/IntermittentLoose connector, worn sensor wiper, or intermittent wiring breakPerform wiggle test on harness; inspect sensor mounting and connector
CID 0168 FMI 01System Voltage — Below NormalLow battery charge, failing alternator, or poor ground connectionTest battery voltage and alternator output under load

Codes and remedies are general guidance for this model family — always confirm with diagnostic tooling and your dealer before major repairs.

IT38F attachments & work tools

Standard Buckets

General-purpose and light-material buckets are standard for the IT38F class, typically ranging from 2.3 to 3.0 m3 (3.0 to 4.0 yd3) capacity. The machine is equipped with a quick-attach coupler system allowing rapid tool changes without leaving the cab. Bucket breakout force is rated at approximately 27,576 to 28,326 lb (122.6 to 126.0 kN) depending on the specific linkage configuration.

Fork Attachments

Standard fork tines are available with a length of 5 ft (1.52 m) for pallet handling. Extended hook configurations increase the max reach to 17.62 ft (5.37 m) and hook height to 22.07 ft (6.73 m) at maximum lift. Static tipping load with forks is rated at 19,546.2 lb (8,865 kg), significantly lower than bucket capacity due to the forward center of gravity.

Specialty Tool Carriers

Material handler configurations are supported with a static tipping load of 11,598.6 lb (5,261 kg). These setups often include extended reach hooks and reinforced linkage to accommodate specialized grapples or sorting tools. The integrated toolcarrier linkage provides the necessary reach and dump clearance for industrial material handling applications.

Hydraulic & Coupler Systems

The hydraulic system utilizes a piston pump with a flow capacity of 78 gal/min (295 L/min) and a relief valve setting of 1000 psi (6895 kPa). Tools requiring auxiliary hydraulics must be connected to the machine's quick-connect couplers, which are standard on the integrated toolcarrier linkage. Total hydraulic cycle time is approximately 9.5 seconds for a complete raise-dump-lower cycle.

Engine & Powertrain

The IT38F is powered by a Cat C6.6 ACERT diesel engine producing 160 hp (119 kW) net power. The machine features a 4-speed forward and 3-speed reverse powershift transmission with a maximum forward speed of 26.9 mph (43.3 km/h). Torque rise is 38%, with peak torque of 620 lb ft (840 Nm) at 1400 rpm.

Fluid Specifications

Recommended fluids include Cat DEO or DEO-ULS diesel engine oil, Cat HYDO Advanced hydraulic oil, and TDTO transmission fluid. The cooling system requires Extended Life Coolant (ELC) with anti-foaming and anti-corrosion properties, with a capacity of 9.6 gal (36.3 L). Hydraulic tank capacity is 23.6 gal (89.3 L).

All IT38F assemblies by section

Every catalogued assembly group for the Caterpillar IT38F. Open an assembly to preview the parts inside — full OEM part numbers are available in Heavy Parts AI.

Electrical And Starting System
130-0956 Sensor Gp-Arc Suppressor
10***02Kit-Receptacle; (2-Pin)(Engine Sensor Wiring Harness)1
10***07Kit-Connecting Plug; (2-Pin)(Electronic Control)1
13***56Sensor Group-Arc Suppressor1
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Operator Station
3e-1906 Compressor Gp-Refrigerant
3E***06Compressor Group-Refrigerant1
7T***32Plug Assem.; (3/8-24)1
9X***85Seal-O-Ring (20.22mm Id)2
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106-5122 Compressor Gp-Clutch & Refrig
10***22Compressor Group-Refrigerant; -Air Conditioner1
7T***32Plug Assem.; (3/8-24)1
9X***85Seal-O-Ring (20.22mm Id)2
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2q-7665 Kit-Air Conditioner -Custom
10***00Fitting As-Air Conditioner; (Quick Disconnect)(Refrigerant)2
10***72Hose Assem.1
10***74Hose Assem.1
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2q-7664 Kit-Air Conditioner -Custom
10***00Fitting As-Air Conditioner; (Quick Disconnect)(Refrigerant)2
10***59Hose Assem.1
10***61Hose Assem.1
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2q-7658 Kit-Air Conditioner -Custom
06***93Grommet; (Rh)1
10***70Grommet1
10***72Support Assem.1
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2q-7663 Kit-Air Conditioner -Custom
10***00Fitting As-Air Conditioner; (Quick Disconnect)(Refrigerant)2
10***99Tube Assem.1
10***59Hose Assem.1
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Frequently asked questions

What engine does the IT38F use?

The IT38F is powered by a Cat C6.6 ACERT diesel engine producing 147 kW (197 hp) gross power.

What is the operating weight of the IT38F?

Operating weight varies by configuration but is approximately 16,681 lb (7,566 kg).

What model replaced the IT38F?

The IT38F was succeeded by the IT38G series integrated toolcarrier.

What IT38F owners discuss

What engine powers the IT38F, and what are the common powertrain or hydraulic behaviors reported for this generation?
The IT38F is powered by a Cat C6.6 ACERT diesel engine. Community reports highlight that the 4-speed powershift transmission is robust but sensitive to fluid condition; low hydraulic oil causes cavitation that destroys pumps. Operators note that the electronically controlled, variable-speed on-demand fan adjusts based on oil, coolant, and inlet manifold temperatures. Hydraulic performance drops gradually due to oil breakdown and pump wear rather than sudden failure. Power loss or smoke is typically linked to airflow issues, dirty air filters, or fuel contamination rather than internal engine failure. Have your dealer verify the specific engine serial prefix and ECM software version for your unit.
What undercarriage or wear patterns are typical for the IT38F integrated toolcarrier?
The IT38F uses a wheeled configuration with 20.5R25 tires. Wear patterns focus on tire life and oscillating rear axle joints rather than track undercarriage. The oscillating rear axle allows for better ground contact but requires regular inspection of pivot pins and bushings for play. The integrated toolcarrier linkage arms and pins are high-wear items subject to fatigue if used for heavy lifting or impact loading. Final drives and travel motors operate under high torque; grinding noises or slow movement often indicate internal bearing failure or lubricant breakdown. Have your dealer verify the oscillating axle seal condition and pin clearance.
What are the common electrical or sensor issues for the IT38F?
Electrical instability is a frequent complaint, often caused by moisture intrusion into connectors, stressed wiring harnesses, or failing charging systems. A weak battery can cause the ECM to behave erratically, leading to unpredictable fault codes and startup failures. Operators often mistake grounding issues or voltage loss under load for control unit failure. Common root causes include loose or corroded grounds, damaged wiring, and battery deterioration. Modern diagnostics rely on stable voltage; intermittent faults often trace back to simple connection issues rather than complex sensor failures. Have your dealer verify the alternator output and ground strap integrity.
What engine quirks or maintenance needs are specific to the IT38F's powerplant?
The C6.6 ACERT engine requires strict adherence to fluid specifications. Using incorrect oil or mixing hydraulic oils (e.g., topping off Cat HYDO Advanced with generic oil) can create sludge that clogs valves and damages pumps. Cross-contamination must be kept below 10%. The engine uses Extended Life Coolant (ELC) which provides extended service intervals but requires specific ethylene glycol-based formulations. Air intake restrictions from dirty filters can damage turbochargers. Fuel quality is critical; low-quality fuel destroys injectors. Regular oil analysis is recommended to monitor for water, fuel, coolant, or silicon contamination. Have your dealer verify the current ELC condition and oil analysis results.
What should you check when buying a used IT38F?
Verify the serial number prefix to confirm the exact build year and configuration, as specs vary by series. Check the oscillating rear axle for excessive play in pivot pins and bushings. Inspect the 20.5R25 tires for uneven wear or damage. Test the 4-speed powershift transmission for smooth shifts and proper hydraulic pressure. Look for signs of hydraulic oil leaks around pump seals and valve banks. Verify the condition of the integrated toolcarrier linkage arms and pins for cracks or elongation. Check the cooling system for blockage or leaks, as overheating is a common failure point. Have your dealer verify the machine build date and original configuration via the official service information system.
How does the IT38F's cooling system operate, and what are the common failure modes?
The IT38F uses an electronically controlled, variable-speed on-demand fan that adjusts speed based on oil, coolant, and inlet manifold temperatures. This system optimizes cooling efficiency and fuel consumption. Common failure modes include fan motor failure, sensor errors, or cooling system blockage from dust and debris. Overheating can lead to head gasket failure or coolant contamination. The cooling system hygiene is critical; blocked radiators or coolers reduce heat rejection capacity. Extended Life Coolant (ELC) should be used to prevent corrosion and foaming. Have your dealer verify the fan motor operation and cooling system pressure integrity.

Compiled from owner and technician discussions across the industry — experiences vary by serial range and machine history.

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