Location and Adjusting Procedure for the Bucket Stops {6001, 6107, 6119, 6129} Caterpillar

Wheel Loader

938G Series II (S/N: RTB273-UP; CRD275-UP; PHN273-UP; B9Y110-UP)

950G Series II (S/N: BAA111-UP; AYB235-UP; AYD227-UP; AYL116-UP; AXR228-UP; AYS111-UP; AXX111-UP)

950H (S/N: N1A1-UP; M1G1-UP; J5J1-UP; K5K1-UP)

950L (S/N: TNS1-UP; LXX1-UP)

950M (S/N: EMB1-UP; ENE1-UP; XCJ1-UP; FTR1-UP; LCR1-UP; J1S1-UP)

950M Z (S/N: HE81-UP)

962G Series II (S/N: BAB222-UP; BAC213-UP; BAD213-UP; AYE371-UP; AYG364-UP; AXS364-UP; AXY214-UP)

962H (S/N: N4A1-UP; M3G1-UP; J6J1-UP; K6K1-UP)

962L (S/N: MTN1-UP; SXS1-UP)

962M (S/N: EJB1-UP; JYD1-UP; LSE1-UP; RCL1-UP; J2S1-UP; F2T1-UP)

962M Z (S/N: SA81-UP)

966G (S/N: 9RS1-UP; 3SW1472-UP)

966G Series II (S/N: AXJ276-UP; AXL273-UP; ANT144-UP; AWY257-UP; ANZ278-UP; AWZ143-UP)

966H (S/N: A6D1-UP; A6G1-UP)

966K (S/N: PBG280-UP; TFS103-UP)

966K Series XE (S/N: NGX101-UP)

966L (S/N: FSL1-UP; FRS1-UP)

966M (S/N: EJA1-UP; DYC1-UP; R8D1-UP; LMM1-UP; KJP1-UP; L8R1-UP)

966M Series XE (S/N: P6C1-UP; B8P1-UP)

972G (S/N: 1EW1-UP)

972G Series II (S/N: AXC437-UP; AXE306-UP; AXN216-UP; AWP168-UP; AXP166-UP; ANY310-UP)

972H (S/N: A7D1-UP; A7G1-UP)

972K (S/N: PEM264-UP; Z4W109-UP)

972L (S/N: RFB1-UP; YJW1-UP)

972M (S/N: L8E1-UP; LSJ1-UP; GGN1-UP; A8P1-UP; JPR1-UP; M8W1-UP)

972M Series XE (S/N: M5S1-UP; EDW1-UP)

980K (S/N: W7K288-UP; GTZ129-UP)

980L (S/N: D8Z1-UP)

980M (S/N: MK21-UP; MGD1-UP; KRS1-UP; N8T1-UP)

982M (S/N: MK61-UP; F9A1-UP; LRS1-UP; K1Y1-UP)

988K (S/N: T8E1-UP; L8X1-UP; LWX1-UP; TWX1-UP)

Introduction

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Personal injury or death can result from fumes, gases and ultraviolet rays from the weld arc. Welding can cause fumes, burn skin and produce ultraviolet rays. Keep your head out of the fumes. Use ventilation, exhaust at the arc, or both, to keep fumes and gases from your breathing area. Wear eye, ear and body protection before working. Protect yourself and others; read and understand this warning. Fumes and gases can be dangerous to your health. Ultraviolet rays from the weld arc can injure eyes and burn skin. Electric shock can cause death. Read and understand the manufacturer's instructions and your employer's safety practices. Do not touch live electrical parts. See "American National Standard Z49.1, Safety in Welding and Cutting" published by the American Welding Society. American Welding Society 2501 N.W. 7th Street Miami, Florida 33125 See "OSHA Safety and Health Standards, 29 CFR 1910", available from U.S. Department of Labor. U.S. Department of Labor Washington, D.C. 20210

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Personal injury can result from flame cutting or welding on painted areas. The effect of gasses from burned paint is a hazard to the person doing the cutting or welding. Do not flame cut or weld on painted areas.

The stops that are located between the bucket and the lift arms are required. The stops prevent damage from occurring to the loader components. The stops must be adjusted properly. External loading of the attachment may result in damage to the tilt linkage and reducing the life of the components.

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

Note: The 950K/ 962K Linkage has been designed with integrated rack stops between the lever and the crossmember and integrated dump stops between the lever and the crossmember, so there should be no modifications to add either rack stops or dump stops between the lift arm and the work tools (pin-on tools or quick coupler).

Illustration 1	g03366101
Full-Rack Position (950K/ 962K) (A) Dump Stop (B) Rack Stop

Illustration 2	g03389218
(C) Intended clearance between lift arm and bucket

Illustration 3	g03366139
Full-Dump Position (950K/ 962K) (A) Dump Stop (B) Rack Stop

Illustration 4	g03366184
(C) Intended clearance between lift arm and bucket

Rack Back Stops (Pin-On Buckets)

The stops may not function properly due to the combined tolerances and the combined clearances. The exact location of the stops for the attachment in relation to the lift arms can only be determined when the two components are pinned together. Install the attachment, and complete the following steps:

1. Move the machine in a location where the ground is as flat, horizontal, and stiff as possible.
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   Illustration 5	g03366194
   (D) Maximum rack (E) Off-rack height

2. Determine the "Offrack height" (E) with an unloaded bucket, raise the lift arm above half height and fully rack the bucket. Lower the lift arm slowly and determine highest lift arm height where either:

   • Gap between lift arm and bucket rack stops is minimum, or

   • where lift arm interferes with bucket rack stops

   Take record of the position of the B-Pin joint from ground line as the "Offrack height".

3. Obtain a full bucket load of the most dense material at the work site. Raise the attachment to the "Offrack height" (E) previously determined. Move the bucket back into the rack position until the limit of the cylinder is reached.
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   Illustration 6	g03366210
   (F) Lift Arm (G) Bucket (H) Stop

4. Measure the gap between the lift arm and the bucket stops at the point for the stops.

5. Use the measured dimensions to create two steel blocks. The width of the blocks must equal the width of the side plate of the lift arm.
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   Illustration 7	g03366212
   (J) 8 mm (0.32 inch) bevel weld (both sides)

6. Identify the point of contact on the attachment for the rack back stops on the lift arm. Weld the block to that point. Chamfer both edges of the block. Weld the blocks with an 8 mm (0.32 inch) bevel weld at location (J). Weld on each side of the block. Refer to Illustration 7.

   Note: Welding the blocks to the side plate of the lift arm may cause the lift arm to fail prematurely. The blocks must be welded only on the attachment.

Rack Back Stops (Fusion Quick Coupler)

1. Repeat Pin-on bucket procedure from Steps 1 through 3, from "Rack Back Stops (Pin-On Buckets)"
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   Illustration 8	g03366214
   (A) Measured clearance

2. Measure the gap between the lift arm and the coupler stops at the point for the stops.

3. Use the measured dimensions to create two steel blocks. The width of the blocks must not exceed the width of the side plate of the lift arm. The length of the block should depend of the welding option described at next step.
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   Illustration 9	g03367176
   Option 1 (A) Extend plate past stop and apply fillet weld at top and bottom only (B) Can weld on top and bottom (C) No weld on side of stop shim

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   Illustration 10	g03367179
   Option 2 (D) Chamfer both edges of the block, weld with bevel weld at top and bottom only (E) Can weld on top and bottom (F) No weld on side of stop shim

4. Weld the blocks inside the coupler stops per one of the two options described below. Weld only on top and bottom of the blocks – Do not weld on side of the blocks. Refer to Illustrations 9 and 10 for location.

   • Option 1: Length of the block = Length of the coupler stop + additional length for fillet welding. Refer to Illustration 9.

   • Option 2: Length of the block = Length of coupler stop, Corners to be chamfered. Refer to Illustration 10.

   Note: Welding the blocks to the side plate of the lift arm may cause the lift arm to fail prematurely. The blocks must be welded only on the attachment.

Dump Stops

The dump stops should contact the loader arms only when the milled surface of the tilt lever and the crossmember make contact. Use the following procedures in order to determine the correct position for the dump stop.

1. Raise the loader arms to the maximum height for the hinge pin. See the Caterpillar specifications for the position of the dump stop.
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   Illustration 11	g03367260
   Full-Dump position (A) Contact between crossmember and lever

2. Slowly place the attachment in the DUMP position. Stop when the tilt lever contacts the lift arm crossmember (A). Refer to Illustration 11.
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   Illustration 12	g03367275
   Full-Dump position (B) Bucket dump stops and lift arms intended to be in contact

3. If contact is made between the dump stops and the loader arms, no adjustment is required. If there is a gap, add material to the bucket so the stops contact the loader arms. Remove material from the bucket stops if the milled surface on the tilt linkage and the crossmember do not make contact. Refer to Illustration 12.

Full-Dump Position (FUSION QUICK COUPLER)

Illustration 13	g03367277
Full-Dump position (FUSION QUICK COUPLER) (C) DO NOT WELD ANY ADDITIONAL SHIM / BLOCK IN THIS AREA

Note: Do not weld spacers to the side plates on the lift arm. This procedure will cause premature failure of the lift arm.

Note: Do not apply to any Fusion Quick Couplers, the bottom area of the Fusion Quick couplers has not been designed to take the loads that are experienced by a dump stop. Welding anything into this area of the Fusion Quick Coupler will cause significant structural issues Refer to Illustration 13.