Hood Durability Improvements on Certain 966K, 972K, 966M, and 972M Medium Wheel Loaders {0635, 0679, 7251} Caterpillar

Wheel Loader

966K (S/N: PBG1-1246,10001-10001; TFS1-1450)

966K Series XE (S/N: NGX1-107,201-441)

966M (S/N: DYC1-238,401-795,1001-1001; KJP1-1286,1601-1601)

966M Series XE (S/N: P6C1-1,301-589,901-901)

972K (S/N: PEM1-947; Z4W1-771)

972M (S/N: A8P1-688,901-901; JPR1-240,301-610,801-801)

972M Series XE (S/N: EDW1-104,201-415,701-701)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.

This special instruction provides information to add structural re-enforcement to the hood supports and add the hood stability brackets. The addition of stabilizer bracket provides more robust structure to the hood and better withstand loads.

Safety

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When removing a major component or attachment, ensure that it is properly blocked or secured before removing mounting hardware. An assembly that is disconnected without proper blocking may shift or fall, resulting in serious injury or death of personnel or machine damage.

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Personal injury can result from rotating and moving parts. Moving fan blades and moving parts will throw or cut any object or tool that falls or is pushed into them. Ensure that no one is working on, underneath or close to the machine before starting the engine. Ensure the area is free of personnel.

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Accidental machine starting can cause injury or death to personnel working on the machine. To avoid accidental machine starting, turn the battery disconnect switch to the OFF position and remove the key. If the machine is not equipped with a battery disconnect switch, disconnect the battery cables from the battery and tape the battery clamps. Place a do not operate tag at the battery disconnect switch location to inform personnel that the machine is being worked on.

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Never use fingers to align a cylinder clevis in a mounting clevis. The cylinder could shift, severely injuring or amputating fingers.

966K, 972K, 966M, and 972M Clamshell Support and Panel Replacement

Illustration 1	g06137746
Rear view

Illustration 2	g06137747

1. Replace the components for clamshell and panels replacement which is listed in Table 1. Secure panels using the clamshell mounting hardware in Table 3.
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   Illustration 3	g06171043
   (A) Insert

2. Remove the six lower inserts (A) on the left-hand and right-hand hood panels.

   Note: Rotate insert (A) in counter-clockwise to remove.

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   Illustration 4	g06137395

3. Drill a 13.0 mm (0.51 inch) hole into each of the six locations (B). Use molded insert boss as a guide to assist drilling.

   Note: Threaded insert boss must be in good condition without any cracks or damage.

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   Illustration 5	g06137399
   (1) 345-6168 Washer (2) 461-7578 Collar (3) 8T-6912 Bolt (4) 7X-0579 Hard Washer (5) 131-3540 Locknut

4. Assemble mounting hardware as shown in Illustration 5

5. Tighten the non-metallic hood panels to 15 ± 3 N·m (133 ± 27 lb in).

6. Tighten the metallic support structures to 55 ± 10 N·m (41 ± 7 lb ft).

966K, 972K, 966M, and 972M Hood Support Structure Rework

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Illustration 6	g06127773
Hood guide installation

Note: Make sure that the hood is in a neutral state and equally supported.

Note: Supporting the hood on the hood tilt actuator will impose a twist in the hood resulting in excessive stress when welding the lower bracket.

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Illustration 7	g06127113
(1) 513-1577 Tube (2) 513-1579 Plate (3) 513-1578 Plate

Note: For Weld placement, refer to Illustrations 12, 13, and 14 in the Weld Specifications section.

1. Open clamshell and with the main hood closed position, place tube (1) , plate (2), and plate (3).

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Illustration 8	g06127115
(4) 513-1581 Plate (A) 312-4034 Baffle

1. Remove and reuse baffle (A). Cut to fit upon reinstallation.

2. Place one plate (4) on each side of lower tube as shown in Illustration 8.

   Note: For Weld placement, refer to Illustrations 12, 13, and 14 in the Weld Specifications section.

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   Illustration 9	g06127119
   (5) 518-6128 Bracket (B) Hood group

3. Weld upper angle iron (5) to the hood group (B).

   Note: For Weld placement, refer to Illustrations 12, 13, and 14 in the Weld Specifications section.

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   Illustration 10	g06127120
   Right-Hand side view (5) 518-6128 Bracket (6) 513-1580 Bracket (B) Hood group

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   Illustration 11	g06127121
   Left-Hand side view

4. Weld lower angle iron (6) to the hood group (B).

Weld Specifications

Illustration 12	g06210710
(1) 513-1577 Tube (3) 513-1578 Plate

Illustration 13	g06211211
Left Side View (1) 513-1577 Tube (2) 513-1579 Plate (3) 513-1578 Plate (4) 513-1581 Plate (5) 518-6128 Bracket (6) 513-1580 Bracket

Illustration 14	g06211538

966K, 972K Hood Stabilizer Guide Installation (Left-Hand Side)

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Illustration 15	g06130381
(C) 325-7744 Sheet

1. Remove sheet (C) from the rear cover assembly.
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   Illustration 16	g06130388
   (7) 501-9794 Guide (D) Diameter of hole is 12.0 mm (0.47 inch) (E) Rear platform

2. Open clamshell and line up guide (7) on the bottom of main hood support as shown in Illustration 16. Ensure that the bottom of the structure is touching the guide of rear platform (E).

3. Mark center of slots in the hood stabilizer guide and drill two holes (D).
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   Illustration 17	g06130390
   (7) 501-9794 Guide (8) 085-8091 Bolt (9) 8T-8549 Locknut (10) 198-4777 Hard Washer (E) Rear platform

4. Install guide (7) using two bolts (8), two locknut (9), and four washers (10) to the rear platform (E).

5. Tighten bolts (8) to 55.0 N·m (40.6 lb ft).
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   Illustration 18	g06127145
   (F) Chain link (G) 384-3416 Air Lines Gp

6. If air lines group (G) is equipped relocate with the chain link (F) as shown in Illustration 18.

966K, 972K Hood Stabilizer Guide - Plate Modification (Left-Hand Side)

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Illustration 19	g06127142
(C) 325-7744 Sheet (H) 51.0 mm (2.01 inch) (J) 130.0 mm (5.12 inch) (K) 230.0 mm (9.06 inch)

1. Cut sheet (C) as per dimensions shown in Illustration 19. Remove and discard the highlighted area.

966K, 972K Hood Stabilizer Guide Installation (Right-Hand Side)

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Illustration 20	g06130421
(L) 325-7741 Sheet

1. Remove sheet (L) from the rear platform.
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   Illustration 21	g06130934
   (7) 501-9794 Guide (D) Diameter of hole is 12.0 mm (0.47 inch) (E) Rear platform

2. Open clamshell and line up guide (7) on the bottom of main hood support as shown in Illustration 21. Ensure that the bottom of the structure is touching the guide of rear platform (E).

3. Mark center of slots in the hood stabilizer guide and drill two holes (D).
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   Illustration 22	g06127136
   (7) 501-9794 Guide (8) 085-8091 Bolt (9) 8T-8549 Locknut (10) 198-4777 Hard Washer (E) Rear platform

4. Install guide (7) using two bolts (8), two locknut (9), and four washers (10) to the rear platform (E).

5. Tighten bolts (8) to 55.0 N·m (40.6 lb ft).

966K, 972K Hood Stabilizer Guide - Plate Modification (Right-Hand Side)

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Illustration 23	g06127139
(7) 501-9794 Guide (L) 325-7741 Sheet (M) 55.0 mm (2.17 inch) (N) 152.0 mm (5.98 inch) (P) 240.0 mm (9.45 inch)

1. Cut sheet (L) as per dimensions shown in Illustration 23. Remove and discard the highlighted area.

966M, 972M Hood Stabilizer Guide Installation (Left-Hand Side)

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Illustration 24	g06127147
(R) 434-3799 Sheet

1. Remove sheet (R) from the rear cover assembly.
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   Illustration 25	g06127149
   (7) 501-9794 Guide (8) 085-8091 Bolt (9) 8T-8549 Locknut (10) 198-4777 Hard Washer (D) Diameter of hole is 12.0 mm (0.47 inch) (S) P-Clip (T) 7I-1024 Hose Guard (U) DEF line

2. Open clamshell and line up guide (7) on the bottom of main hood support as shown in Illustration 25. Ensure that the bottom of the structure is touching the guide of rear platform.

3. Mark center of slots in the hood stabilizer guide and drill two holes (D).

4. Install guide (7) using two bolts (8), two locknut (9), and four washers (10) to the rear platform (E).

5. Attach hose guard (T) to both sides of p-clip (S) to cover DEF line (U).

   Note: Be care to route hoses away from mounting hardware.

966M, 972M Hood Stabilizer Guide - Plate Modification (Left-Hand Side)

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Illustration 26	g06127153
(7) 501-9794 Guide (R) 434-3799 Sheet (V) 117.0 mm (4.61 inch)

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Illustration 27	g06127155
(R) 434-3799 Sheet

1. Cut sheet (R) as per dimensions shown in Illustration 27. Remove and discard the highlighted area.

   Note: Be careful not to oversize the cut out and created a dirt path into the DEF tank box. Align rear most cut to the front edge of DEF box.

966M, 972M Hood Stabilizer Guide Installation (Right-Hand Side)

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Illustration 28	g06127123
(W) 465-2759 Sheet

1. Remove sheet (W) from the rear platform.
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   Illustration 29	g06127125
   (7) 501-9794 Guide (D) Diameter of hole is 12.0 mm (0.47 inch) (E) Rear platform

2. Open clamshell and line up guide (7) on the bottom of main hood support as shown in Illustration 29. Ensure that the bottom of the structure is touching the guide of rear platform (E).

3. Mark center of slots in the hood stabilizer guide and drill two holes (D).
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   Illustration 30	g06127136
   (7) 501-9794 Guide (8) 085-8091 Bolt (9) 8T-8549 Locknut (10) 198-4777 Hard Washer (E) Rear platform

4. Install guide (7) using two bolts (8), two locknut (9), and four washers (10) to the rear platform (E).

5. Tighten bolts (8) to 55.0 N·m (40.6 lb ft).

966M, 972M Hood Stabilizer Guide - Plate Modification (Right-Hand Side)

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Illustration 31	g06127158
(7) 501-9794 Guide (X) 438-8791 Sheet (Y) 225.0 mm (8.86 inch)

1. Cut sheet (X) as per dimensions shown in Illustration 31. Remove and discard the highlighted area.