Hood Structure Field Assembly Instructions{7251, 7960} Caterpillar

Wheel Loader:

950K (S/N: R4A1-UP; J5M1-UP; FER1-UP)

962K (S/N: T6A1-UP; FLL1-UP; X4T1-UP)

966K (S/N: PBG1-UP; TFS1-UP)

972K (S/N: PEM1-UP; Z4W1-UP)

980K (S/N: W7K1-UP; GTZ1-UP)

Introduction

This Special Instruction contains the assembly procedure and the installation information to assemble the K Series Wheel Loader hood structure for field assembly.

Choose a flat area that should be approximately 6.0 m (20 ft) long and 6.0 m (20 ft).

Do not perform any procedure or do not order parts until you understand the information that is contained in this document.

Procedure

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Illustration 1	g03513100

1. Lifting Points are provided on Brackets As. Use the appropriate hardware. Refer to Table 1.
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   Table 1

   Approximate Bracket Weights
   Machine	Bracket Weight
   950K 962K	33 kg (72.8 lb)
   966K 972K	20 kg (44.0 lb)
   980K	30 kg (66.1 lb)

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Illustration 2	g03513113
(A) 8T-4910 Bolt (B) 5P-1076 Hard Washer (C) 124-3647 Spacer (D) 419-4928 Support As (E) Hood Support As–RH

2. Align Support As (D) to Hood Support As–RH (E). Torque bolts to 100 N·m (73.76 lb ft).
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   Table 2

   Required parts
   Item	Qty	Part Number	Description
   A	4	8T-4910	Bolt
   B	4	5P-1076	Hard Washer
   C	4	124-3647	Spacer

   Note: (950K, 962K, 966K, and 972K Only)

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Illustration 3	g03513199
950K to 972K (F) Bracket As (G) Support As (Left-hand) (H) Support As (Right-hand)

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Illustration 4	g03541605
980K Refer to Table 3 (F) Bracket As (G) Support As (Left-hand) (H) Support As (Right-hand)

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Illustration 5	g03541541
Refer to Table 5

3. Assemble Main Hood Supports on a flat level surface to ensure proper alignment. Support Bracket As (F) with an overhead lifting device when assembling to Left-Hand Support Structure (G) and Right-Hand Support Structure (H). Refer to Table 5 for correct parts for your machine. Refer to Tables 4 and 5 for the proper hardware for your machine.
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   Table 3

   Bracket and Supports
   Item	Machine	Part Number	Description
   F	950K 962K	336-8650	Bracket As
   	966K 972K	312-4015	Bracket As
   	980K	389-6029	Bracket As
   G	950K 962K	312-4070	Support As (Left hand)
   	966K 972K	312-4020	Hood Support As (Left hand)
   	980K	443-4891	Hood Support As (Left hand)
   H	950K 962K	312-4080	Support As (Right-hand)
   	966K 972K	312-4040	Support As (Right-hand)
   	980K	443-4890	Support As (Right-hand)

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   Table 4

   Hardware (for 950K, 962K, 966K, and 972K Machines)
   Item	Qty	Part Number	Description
   J	4	8T-4195	Bolt
   K	4	8T-4121	Hard Washer
   L	2	8T-5005	Bolt
   M	4	198-4777	Hard Washer
   N	2	8T-6466	Bolt
   P	4	8T-4136	Bolt
   R	4	8T-4121	Hard Washer

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   Table 5

   Hardware (for 980K Machines)
   Item	Qty	Part Number	Description
   A	8	8T-4195	Bolt
   J	4	8T-4196	Bolt
   K	16	8T-4121	Hard Washer
   L	3	8T-5005	Bolt
   M	4	198-4777	Hard Washer
   R	4	8T-4137	Bolt
   W	1	8T-4172	Bolt

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Illustration 6	g03513298
(G) Support As (Left-hand) (S) 372-3138 Bracket As

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Illustration 7	g03513498
(G) Support As (Left-hand) (S) 372-3138 Bracket As (T) 372-3136 Pin As

4. Align Hood Support (G) to Bracket As (S). The back vertical surface of Bracket As (S) will be used as the reference plane. Refer to Illustrations 6 and 7.

   Assemble two Bracket As (S) and two Pin As (T) to Support As (Left-hand) (G) and Support As (Right-hand) (H). Align the rear surface of the hinge brackets with a flat planar surface.

   Note: Ensure hinge rear surface remains aligned throughout assembly procedure

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Illustration 8	g03513537
(G) Support As (Left-hand) (H) Support As (Right-hand) (S) 372-3138 Bracket As (T) 372-3136 Pin As

5. Center Support As (Left-hand) (G) and Support As (Right-hand) (H) into Bracket As (S). Refer to Illustration 8.

   Note: Ensure that Hood Supports remain centered throughout assembly procedure

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Illustration 9	g03513581

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Illustration 10	g03513696
950K V1 = V2 Measurement Location Points

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Illustration 11	g03515158
950K H1 = H2 Measurement Points

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Illustration 12	g03515202
966K/972K V1 = V2 Measurement Points

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Illustration 13	g03515205
966K/972K H1 = H2 Measurement Points

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Illustration 14	g03515260
980K V1 = V2 Measurement Points

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Illustration 15	g03515261
980K H1 = H2 Measurement Points

6. Check for Squareness. Measure vertical and horizontal corner to corner dimensions to ensure squareness. Refer to Illustrations 9 through 15 and Table 6.
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   Table 6

   Approximate Length
   Model	V1	V2	H1	H2	S1 (1)
   950K 962K	2102 ± 5 mm (82.8 ± 0.2 inch)	2102 ± 5 mm (82.8 ± 0.2 inch)	1573 ± 5 mm (61.9 ± 0.2 inch)	1573 ± 5 mm (61.9 ± 0.2 inch)	1616 ± 10 mm (63.6 ± 0.4 inch)
   966K 972K	2039 ± 5 mm (80.3 ± 0.2 inch)	2039 ± 5 mm (80.3 ± 0.2 inch)	1613 ± 5 mm (63.5 ± 0.2 inch)	1613 ± 5 mm (63.5 ± 0.2 inch)	1554 ± 10 mm (61.2 ± 0.4 inch)
   980K	2208 ± 5 mm (86.9 ± 0.2 inch)	2208 ± 5 mm (86.9 ± 0.2 inch)	1816 ± 5 mm (71.5 ± 0.2 inch)	1816 ± 5 mm (71.5 ± 0.2 inch)	1670 ± 10 mm (65.7 ± 0.4 inch)

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   ( 1 )

   Outside to Outside

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Illustration 16	g03515336

7. Main Hood Support Torque Sequence. Alternate Side to Side when torquing bolts. Refer to Illustration 16 and Table 7.

   Note: Ensure that hinge pins remain align throughout assembly. Refer to Step 4

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   Table 7

   Parts and Torque Points
   Torque Point	Qty	Part Number	Description	Torque
   A	4	124-3647	Spacer	100 N·m (73.76 lb ft)
   	4	5P-1076	Hard Washer
   	4	8T-4910	Bolt
   B	4	198-4777	Hard Washer	55 N·m (40.57 lb ft)
   	4	8T-5005	Bolt
   C	4	8T-4121	Hard Washer	55 N·m (40.57 lb ft)
   	4	8T-4195	Bolt
   D	4	8T-4121	Hard Washer	55 N·m (40.57 lb ft)
   	4	8T-4136	Bolt

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Illustration 17	g03515382

8. Assemble the Clam Shell Structure by utilizing the Main Hood Structure as an assembly fixture. Assemble all hardware loose utilizing the latch and latch pin to center the Clam Shell Structure. Refer to Illustration 17.

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Illustration 18	g03515393

9. Torque Clam Shell Structure to 55 N·m (40.57 lb ft). Follow Torque sequence. Refer to Illustration 18.