Caterpillar cat 963 track loader (prefix 48 z) service repair manual (48z00001 and up)

Service Repair Manual
Models
963 TRACK LOADER

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Product: TRACK LOADER
Model: 963 TRACK LOADER 48Z
Configuration: 963 TRACK TYPE LOADER 48Z00001-UP (MACHINE) POWERED BY 3304 ENGINE
Disassembly and Assembly
26SI Series Alternator
Media Number -RENR1252-01 Publication Date -01/10/1999 Date Updated -09/10/2001
i01167078
Alternator - Assemble
SMCS - 1405-016
Assembly Procedure
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are
worn or damaged, use new parts for replacement.
Note: Do not strike the diodes. The shock of such an impact can damage the diodes. Use
proper tools in order to press the diodes in the mountings.
Illustration 1 g00628072
1. Install 3 diodes (11) in heat sink (12) .
1/10963 TRACK TYPE LOADER 48Z00001-UP (MACHINE) POWERED BY 3304 EN...
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Note: Do not strike the bushing. Shocks from striking the housing can cause damage.
2. Press bushing (43) in housing (14) .
3. Install 3 diodes (13) in housing (14) .
4. Press collar (42) on rotor (39) .
5. Slide retainer (41) on rotor (39) .
6. Press bearing (40) on rotor (39) .

7. Press housing (31) on rotor (39) and bearing (40) .
8. Install 4 screws (38) in housing (31) .
Note: Do not strike the bearing. Shocks from striking the housing can cause damage.
9. Install the inner race. Press bearing (37) into the housing.

10. Press cap (36) in housing (14) .
11. Install the coil and support (34) in housing (14). Guide the field leads and the grommet
through the hole as the coil is installed in housing (14). Install 3 screws (33) .
12. Press the stator (32) and housing (14) together. Guide the stator leads and the grommet
through the hole as the stator is installed in housing (14) .

Note: Do not damage exposed stator windings or field windings. Bumping the windings or
scraping the windings may break the insulation. Broken insulation may create a short circuit
or a ground.
13. Join housing (31) and housing (14). Install 4 bolts (30) .
Note: Many of the alternator's internal components are covered with dielectric grease. If the
grease is removed, reapply the grease.

14. Install Insulator (29). Install the heat sink and diode assembly (12) in housing (14) .
15. Install separator (28) .
16. Install alternator output terminal (27). Install insulator (26). Install the nut and washer (25) .
17. Install diode trio (24) and install screw (23) .

18. Install the 3 screws and insulators (18). Connect wire (19) .
19. If the "R" terminal is used, install the following components: nut (20), lead (21), the washer
and terminal (21) .
20. Install the screw and insulator (16). Connect capacitor lead (17) .
Note: The 3 output diodes (11) are located in heat sink (12). These diodes are identical in
polarity. Diode (11) has red insulation on the wire. The 3 ground diodes (13) are located in
housing (14). These diodes are identical in polarity. Diode (13) has black insulation on the
wire.
21. Connect 6 diode leads. Connect 3 phase leads. Connect 3 stator phase leads. Install 3 nuts
(15).
Table 1

Alternator
Ground
Current Flow of the Output
Diodes
Current Flow of the Ground
Diodes
Negative
Lead to the Heat Sink Housing to the Lead
Red Wire Black Wire
22. Install mounting plate (10).
23. Install regulator (9) .
24. Install grounded mounting screw (8) .

25. Install 2 insulated screws (6). Connect the 3 leads.
Note: The regulator and the mounting plate are coated with dielectric grease. If the grease is
removed, reapply the grease.
26. Install nut (7) and connect the wire.
27. Install gasket (5) .

28. Position cover (4). Install 7 screws (3) .
29. Position plate (2). Install 4 screws (1) .
30. Install the fan, the pulley, the washer, and the pulley nut.
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sun Sep 15 08:42:16 UTC+0800 2019
10/10963 TRACK TYPE LOADER 48Z00001-UP (MACHINE) POWERED BY 3304 E...

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963 TRACK-TYPE LOADER
Media Number -SENR2284-00 Publication Date -01/07/1981 Date Updated -11/10/2001
Air Cleaner Housing
SMCS - 1051-11; 1051-12
Remove Air Cleaner Housing
1. Remove cover (1) from the air cleaner housing.
2. Remove primary filter element (2).
3. Remove eight bolts (3) and secondary filter element (4) from the filter housing.

4. Loosen clamp (5) on the rubber air line to the air cleaner.
5. Remove two nuts (6) and air cleaner housing (7).
Install Air Cleaner Housing
1. Put the gasket and air cleaner housing (2) in position on the air inlet pipe and install the nuts
that hold it in place.
2. Put rubber air line (1) from the precleaner in position on the air cleaner housing and tighten the
clamp to hold it in place.
3. Put secondary filter element (3) in position in the air cleaner housing and install the eight bolts
that hold it in place.

4. Install primary filter element (4).
5. Install the cover on the air cleaner housing and tighten clamp bolts (5) finger tight only. Do not
use a tool to tighten the clamp bolts.
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sun Sep 15 08:45:11 UTC+0800 2019

Shutdown SIS
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963 TRACK-TYPE LOADER
Media Number -SENR2284-00 Publication Date -01/07/1981 Date Updated -11/10/2001
Turbocharger
SMCS - 1052-11; 1052-12; 1052-15; 1052-16
Remove Turbocharger
1. Remove turbocharger oil inlet line (1) and outlet line (2).
2. Remove the bolts that hold exhaust elbow (3) to the exhaust manifold and move the exhaust
elbow and coupling (4) clear of the turbocharger.
3. Loosen clamp (5) on the turbocharger air outlet and clamp (6) on the turbocharger air inlet.

4. Remove four bolts (7). Remove turbocharger (8) from the exhaust manifold and air lines.
Install Turbocharger
1. Install a new gasket (1) if necessary.
2. Put the turbocharger in position on the exhaust manifold and air lines. Put 5P3931 Anti-Seize
Compound on the threads of the bolts that hold the turbocharger to the exhaust manifold. Tighten
the bolts to the standard torque.
3. Put the clamps in position on air lines (2) and tighten them.
4. Put coupling (3) and exhaust elbow (4) in position on the turbocharger and exhaust manifold. Put
5P3931 Anti-Seize Compound on the threads of the bolts that hold the exhaust elbow to the exhaust
manifold. Tighten the bolts to the standard torque.

5. Install the gaskets and turbocharger oil outlet line (5) and oil inlet line (6).
Disassemble Turbocharger
start by:
a) remove turbocharger
1. Put the turbocharger in position tool (A).
2. Put a mark on compressor housing (1) and the backplate assembly for use at assembly. Remove
the compressor housing from the backplate assembly.
3. Change the position of tool (A) so the compressor wheel is up as shown.
4. Put a mark on housing (2) and turbine housing (3) so that the housing can be put back in the same
position in the turbine housing at assembly.

5. Remove the bolts, lockplates and clamps that hold the housing in the turbine housing and remove
the housing.
6. Put the housing in position on tool (B).
7. Use tool (C) and a socket of the correct size to remove nut (5) from the shaft.
NOTICE
Do not put a side force on the shaft when the nut is removed.
8. Remove compressor wheel (4) from the shaft.
9. Remove the housing from the shaft.
10. Remove shroud (6) from the turbine wheel and shaft.
11. Remove seal ring (7) from the turbine wheel.
12. Put a mark on the housing and backplate assembly for use at assembly. Remove the bolts and
plates that hold the housing to the backplate assembly. Remove the housing.

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13. Remove bearing (8), collar (9) and the seal ring from backplate assembly (10).
14. Remove the seal ring and bearing from the collar.
15. Remove seal ring (11) from the housing.
16. Remove the snap ring, bearing (12) and the snap ring from each side of the housing.
Assemble Turbocharger
1. Make sure all oil passages are clean and free of all dirt or foreign material. Put clean engine oil on
all of the parts before assembly.
2. Install the inner snap ring, bearing (1) and snap ring (2) in each side of the housing.
NOTE: The snap rings must be installed with the round side toward the bearing.

3. Install the seal ring on collar (4).
4. Put bearing (3) in position on the collar.
NOTICE
The oil grooves in the bearing must be clean and free of all dirt or
foreign material. The bearing must be installed with the oil grooves
toward the housing.
5. Put the bearing and collar in position on the housing so the oil grooves in the bearing are toward
the housing and the holes in the bearing are in alignment with the pins in the housing.
NOTICE
Be extra careful during installation of the bearing and collar not to
cause damage to the seal ring on the collar.
6. Install the seal ring on the housing.
7. Put the backplate assembly in position on the housing respective to the marks put on the housing
and backplate at disassembly. Install the plates and bolts. Tighten the bolts to a torque of 8.5 - 10.2
N·m (75 - 90 lb.in.).
8. Install shroud (5) on the housing.

9. Put 6V2055 High Vacuum Grease in the groove for seal ring (7). Make sure the grease fills the
groove approximately one half or more of the groove depth for the complete circumference of the
groove to help make a carbon dam under the seal. Install seal ring (7). Carefully install turbine
wheel and shaft (6) in the housing.
10. Put the housing, turbine wheel and shaft and the backplate assembly in position on tool (A).
11. Install compressor wheel (8) on the turbine shaft.
12. Put clean engine oil on the threads of the shaft. Install the nut that holds the compressor wheel in
place. Tighten the nut with tool (D) to a torque of 2.3 N·m (20 lb.in.). Put a mark on the nut and
shaft. Tighten the nut 100° more.
NOTICE
When the nut is tightened, do not put a side force on the shaft.

13. If the turbine housing was removed from tool (B), put the turbine housing in position on tool
(B).
14. Put the housing and wheels in position in the turbine housing respective to the marks put on the
housings at disassembly.
15. Put 5P3931 Anti-Seize Compound on the threads of bolts (9). Install the clamps, lockplates and
the bolts (9). Tighten the bolts to a torque of 13 ± 1.7 N·m (115 ± 15 lb.in.). Bend the lockplates
against the bolt heads.
16. Put compressor housing (10) in position on the backplate assembly respective to the marks put
on the housing and backplate assembly at disassembly.
17. Install the clamps, lockplates and bolts that hold the compressor housing in place. Tighten the
bolts to a torque of 13 ± 1.7 N·m (115 ± 15 lb.in.). Bend the lockplates against the bolt heads.
18. Remove the turbocharger from tool (B).
NOTE: If new components have been installed at assembly and the correct position for the turbine
housing or compressor housing is not known, put the housings in their correct position with the
9S9143 Gauge Group. A line through the center of the openings in the turbine housing and
compressor housing must be at the angle shown. See SPECIAL INSTRUCTIONS FORM
GMG00579.
end by:
a) install turbocharger

Caterpillar cat 963 track loader (prefix 48 z) service repair manual (48z00001 and up)

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Caterpillar cat 963 track loader (prefix 48 z) service repair manual (48z00001 and up)