Caterpillar cat 963 c track loader (prefix bbd) service repair manual (bbd00001 and up)

Service Repair Manual
Models
963C TRACK LOADER

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Product: TRACK LOADER
Model: 963C TRACK LOADER BBD
Configuration: 963C TRACK-TYPE LOADER TIER II BBD00001-UP (MACHINE) POWERED BY 3126B Engine
Disassembly and Assembly
3126B Engines for Caterpillar Built Machines
Media Number -SENR9581-06 Publication Date -01/08/2018 Date Updated -17/08/2018
i01516166
Fuel Transfer Pump - Remove - If Equipped
SMCS - 1256-011
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
Dispose of all fluids according to local regulations and mandates.
1/2963C TRACK-TYPE LOADER TIER II BBD00001-UP (MACHINE) POWERED B...
2019/9/6https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisw...

Illustration 1 g00644483
1. Remove the fuel inlet line and the fuel outlet line from fuel transfer pump (4). Immediately
cap fuel inlet (1) and fuel outlet (2) or plug fuel inlet (1) and fuel outlet (2) in order to
prevent contamination.
2. Remove two bolts (3) and fuel transfer pump (4) from the unit injector hydraulic pump.
3. Remove the O-ring seal from the unit injector hydraulic pump. Inspect the O-ring seal for
wear or damage. If the O-ring seal is worn or damaged, use a new part for replacement.
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Sep 6 12:05:24 UTC+0800 2019

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i04404120
Fuel Transfer Pump - Install - If Equipped
SMCS - 1256-012
Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1U-6396 O-Ring Assembly Compound 1
B 161-9203 Grease Cartridge 1
NOTICE
1. Clean all components and the mating surfaces. Inspect all components. If any component is
worn or damaged, use a new part for replacement.
2. Lubricate the O-ring seal with Tooling (A) and install the O-ring seal on the unit injector
hydraulic pump.
3. Use your finger to apply a small amount of Tooling (B) on the splines of the unit injector
hydraulic pump. Only a small amount of grease is required to evenly coat the splines.

4. Position fuel transfer pump (4) on the unit injector hydraulic pump and install two bolts (3) .
5. Remove the plugs on fuel outlet (2) and fuel inlet (1) .
6. Install the fuel outlet line and the fuel inlet line.
Fri Sep 6 12:06:05 UTC+0800 2019

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i01378042
Fuel Pressure Regulator - Remove and Install
SMCS - 1715-010
Removal Procedure
NOTICE
1. Remove fuel pressure regulator (1) from the rear of the cylinder head.

2. Remove O-ring seal (2) from fuel pressure regulator (1).
NOTICE
1. Ensure that the orifice in fuel pressure regulator (1) is open and clean. Install a new O-ring
seal (2) on fuel pressure regulator (1).

2. Install fuel pressure regulator (1) in the rear of the cylinder head.
Fri Sep 6 12:06:46 UTC+0800 2019

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i01976263
Unit Injector - Remove
SMCS - 1290-011
Removal Procedure
Table 1
Required Tools
A 1U-7587 Pry Bar 1
B(1)
4C-5027 Tap Wrench 1
4C-6161 Tube Brush 1
4C-6774 Vacuum Gun Kit 1
8T-7765 Surface Reconditioning Pad 1
1U-5512 Abrasive Material 1
9U-6102 Reamer 1
9U-6862 Tapered Brush 1
C(2)
4C-4057 Tube 1
1U-5718 Vacuum Pump 1
1U-5814 Bottle Assembly 1
(1)
Tools for cleaning carbon deposits from the injector sleeve bores
(2)
Tools for evacuating fuel from the cylinders
Start By:

a. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve
Mechanism Cover - Remove and Install".
NOTICE
NOTICE
containing fluids.
Cat products.
Removal Of The Injector

1. Remove oil drain plugs (1) at each end of the cylinder head.
2. Allow the engine oil to drain from the ports in the cylinder head before the injector is
removed.
3. Disconnect harness connector (2).

Note: Some of these engines were built without the deflector. During the installation of the
unit injectors, the deflectors (Y) should be installed.
4. Remove bolt (3).
5. Remove bolt (4).

6. Place Tooling (A) under clamp (5) on the flywheel side of the injector.
7. Tooling (A) should be placed at this location in order to gently remove the injector. Use
Tooling (A) to remove the injector.
8. Do not pry at location (Z).
9. Remove the O-Ring seals (6) from the injector.
10. Repeat Step 3 through Step 9 for the remainder of the injectors.
Steps For Cleaning The Carbon Deposits

Cleanliness is very important in the area around the sleeve and the sleeve bore when you are
reinstalling the injector. This injector has a metal seal (7) between the bottom of the injector's case
and a seat in the cylinder head. Clean the carbon from the seat area that is inside of the cylinder
head. Also clean the carbon from the end of the injector if the injector should be reinstalled.
The fine grade of the Scotch Brite material is preferred. Scotch Brite is available from the Tools
And Shop Products Guide as the abrasive material and as the surface reconditioning pad.
If the sleeve of the injector has been removed from the engine, use a reamer to remove carbon
deposits from the angled surface.
Note: Do not use the reamer in order to remove metal from the sleeve. Use the reamer in order to
remove carbon only.
If the sleeve of the injector is installed in the engine, use the tube brush to clean the carbon
deposits from the inside of the sleeve.
If you choose to clean the angled seat on the injector with a wire brush, the wire brush should not
contact the tip of the injector. Failure of the tip and major engine damage may result.
Note: Using power tools in order to rotate the material should not be necessary. The carbon in the
sleeve is more removable than the carbon at locations that are exposed to higher temperatures.
The following procedure is the preferred method of cleaning the sleeve bore.
1. Place a 38 mm (1.5 inch) square piece of Scotch Brite material on the end of a tapered
brush.
2. Twist the tapered brush with the tap wrench against the lower surface of the sleeve bore.
3. The surface should be cleaned until the surface is smooth and shiny. The entire sleeve bore
should be cleaned in order to remove any loose carbon particles.
Note: A vacuum gun kit is available in order to clean the loose material from the sleeve bore.

Evacuation Of Fuel And Oil From The Cylinder
Evacuate as much fuel and oil as possible from the cylinder before installation of the injector. Use
Tooling (C) to evacuate the fuel. Several evacuations may be necessary.
Fri Sep 6 12:07:27 UTC+0800 2019

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i05042449
Unit Injector - Install
SMCS - 1290-012
Table 1
Required Tools
A 149-2955 Seal Protector 1
B 149-2956 Seal Installer 1
C 152-1057 Fuel Injector Installer 1
NOTICE
NOTICE
The correct procedures and tooling specifications must always be used.
Failure to follow any of the procedures may result in damage,
malfunction, or possible engine failure.

1. Install oil drain plugs (8) .

This illustration is of the 154-8016 Fuel Injector Seals .
(14) Metal Seal
(15) 133-3715 Backup Ring
(17) 9X-7557 O-Ring Seal
(18) 148-2903 O-Ring Seal
(20) 109-3207 O-Ring Seal

(A) 149-2955 Seal Protector
(B) 149-2956 Seal Installer
NOTICE
The correct procedures and tooling specifications must always be used.
Failure to follow any of the procedures may result in damage,
malfunction, or possible engine failure.
Note: Install the upper seal pack first. Then install the middle seal pack. Finally, install the bottom O
-Ring Seal.
2. Both the 149-2955 Seal Protector (A) and the 149-2956 Seal Installer (B) should be used when you
are installing the upper high-pressure seals.
Note: New seals should be installed after each removal of the injector from the engine.
3. Lubricate the O-Ring seals and the sleeve bore of the injector sparingly with clean engine oil.
Note: Proper installation of the injector is important. Damage to the upper high-pressure seals can
cause excessive oil leakage under the valve cover. Damage to the upper high-pressure seals may

cause the engine not to start due to a low actuation pressure. Damage to the lower high-pressure seals
may allow high-pressure oil to leak into the fuel supply passage. Damage to the lower-pressure seals
will result in excessive oil consumption.
(X) 8T-2396 Bolts .
(Y) 159-0288 Deflector .
Note: Some of these engines were built without the 159-0288 Deflector . During the installation of
the unit injectors, the deflectors should be installed. Six 159-0288 Deflectors and six 8T-2396 Bolts
are required for each engine. These new deflectors and bolts replace the former 6V-8653 Bolts .

(C) 152-1057 Fuel Injector Installer
4. Carefully install the injector into the injector bore. If access permits you to seat the injector, push the
injector straight down on top of the injectors solenoid by hand until the injector is firmly seated in
the injector bore. Pushing hard enough to compress the injector seals may be difficult. If the injector
cannot be seated by hand, use a 152-1057 Fuel Injector Installer (C) .
Note: Do NOT pry on the top of the injector with another tool. Do NOT strike the injector with
a hammer. Damage to the injector will result. Damage to the injector that is due to improper
installation is not a warrantable failure.
(2) Wiring Harness Connection
(3) Clamp
(10) Shoulder Bolt
(11) Socket Head Bolt
Note: Do not use the shoulder bolt and the socket head bolt in order to seat the injector. If a side load
is placed on the bolts, the bolts may fail.
Note: Install new bolts (10) and (11) .

5. After the injector is seated, position the clamp (2) and tighten the Shoulder Bolt (10) to a torque of 6
N·m (50 lb in). Then tighten the Socket Head Bolt (11) to a torque of 12 N·m (9 lb ft).
6. Insert the harness connectors (2) back into the injector solenoids. Ensure that the clips are snapped
back into the proper position.
7. Check the system for leaks by using the following procedure.
Check the Fuel System for Leaks
1. Visually inspect the components of the injector for oil leaks around the outside diameter.
2. Disconnect the injector wiring harness with the 12-pin connector. The harness is located between the
hydraulic pump and the cylinder head. Disconnect the Injection Actuation Pressure Sensor
connector. This connector is located on the top of the unit injector hydraulic pump. The oil pressure
should raise to about 2500 psi.
3. Crank the engine in order to allow the actuation pressure to rise. Cranking the engine also purges the
air from the system.
4. Visually check for oil leaks in the area that is between the outside diameter of the injector and the
cylinder block.
Note: A small amount of seepage from the injectors vent hole during cranking is normal. A large
steady flow from one injector that is greater than the flow from the other injectors may indicate a
problem with that injector.
5. If no leaks are found, connect the injector wiring harness.
6. Start the engine.
7. Check for oil leaks while the engine is running at idle.
8. If no leaks are found, install the ET or other electronic service tools and clear all codes.
End By: Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism
Cover - Remove and Install".
Fri Sep 6 12:08:08 UTC+0800 2019

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i04466734
Unit Injector Sleeve - Remove
SMCS - 1713-011
Removal Procedure
Table 1
Required Tools
A 151-4832 Injector Sleeve Tool 1
Start By:
a. Remove the unit injectors. Refer to Disassembly and Assembly, "Unit Injector - Remove".
NOTICE

1. Install Tooling (A) into unit injector sleeve (1).
2. Use Tooling (A) in order to remove unit injector sleeve (1) from the cylinder head.
3. Remove O-ring seals (2) from unit injector sleeve (1).
Fri Sep 6 12:08:49 UTC+0800 2019

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i07032358
Unit Injector Sleeve - Install
SMCS - 1713-012
Table 1
Required Tools
B 221-9777 Sleeve Installer Tool 1
C - Loctite 620 -1
NOTICE

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1. Install two new O-ring seals (2) on unit injector sleeve (1).
2. Place unit injector sleeve (1) on Tooling (B).

3. Lubricate the new O-ring seals with clean engine oil.
4. Apply Tooling (C) to the base of the injector sleeve bore that is indicated by Dimension (A).
5. Use Tooling (B) and a hammer to install the unit injector sleeve in the cylinder head.
End By:
a. Install the unit injectors. Refer to Disassembly and Assembly, "Unit Injector - Install".
Fri Sep 6 12:09:30 UTC+0800 2019

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i02366599
Injection Actuation Pressure Control Valve - Remove and
Install
SMCS - 5051-010
Removal Procedure
Table 1
Required Tools
A 5P-0333 Crowfoot Wrench 1
NOTICE
NOTICE
containing fluids.

Cat products.
1. Disconnect harness assembly (2) from injection actuation pressure control valve (1).

2. Remove nut (3), spacer (5), and solenoid valve (4) from injection actuation pressure control
valve (1).
3. Use Tooling (A) and an extension in order to remove the injection actuation pressure control
valve from the unit injector hydraulic pump.
4. Remove O-ring seals (6) and (8), and backup ring (7) from injection actuation pressure
control valve (1).
Table 2
Required Tools
A 5P-0333 Crowfoot Wrench 1
NOTICE

Caterpillar cat 963 c track loader (prefix bbd) service repair manual (bbd00001 and up)

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