Corrosion Protection Package for Certain Wheel Loader Machines{0645, 1000, 7000, 7559} Caterpillar

Wheel Loader:

924H (S/N: KLN1-UP)

938H (S/N: JKM1-UP)

950H (S/N: M1G1-UP)

962H (S/N: M3G1-UP)

Integrated Toolcarrier:

IT38H (S/N: JNJ1-UP)

IT62H (S/N: M5G1-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 standard machine Service Manual and the Parts Manual should be used if the service information is not in this supplementary custom product support literature.

ReferenceFor the 924H Wheel Loaders (S/N: KLN1-UP), refer to service literature for the 328-7484 Protection Corrosion Ar on the Cat@Work web site.

ReferenceFor the 938H Wheel Loaders (S/N: JKM1-UP), refer to service literature for the 306-9130 Protection Corrosion Ar on the Cat@Work web site.

ReferenceFor the 950H Wheel Loaders (S/N: M1G1-UP), refer to service literature for the 371-6719 Protection Corrosion Ar (3-Valve) or 371-6720 Protection Corrosion Ar (2-Valve) on the Cat@Work web site.

ReferenceFor the 962H Wheel Loaders (S/N: M3G1-UP), refer to service literature for the 371-6719 Protection Corrosion Ar (3-Valve) or 371-6720 Protection Corrosion Ar (2-Valve) on the Cat@Work web site.

ReferenceFor the IT38H Integrated Toolcarrier (S/N: JNJ1-UP), refer to service literature for the 324-7858 Protection Corrosion Ar on the Cat@Work web site.

ReferenceFor the IT62H Integrated Toolcarrier (S/N: M5G1-UP), refer to service literature for the 371-6718 Protection Corrosion Ar on the Cat@Work web site.

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, loader frame, and outside of the machine.

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

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

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

• 4C-9612 Silicone Sealant is applied to all bolted electrical connections.

• For the 924H Wheel Loaders, treat the radiator core, oil cooler core, hood group, left-hand door, right-hand door, rear radiator door, and (ATAAC) cores with Cataphoretic Dip Painting (KTL Coating) plus one coat of black esther epoxy duo-components.

• For the 924H Wheel Loaders, treat the core of the air conditioner with one coat of black esther epoxy duo-components.

• For the 938H Wheel Loaders, 950H Wheel Loaders, 962H Wheel Loaders, IT38H Integrated Toolcarrierand the IT62H Integrated Toolcarrier, treat the oil cooler core,(ATAAC) cores, and core of the air conditioner with a Cataphoretic Dip Painting (KTL Coating).

• The material of the fuel tank cap is plastic.

• The alternator has a protected compartment for the electronic components. The alternator capacity for the 950H, 962H, and the IT62H has decreased from an 80 Amp rating to a 75 Amp rating. The alternator capacity for the 924H has a 95 Amp rating with additional protection and filtration.

• The electrical box is treated with silicone. All electrical connections are treated with silicone.

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

Maintenance

Every Day

Park the machine in a dry, 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 process 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 other articulated areas. Refer to the Operation and Maintenance Manual for the machine.

• Apply grease to the hood actuator of the 924H, 938H, 950H, 962H, IT38H and the IT62H.

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

Inspect:

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

   • Apply 151-1340 Dielectric Grease on all fuses.

   • Apply 4C-9612 Silicone Sealant to all unsealed connector terminals.

2. Other electrical connections
   • Inspect other sealed connections for damage or rust.

   • Inspect other unsealed connections for damage or rust, and repair with 4C-9612 Silicone Sealant . Use the following repair procedure in order to repair the connectors.

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 the 4C-4190 Yellow Primer Paint . Allow the layer of primer paint to dry for 8 hours.

4. Apply a layer of the 4C-4183 Black Paint . This black paint is an esther epoxy primer. Allow the paint to dry for 8 hours.

5. Apply a layer of the 4C-4190 Yellow Primer Paint . Allow the paint to dry for 8 hours.

6. Apply a layer of yellow polyurethane 4C-4184 Yellow Paint . Allow the paint to dry for 8 hours.

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 and handling.

• Any attachments are added to the machine after shipment.

The following items are available through the Caterpillar parts distribution system.

• 4C-4190 Yellow Primer Paint

• 4C-4183 Black Paint

• 4C-4184 Yellow Paint

Every Month

• Apply the antirust products Tecty or Dinitrol to the following items: 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.

For the 924H Wheel Loaders and the 924G Wheel Loaders, refer to service literature for the 328-7484 Protection Corrosion Ar on the Cat@Work web site.

For the 938H Series II Wheel Loaders, refer to service literature for the 306-9130 Protection Corrosion Ar on the Cat@Work web site.

For the 950H Wheel Loaders and the 962H Wheel Loaders, refer to service literature for the 371-6719 Protection Corrosion Ar (3-Valve) or 371-6720 Protection Corrosion Ar (2-Valve) on the Cat@Work web site.

For the IT38H Integrated Toolcarrier, refer to service literature for the 324-7858 Protection Corrosion Ar on the Cat@Work web site.

For the IT62H Integrated Toolcarrier, refer to service literature for the 371-6718 Protection Corrosion Ar on the Cat@Work web site.

Alternator Filter Removal and Installation Instructions

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Illustration 1	g01636407

1. Locate the filter on the back side of the alternator.

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Illustration 2	g01636406

2. There are three wing nuts on the filter housing that must be loosened.

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3. Remove the 239-8521 Support Assembly .

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Illustration 4	g01636414

4. Remove the filter 240-6576 Filter .

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Illustration 5	g01636447

5. Replace the 3G-4090 Tape Gasket .

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Illustration 6	g01636449

6. Install a new filter.

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7. Remove the 185-2651 Cover . The 151-1340 Dielectric Grease should be applied to all bolted connections to protect these components from corrosion.

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Illustration 8	g01636457

8. Apply 4C-9612 Silicone Sealant to exposed areas of connections and components in order to protect these items from corrosive damage.

Instructions for Maintenance of Electrical Connectors

1. Inspect sealed connectors and the receptacles for damages or corrosion.

2. Inspect connectors that are not sealed and repair using the following procedure.
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   Illustration 9	g01636885

   1. Remove the 8T-6885 Heat Shrink Tube from the connectors by cutting the tube lengthwise.
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   Illustration 10	g01636887

   2. Replace damaged parts.

   3. Assemble a new 8T-6885 Heat Shrink Tube to the assembled connections. Apply 4C-9612 Silicone Sealant to both sides of the tube. Warm the surface of the 8T-6885 Heat Shrink Tube to the desired size for proper protection of the connections.

The following items are available through the Caterpillar parts distribution system.

• 4C-9612 Silicone Sealant

• 8T-6885 Heat Shrink Tube

• 151-1340 Dielectric Grease

Protection for the Solenoid to the Power Train

Illustration 11	g01637419

Illustration 12	g01638894
View A-A with a magnified view (1) 4C-9612 Silicone Sealant (2) 135-5010 Tube (3) 8T-6885 Heat Shrink Tube (4) 4C-9612 Silicone Sealant