Product:INTEGRATEDTOOLCARRIER
Model:IT38GIIINTEGRATEDTOOLCARRIERJAN
Configuration:IT38GIIIntegratedToolcarrierJAN00001-UP(MACHINE)POWEREDBY3126BEngine
OperationandMaintenanceManual
938GSeriesIIWheelLoaderandIT38GSeriesIIIntegratedToolcarrier
MediaNumber-SEBU7581-09PublicationDate-01/03/2010DateUpdated-25/03/2010
Foreword
LiteratureInformation
Thismanualshouldbestoredintheoperator'scompartmentintheliteratureholderorseatback literaturestoragearea.
Thismanualcontainssafetyinformation,operationinstructions,transportationinformation, lubricationinformationandmaintenanceinformation.
Somephotographsorillustrationsinthispublicationshowdetailsorattachmentsthatcanbedifferent fromyourmachine.Guardsandcoversmighthavebeenremovedforillustrativepurposes.
Continuingimprovementandadvancementofproductdesignmighthavecausedchangestoyour machinewhicharenotincludedinthispublication.Read,studyandkeepthismanualwiththe machine.
Wheneveraquestionarisesregardingyourmachine,orthispublication,pleaseconsultyourCat dealerforthelatestavailableinformation.
Safety
Thesafetysectionlistsbasicsafetyprecautions.Inaddition,thissectionidentifiesthetextand locationsofwarningsignsandlabelsusedonthemachine.
Readandunderstandthebasicprecautionslistedinthesafetysectionbeforeoperatingorperforming lubrication,maintenanceandrepaironthismachine.
Operation
Theoperationsectionisareferenceforthenewoperatorandarefresherfortheexperiencedoperator. Thissectionincludesadiscussionofgauges,switches,machinecontrols,attachmentcontrols, transportationandtowinginformation.
Photographsandillustrationsguidetheoperatorthroughcorrectproceduresofchecking,starting, operatingandstoppingthemachine.
Operatingtechniquesoutlinedinthispublicationarebasic.Skillandtechniquesdevelopasthe operatorgainsknowledgeofthemachineanditscapabilities.
Maintenance
Themaintenancesectionisaguidetoequipmentcare.TheMaintenanceIntervalSchedule(MIS)lists theitemstobemaintainedataspecificserviceinterval.Itemswithoutspecificintervalsarelisted underthe"WhenRequired"serviceinterval.TheMaintenanceIntervalScheduleliststhepage numberforthestep-by-stepinstructionsrequiredtoaccomplishthescheduledmaintenance.Usethe MaintenanceIntervalScheduleasanindexor"onesafesource"forallmaintenanceprocedures.
MaintenanceIntervals
Usetheservicehourmetertodetermineservicingintervals.Calendarintervalsshown(daily,weekly, monthly,etc.)canbeusedinsteadofservicehourmeterintervalsiftheyprovidemoreconvenient servicingschedulesandapproximatetheindicatedservicehourmeterreading.Recommendedservice shouldalwaysbeperformedattheintervalthatoccursfirst.
Underextremelysevere,dustyorwetoperatingconditions,morefrequentlubricationthanisspecified inthemaintenanceintervalschartmightbenecessary.
Performserviceonitemsatmultiplesoftheoriginalrequirement.Forexample,atevery500service hoursor3months,alsoservicethoseitemslistedunderevery250servicehoursormonthlyandevery 10servicehoursordaily.
CaliforniaProposition65Warning
DieselengineexhaustandsomeofitsconstituentsareknowntotheStateofCaliforniatocause cancer,birthdefects,andotherreproductiveharm.
Batteryposts,terminalsandrelatedaccessoriescontainleadandleadcompounds.Washhandsafter handling.
CertifiedEngineMaintenance
Propermaintenanceandrepairisessentialtokeeptheengineandmachinesystemsoperating correctly.Astheheavydutyoff-roaddieselengineowner,youareresponsiblefortheperformanceof therequiredmaintenancelistedintheOwnerManual,OperationandMaintenanceManual,and ServiceManual.
Itisprohibitedforanypersonengagedinthebusinessofrepairing,servicing,selling,leasing,or tradingenginesormachinestoremove,alter,orrenderinoperativeanyemissionrelateddeviceor elementofdesigninstalledonorinanengineormachinethatisincompliancewiththeregulations (40CFRPart89).Certainelementsofthemachineandenginesuchastheexhaustsystem,fuel system,electricalsystem,intakeairsystemandcoolingsystemmaybeemissionrelatedandshould notbealteredunlessapprovedbyCaterpillar.
MachineCapacity
Additionalattachmentsormodificationsmayexceedmachinedesigncapacitywhichcanadversely affectperformancecharacteristics.Includedwouldbestabilityandsystemcertificationssuchas brakes,steering,androlloverprotectivestructures(ROPS).ContactyourCatdealerforfurther information.
CatProductIdentificationNumber
EffectiveFirstQuarter2001theCatProductIdentificationNumber(PIN)haschangedfrom8to17 characters.Inanefforttoprovideuniformequipmentidentification,Caterpillarandotherconstruction equipmentmanufacturersaremovingtocomplywiththelatestversionoftheproductidentification numberingstandard.Non-roadmachinePINsaredefinedbyISO10261.ThenewPINformatwill applytoallCatmachinesandgeneratorsets.ThePINplatesandframemarkingwilldisplaythe17 characterPIN.Thenewformatwilllooklikethefollowing:
This is the sample of the manual if you need complete manual Click Here to download
2.MachineDescriptor(characters4-8)
3.CheckCharacter(character9)
4.MachineIndicatorSection(MIS)orProductSequenceNumber(characters10-17).Thesewere previouslyreferredtoastheSerialNumber.
MachinesandgeneratorsetsproducedbeforeFirstQuarter2001willmaintaintheir8characterPIN format.
Componentssuchasengines,transmissions,axles,etc.andworktoolswillcontinuetousean8 characterSerialNumber(S/N).
Copyright1993-2025CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
WedFeb2615:43:33UTC+05302025
Product:INTEGRATEDTOOLCARRIER
Model:IT38GIIINTEGRATEDTOOLCARRIERJAN
Configuration:IT38GIIIntegratedToolcarrierJAN00001-UP(MACHINE)POWEREDBY3126BEngine
OperationandMaintenanceManual
938GIIWheelLoaderandIT38GIIIntegratedToolcarrier
MediaNumber-SEBU7581-10PublicationDate-01/05/2019DateUpdated-31/05/2019
ArticulationBearings-Lubricate
SMCS-7057-086-BD;7065-086-BD;7066-086-BD
CrushingHazard.InsurethatthemachineignitionswitchisintheOFF positionandthattheparkingbrakeisengagedbeforeenteringthe articulationarea.Failuretodosocouldresultinseriousinjuryordeath. Illustration1g00107435
Note:Oncertainmodels,thefittingswillbeaccessiblefromtheleftsideofthemachine. Wipeoffthefittingsbeforeanylubricantisapplied. Applylubricantthroughfittings(1)and(2)onthearticulationhitches.
WedFeb2615:48:15UTC+05302025
Product:INTEGRATEDTOOLCARRIER
Model:IT38GIIINTEGRATEDTOOLCARRIERJAN
Configuration:IT38GIIIntegratedToolcarrierJAN00001-UP(MACHINE)POWEREDBY3126BEngine
OperationandMaintenanceManual 938GIIWheelLoaderandIT38GIIIntegratedToolcarrier
MediaNumber-SEBU7581-10PublicationDate-01/05/2019DateUpdated-31/05/2019
1.Opentheenginehood.Themagneticfiltersfortheaxleoilcoolerarelocatedontheright sideoftheengine.
Illustration2g00875415
2.Removethetwomagneticfiltersfromtheaxleoilcoolerlines.
3.Washthefiltersinacleannonflammablesolvent.Inspectthefiltersfordamage.Replacethe filtersifthefiltersaredamaged.
Note:Iftheoilsamplesforthedifferentialoilshowaparticlecountthatishigherthan normal,cleanthefiltersfortheaxleoilcooleratanearlierinterval.
4.Installthetwofiltersfortheaxleoilcooler.
5.Closetheenginehood.
6.Starttheengine.Operatethemachineinordertocirculatetheoil.
7.Stoptheengine.
Illustration3g00277215
FrontDifferentialandFinalDriveFillerPlug
Illustration4g00110469
RearDifferentialandFinalDriveFillerPlug
8.Removethedipstick/fillplugforthefrontdifferentialandthedipstick/fillplugfortherear differential.Checktheoillevel.
9.MaintaintheoillevelbetweentheADDmarkandtheFULLmarkonthedipstick/fillplug. Addoil,ifnecessary.Replacethedipstick/fillplug.
Copyright1993-2025CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
WedFeb2615:48:30UTC+05302025
Product:INTEGRATEDTOOLCARRIER
Model:IT38GIIINTEGRATEDTOOLCARRIERJAN
Configuration:IT38GIIIntegratedToolcarrierJAN00001-UP(MACHINE)POWEREDBY3126BEngine
OperationandMaintenanceManual
938GIIWheelLoaderandIT38GIIIntegratedToolcarrier
MediaNumber-SEBU7581-10PublicationDate-01/05/2019DateUpdated-31/05/2019
AxleOscillationBearings-Lubricate
SMCS-3268-086-BD;3278-086-BD
CrushingHazard.InsurethatthemachineignitionswitchisintheOFF positionandthattheparkingbrakeisengagedbeforeenteringthe articulationarea.Failuretodosocouldresultinseriousinjuryordeath.
Wipeoffthefittingsbeforeyouapplyanylubricant.
Applylubricantthroughtworemotefittingsnearthearticulationhitchontherightsideofthe machine.
Copyright1993-2025CaterpillarInc. AllRightsReserved.
WedFeb2615:48:46UTC+05302025
Product:INTEGRATEDTOOLCARRIER
Model:IT38GIIINTEGRATEDTOOLCARRIERJAN
Configuration:IT38GIIIntegratedToolcarrierJAN00001-UP(MACHINE)POWEREDBY3126BEngine
OperationandMaintenanceManual
938GIIWheelLoaderandIT38GIIIntegratedToolcarrier
MediaNumber-SEBU7581-10PublicationDate-01/05/2019DateUpdated-31/05/2019
BackupAlarm-Test
SMCS-7406-081
TurntheenginestartswitchkeytotheONpositioninordertoperformthetest.
Applytheservicebrake.MovethetransmissiondirectioncontrollevertoREVERSEposition. Thebackupalarmshouldimmediatelysound.Thebackupalarmwillcontinuetosounduntilthe transmissiondirectioncontrolleverismovedtotheNEUTRALpositionortotheFORWARD position.
Illustration1g00924571
Thebackupalarmismountedinthebackofthemachinebehindthereargrill.
Illustration2g00844425
Athree-positionswitchattherearofthebackupalarmregulatesthesoundofthealarm.The soundofthealarmcanbeadjustedtoHIGH,LOW,orMEDIUM.
Thealarmissetatthemaximumsoundlevelwhenthemachineisshippedfromthefactory.The settingshouldremainonhigh,unlessthejobsiterequiresalowersoundlevel.
Copyright1993-2025CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
WedFeb2615:49:04UTC+05302025
Product:INTEGRATEDTOOLCARRIER
Model:IT38GIIINTEGRATEDTOOLCARRIERJAN
Configuration:IT38GIIIntegratedToolcarrierJAN00001-UP(MACHINE)POWEREDBY3126BEngine
OperationandMaintenanceManual 938GIIWheelLoaderandIT38GIIIntegratedToolcarrier
MediaNumber-SEBU7581-10PublicationDate-01/05/2019DateUpdated-31/05/2019 i01894639
Battery-Clean
SMCS-1401-070
Illustration1g00985882
Thebatteriesarelocatedinthebatterycompartmentontheleftrearbumper.
Cleanthebatterysurfaceswithacleancloth.Keeptheterminalscleanandkeeptheterminals coatedwithpetroleumjelly.Installthepostcoversafteryoucoattheterminalpostswith petroleumjelly.
Copyright1993-2025CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
WedFeb2615:49:21UTC+05302025
Product:INTEGRATEDTOOLCARRIER
Model:IT38GIIINTEGRATEDTOOLCARRIERJAN
Configuration:IT38GIIIntegratedToolcarrierJAN00001-UP(MACHINE)POWEREDBY3126BEngine
OperationandMaintenanceManual
938GIIWheelLoaderandIT38GIIIntegratedToolcarrier
MediaNumber-SEBU7581-10PublicationDate-01/05/2019DateUpdated-31/05/2019
Battery-Recycle
SMCS-1401-561
Alwaysrecycleabattery.Neverdiscardabattery.
Alwaysreturnusedbatteriestooneofthefollowinglocations:
•Abatterysupplier
•Anauthorizedbatterycollectionfacility
•Recyclingfacility
Copyright1993-2025CaterpillarInc. AllRightsReserved.
PrivateNetworkForSISLicensees.
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WedFeb2615:49:35UTC+05302025
Product:INTEGRATEDTOOLCARRIER
Model:IT38GIIINTEGRATEDTOOLCARRIERJAN
Configuration:IT38GIIIntegratedToolcarrierJAN00001-UP(MACHINE)POWEREDBY3126BEngine
OperationandMaintenanceManual
938GIIWheelLoaderandIT38GIIIntegratedToolcarrier
MediaNumber-SEBU7581-10PublicationDate-01/05/2019DateUpdated-31/05/2019
BatteryHold-Down-Tighten
SMCS-7257-527 Illustration1g00985882
Thebatteriesarelocatedinthebatterycompartmentontheleftrearbumper.
Tightenthehold-downsforthebatteryinordertopreventthebatteriesfrommovingduring machineoperation.
Copyright1993-2025CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
WedFeb2615:49:52UTC+05302025
Product:INTEGRATEDTOOLCARRIER
Model:IT38GIIINTEGRATEDTOOLCARRIERJAN
Configuration:IT38GIIIntegratedToolcarrierJAN00001-UP(MACHINE)POWEREDBY3126BEngine
OperationandMaintenanceManual
938GIIWheelLoaderandIT38GIIIntegratedToolcarrier
MediaNumber-SEBU7581-10PublicationDate-01/05/2019DateUpdated-31/05/2019
BatteryorBatteryCable-Inspect/Replace
SMCS-1401-040;1401-510;1402-040;1402-510
Personalinjurymayoccurfromfailuretoproperlyservicethebatteries.
Batteriesgiveoffflammablefumesthatcanexplode.Electrolyteisan acidandcancausepersonalinjuryifitcontactstheskinoreyes.
Preventsparksnearthebatteries.Sparkscouldcausevaporstoexplode. Donotallowjumpercableendstocontacteachotherortheengine. Improperjumpercableconnectionscancauseanexplosion.
Alwayswearprotectiveglasseswhenworkingwithbatteries.
1.Preparethemachineformaintenance.RefertoOperationandMaintenanceManual,Prepare theMachineforMaintenance.
2.TurntheenginestartswitchkeyOFF.TurnalloftheswitchesOFF.
3.TurnthebatterydisconnectswitchOFF.Removethekey.
4.Disconnectthenegativebatterycablefromthedisconnectswitch.
Note:Donotallowthedisconnectedbatterycabletocontactthedisconnectswitch.
5.Disconnectthenegativebatterycableatthebattery.
6.Disconnectthepositivebatterycableatthebattery.
7.Inspectthebatteryterminalsforcorrosion.Inspectthebatterycablesforwearordamage.
8.Makeanynecessaryrepairs.Ifnecessary,replacethebatterycablesorthebattery.
9.Connectthepositivebatterycableatthebattery.
10.Connectthenegativebatterycableatthebattery.
11.Connectthebatterycableatthebatterydisconnectswitch.
12.InstallthekeyandturnthebatterydisconnectswitchON.
RecycletheBattery
Alwaysrecycleabattery.Neverdiscardabattery.
Alwaysreturnusedbatteriestooneofthefollowinglocations:
•Abatterysupplier
•Anauthorizedbatterycollectionfacility
•Recyclingfacility
Copyright1993-2025CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
WedFeb2615:50:09UTC+05302025
Product:INTEGRATEDTOOLCARRIER
Model:IT38GIIINTEGRATEDTOOLCARRIERJAN
Configuration:IT38GIIIntegratedToolcarrierJAN00001-UP(MACHINE)POWEREDBY3126BEngine
OperationandMaintenanceManual
938GIIWheelLoaderandIT38GIIIntegratedToolcarrier
MediaNumber-SEBU7581-10PublicationDate-01/05/2019DateUpdated-31/05/2019 i02211920
Belt-Inspect/Adjust/Replace
SMCS-1397-510;1397-025;1397-040
Yourmachineisequippedwithasingleserpentinebelt.Stoptheengine.Opentherearhood.Thebelt islocatedattherearoftheengine.Inspecttheconditionoftheserpentinebelt.Replacethebeltifthe beltiscrackedorfrayed. Illustration1g00752925
(1)Idlerpulley
(2)Idlerpulley
(3)Alternator
(4)Squarehole
(5)Tensioner
(6)Waterpump
(7)Serpentinebelt
(8)Crankshaftpulley
(9)Compressor(IfEquipped)
(10)Idlerpulley
Atensioner(5)keepsthecorrecttensiononthebelt(7).Insertaratchetwithasquaredriveintothe hole(4).Rotatethetensionerclockwiseinordertorelievetensiononthebelt.Removethebelt.
Installthenewbelt.Besurethatthenewbeltisroutedcorrectly,asshown.View(A)represents machinesthatarenotequippedwithanairconditioner.View(B)representsmachinesthatare equippedwithanairconditioner.Rotatethetensionerclockwiseinordertoinstallthenewbelt. Releasethetensionerwhenthenewbeltisinstalled.Thecorrecttensionwillautomaticallybe applied.
BeltfortheAxleOilCoolerPump(IfEquipped)
Yourmachineisequippedwithasingleserpentinebelt.Stoptheengine.Opentherearhood.Thebelt islocatedattherearoftheengine.Inspecttheconditionoftheserpentinebelt.Replacethebeltifthe beltiscrackedorfrayed. Illustration2g01100200
(1)Axleoilcoolerpump
(2)Idlerpulley
(3)Idlerpulley
(4)Alternator
(5)Squarehole
(6)Tensioner
(7)Waterpump
(8)Serpentinebelt
(9)Crankshaftpulley
(10)Compressor(IfEquipped)
Atensioner(6)keepsthecorrecttensiononthebelt(8).Insertaratchetwithasquaredriveintothe hole(5).Rotatethetensionerclockwiseinordertorelievetensiononthebelt.Removethebelt.
Installthenewbelt.Besurethatthenewbeltisroutedcorrectly,asshown.View(A)represents machinesthatarenotequippedwithanairconditioner.View(B)representsmachinesthatare equippedwithanairconditioner.Rotatethetensionerclockwiseinordertoinstallthenewbelt. Releasethetensionerwhenthenewbeltisinstalled.Thecorrecttensionwillautomaticallybe applied.
Copyright1993-2025CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
WedFeb2615:50:26UTC+05302025
Product:INTEGRATEDTOOLCARRIER
Model:IT38GIIINTEGRATEDTOOLCARRIERJAN
Configuration:IT38GIIIntegratedToolcarrierJAN00001-UP(MACHINE)POWEREDBY3126BEngine
OperationandMaintenanceManual
938GIIWheelLoaderandIT38GIIIntegratedToolcarrier
MediaNumber-SEBU7581-10PublicationDate-01/05/2019DateUpdated-31/05/2019
BrakeAccumulator-Check
SMCS-4263-535 Illustration1g00877459
1.TurntheenginestartswitchtotheONposition.Thealertindicator(1)forbrakeoilpressure shouldcomeonifthebrakingsystemisnotatnormaloperatingpressure.
2.Starttheengine.Runtheengineathalfspeedfortwominutesinordertoincreasethe accumulatorpressure.Thealertindicator(1)forbrakeoilpressureshouldgooff.
3.Stoptheengine.Applytheservicebrakepedalandreleasetheservicebrakepedaluntilthe alertindicatorforbrakeoilpressurecomeson.Thiswilldecreasetheaccumulatorpressure. Aminimumoffiveapplicationsoftheservicebrakepedalarerequired.
Note:Theparkingbrakeindicatorlight(2)willbeonwhenthealertindicatorforbrakeoil pressurecomeson.
4.Ifthealertindicatorcomesonafterlessthanfiveapplicationsofthebrake,measurethe accumulatorprechargepressure.AnauthorizedCaterpillardealercanmeasurethenitrogen gaspressureintheaccumulator.Useonlydrynitrogengasforrecharging.
Copyright1993-2025CaterpillarInc. AllRightsReserved. PrivateNetworkForSISLicensees.
WedFeb2615:50:41UTC+05302025
Product:INTEGRATEDTOOLCARRIER
Model:IT38GIIINTEGRATEDTOOLCARRIERJAN
Configuration:IT38GIIIntegratedToolcarrierJAN00001-UP(MACHINE)POWEREDBY3126BEngine
OperationandMaintenanceManual
938GIIWheelLoaderandIT38GIIIntegratedToolcarrier
MediaNumber-SEBU7581-10PublicationDate-01/05/2019DateUpdated-31/05/2019 i01732078
BrakeDiscs-Check
SMCS-4255-535
Reference:Forthecorrectprocedure,refertotheTestingandAdjustingServiceManualofthe brakingsystemforyourmachineorconsultyourCaterpillardealer.
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WedFeb2615:50:56UTC+05302025
This is the sample of the manual if you need complete manual Click Here to download