Corrosion Protection Package for Wheel Loaders{0645, 7000, 7559} Caterpillar

Wheel Loader:

938G Series II (S/N: PHN1-UP)

950G Series II (S/N: AYL1-UP)

962G Series II (S/N: BAB1-UP)

966G Series II (S/N: AXJ1-UP)

972G Series II (S/N: AXN1-UP)

Introduction

Use the supplemental literature with the appropriate Service Manual, Operation and Maintenance Manual, and Parts Manual that is available for each standard machine. Use this supplement to determine the difference between the custom modifications and a standard machine. The standard removals and the attachment removals are listed.

The Service Manual and the Parts Manual that is available for the standard machine should be used if the service information is not in this supplementary custom product support literature.

Reference: 938G Series II (S/N: PHN1-UP) Service Manual, RENR6060, Operation and Maintenance Manual, SEBU7581 and Parts Manual, SEBP3491

Reference: 950G Series II (S/N: AYL1-UP) Service Manual, RENR4302, Operation and Maintenance Manual, SEBU7459, Parts Manual, SEBP23280 and Custom Parts Manual, SEBC1345

Reference: 962G Series II (S/N: BAB1-UP) Service Manual, RENR4302, Operation and Maintenance Manual, SEBU7459, Parts Manual, SEBP3285 and Custom Parts Manual, SEBC1345

Reference: 966G Series II (S/N: AXJ1-UP) Service Manual, RENR4380, Operation and Maintenance Manual, SEBU7458 and Parts Manual, SEBP3279

Reference: 972G Series II (S/N: AXN1-UP) Service Manual, RENR4380, Operation and Maintenance Manual, SEBU7458 and Parts Manual, SEBP3278

Corrosion Protection

The corrosion protection package consists of the following items:

• A first layer of Black Esther epoxy primer is applied to the inside of the engine compartment, to the loader frame, and to the outside of the machine.

• A second layer of Yellow Esther epoxy duo-components is applied to the inside of the engine compartment, to the loader frame, and to the outside of the machine.

• A third layer of Yellow Polyurethane is applied to the engine compartment and to the outside of the machine.

• An Antirust protective coating is applied to the following: sheets, articulation joints, hinges and latches.

• 151-1340 Dielectric Grease is applied to all electrical terminals and to all electrical connections.

• 8T-0065 RTV Silicone Sealant is applied to all bolted electrical connections.

• Apply heat shrink tubing onto electrical connections, pressure switches, relays and solenoids.

• The radiator cores, the air conditioner, the oil cooler, and the ATAAC cores are treated with Heresite coating. The water core is treated with another layer of Esther epoxy duo-components.

• The Main Hydraulic valve is treated prior to assembly with one layer of Esther epoxy primer and one layer of Esther epoxy duo-components.

• The Supplemental Steering receives the treatment for the electrical connections and the treatment for the paint prior to assembly.

• Zinc plated parts are treated with three layers of paint: One layer of Esther epoxy primer, one layer of Esther epoxy duo-components and one layer of Polyurethane

• Hardware on the ladder, on the cab doors, on the battery door, and on the platform is replaced by stainless steel hardware.

• A rubber sheet is placed over the front frame in order to avoid material from entering the Main Hydraulic Valve compartment.

• The cap for the fuel tank is coated with Epoxy.

• The alternator offers a sealed compartment for the electronic components. The alternator capacity has increased from a 50 Amp rating to a 70 Amp rating on the 938G. The capacity for the 950G up to the 962G is 70 Amp.

• The electrical box is sealed and treated. All electrical connections are treated with silicone and heat shrink tubing. The electrical box is treated with two extra layers of paint.

• The disconnect switch is sealed.

• The service brake control offers stainless steel tubes and stainless steel hardware.

• Front hoses are treated with heat shrink tubing.

• The heater cores and evaporator cores are treated with a black epoxy paint. All of the connections are sealed with 8T-0065 RTV Silicone Sealant or a similar sealant.

• There are grease points on the hinges for the cab, hinges for the radiator core and hinges for the hood.

• The turbine precleaner improves efficiency by extending the life of the air cleaner.

• The automatic lubrication system contains stainless steel valves, stainless steel connectors, and stainless steel couplings. The automatic lubrication system is an attachment. Use of the automatic lubrication system with the corrosion protection package is recommended.

Maintenance

Every Day

Park the machine in a dry, well ventilated area whenever the machine is not being used.

The cab doors and the cab windows should be closed during operation of the machine. The cab blower should be run at medium speed in order to prevent corrosive materials from entering the cab. This may require more frequent cleaning of the cab filters.

Clean the radiator frequently under the following conditions:

• Dusty applications

• Working with materials that plug

• Working with materials that stick

Every Week or Every Two Weeks

Note: Because of varying conditions, only actual experience in a particular application can dictate the adequate amount of maintenance.

Cleaning:

• Remove the buildup of corrosive material by washing the machine with cold water. Use low water pressure with a maximum pressure of 100 Bars.

• Use compressed air in order to dry the machine completely.

Greasing:

When the machine is completely dry, immediately perform the following:

• Apply grease to all hinges and latches on the cab.

• Apply grease to all hood hinges and latches.

• Apply grease to all hinges for the oil cooler.

• Apply grease to all hinges for the air conditioner condenser.

• Apply grease to all other articulated areas. Refer to the Operation and Maintenance Manual for the machine.

• Apply grease to the hood actuator.

• Apply grease or spray oil in any area with friction.

Inspect:

1. Fuse Box
   • Inspect the inside of the fuse box.

   • Apply dielectric grease on all fuses.

   • Apply silicone sealant to all unsealed connector terminals.

2. Other electrical connections
   • Inspect other sealed connections for damage or rust, and apply 151-1340 Dielectric Grease inside the connector.

   • Inspect other unsealed connections for damage or rust, and repair with 8T-0065 RTV Silicone Sealant . Use the following repair procedure in order to repair the connectors.

   Procedure for Repair of electrical connectors

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   Illustration 1	g00947239

   1. Use a cutter and cut the shrinkable tube around the center of the connector.
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   Illustration 2	g00947240

   2. Disconnect the electrical connector and remove the shrinkable tube.
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   Illustration 3	g00947241

   3. Repair the connector. Slide new shrink tubing over one of the connectors and reconnect the connector fully in order to avoid failure in the field.
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   Illustration 4	g00947242

   4. Apply silicone on both sides and shrink the tubing.

3. Paint

Inspect the paint over the entire machine for damage. Use the following process to repair the paint if the paint is damaged:

1. Sand the damaged area with sandpaper.

2. Remove dust and degrease the surface.

Note: Refer to Sigma Coatings Reference numbers for paint.

3. Apply a layer of gray primer paint. "5215-5004" base and "5053-0003" hardener. Allow the layer of gray primer paint to dry to touch.

4. Apply a layer of black "5063-8007" Esther epoxy primer. Allow the paint to dry for a minimum of 12 hours and a maximum of 72 hours.

5. Apply a layer of yellow Esther epoxy duo-components:"5216-3001" base and "5531-0005" hardener. Allow the paint to dry for a minimum of 12 hours and a maximum of 72 hours.

6. Apply a layer of yellow Polyurethane: "7412-3002" base and "5231-0002" hardener.

Use steps 1 through 6 whenever the following conditions exist:

• Parts are disassembled for repair or disassembled for maintenance.

• The original coating is damaged or scratched by tools, handling, etc.

• Any attachments are added to the machine after shipment.

Every Month

• Apply antirust products "Tectyl" or "Dinitrol" in: articulation joints and other joints: fenders, platforms, sheet metal, handholds, loader frames, hydraulic valves and hoses.

• Remove accumulated corrosive materials from the inside of the compartments of the actuator group for the hood and the tool box .

Note: Reminder: Because of varying conditions, only actual experience in a particular application can dictate the adequate amount of maintenance.