Caterpillar cat 963 track loader (prefix 29 s) service repair manual (29s00001 and up)

Service Repair Manual
Models
963 TRACK LOADER

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Product: TRACK LOADER
Model: 963 TRACK LOADER 29S
Configuration: 963 TRACK TYPE LOADER 29S00001-UP (MACHINE) POWERED BY 3304 ENGINE
Disassembly and Assembly
963 TRACK-TYPE LOADER
Media Number -SENR2284-00 Publication Date -01/07/1981 Date Updated -11/10/2001
Balancer Shafts
SMCS - 1220-11; 1220-12
Remove Balancer Shafts
start by:
a) remove timing gear cover
b) remove oil pump
1. Remove bolts, lock and washer (1) that hold the balancer shafts in the cylinder block.
2. Remove balancer shaft (2) from the cylinder block.
Install Balancer Shafts
b. Put the engine on top center compression stroke. See FINDING TOP CENTER
COMPRESSION POSITION FOR NO. 1 PISTON in TESTING AND ADJUSTING.
1/2963 TRACK TYPE LOADER 29S00001-UP (MACHINE) POWERED BY 3304 EN...
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2. Put clean engine oil on the balancer shaft. Put balancer shaft (1) in position in the cylinder
block. Install washer (2), locks and bolts.
3. Turn both balancer shafts until the flat part on each shaft is away from the oil pan plate. Install
two 3/8"-16 NC bolts 1 1/2" long through the oil pan plate and into the holes in the balancer
shafts. This will make the shafts so they will not turn. Do not tighten the bolts against the bottom
of the holes in the shafts.
4. Install oil pump. See INSTALL OIL PUMP.
5. Remove the two 3/8"-16 NC bolts from the balancer shafts. Check to see that the balancer shaft
timing is correct. The balancer shaft timing is correct when the holes in the balancer shafts are in
alignment with the holes in the oil pan plate, and No. 1 piston is at top center compression
position.
end by:
a) install timing gear cover
b) install oil pan
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
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Tue Sep 17 11:59:15 UTC+0800 2019

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Balancer Shaft Bearings
SMCS - 1220-28
Remove Balancer Shaft Bearings
start by:
a) remove hydraulic pump gear train
b) remove oil pan
c) remove oil pump
d) remove blanacer shafts

1. Remove the front bearing for the balancer shaft with tooling (A).
2. Remove the center bearing for the balancer shaft with tooling (A).
3. Remove the rear bearing for the balancer shaft with tooling (A).
4. Do Steps 1, 2 and 3 again for the other balancer shaft bearings.
Install Balancer Shaft Bearings
1. Install balancer shaft front bearing (1) with tooling (A). Make sure the oil hole in the bearing is
in alignment with the oil hole in the cylinder block. The bearing must be 0.8 ± 0.5 mm (.03 ± .02
in.) inside the end of the cylinder block after installation.
2. Use tooling (A) to install the balancer shaft center bearing so the front of the bearing is 290.6 ±
0.5 mm (11.44 ± .02 in.) from the front surface of the cylinder block. Make sure the oil hole in the
bearing is in alignment with the oil hole in the cylinder block.

3. Use tooling (A) to install balancer shaft rear bearing (2) so the front of the bearing is 601.0 ±
0.5 mm (23.66 ± .02 in.) from the front surface of the cylinder block. Make sure the oil hole in the
bearing is in alignment with the oil hole in the cylinder block.
end by:
a) install balancer shafts
b) install oil pump
c) install oil pan
d) install hydraulic pump gear train
Tue Sep 17 12:00:04 UTC+0800 2019

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Camshaft
SMCS - 1210-11; 1210-12
Remove Camshaft
start by:
a) remove valve lifters
b) remove timing gear cover
1. Turn the crankshaft until the "C" mark on the crankshaft gear is in alignment with the "C" mark
on the camshaft gear.

NOTE: To keep the engine timing correct during removal and installation of the camshaft, put a
mark on the teeth of the fuel injection pump drive gear and idler gear at location (A). Put a mark
on the teeth of the idler gear and camshaft gear at location (B). The engine timing will be correct
when the marks at locations (A) and (B) are in alignment and the "C" marks on the crankshaft and
camshaft gears are in alignment.
2. Remove bolts (1) that hold!he camshaft gear to the camshaft. Remove the camshaft gear.
3. Bend the locks away from bolts (2). Remove bolts (2), the lock and thrust plate that hold the
camshaft in place.
4. Install a 3/8"-16 NC forged eyebolt in the end of the camshaft. Use the eyebolt and a crow foot
bar to carefully remove camshaft (3). Use extra care not to damage the camshaft bearings as the
camshaft is removed.
Install Camshaft
1. Put clean engine oil on the cams and bearing journals of the camshaft. Install a 3/8"-16 NC
forged eyebolt in the camshaft. Use the eyebolt and a crow foot bar to hold camshaft (1) up during
installation so the camshaft bearings will not be damaged.

2. Install thrust plate (2), the lock and bolts that hold the camshaft in place. Turn the camshaft so
the notch in the end of the camshaft is in the position shown.
3. Put camshaft gear (3) in position on the camshaft so the "C" mark on the camshaft gear is in
alignment with the "C" mark on the crankshaft gear. Install the bolts that hold the camshaft gear in
place and tighten to a torque of 55 ± 7 N·m (41 ± 5 lb.ft.).
NOTE: If the bolts can not be installed in the end of the camshaft, remove the camshaft gear.
Turn the camshaft as needed and install the camshaft gear again. If a replacement of any of the
timing gears was made, it will be necessary to check the engine timing to make sure the timing is
correct. See INSTALL FUEL INJECTION PUMP HOUSING AND GOVERNOR.
end by:
a) install timing gear cover
b) install valve lifters
Tue Sep 17 12:00:54 UTC+0800 2019

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Camshaft Bearings
SMCS - 1211-11; 1211-12
Remove Camshaft Bearings
start by:
b) remove camshaft
c) remove oil pan
1. Remove the camshaft bearings from the cylinder block with tool group (A) and wrench (B).
Start with the front bearing.
Install Camshaft Bearings

TYPICAL EXAMPLE
1. Use tooling (A) and (B) to install the camshaft bearings in the cylinder block. Start with the
front bearing. The bearings must be installed with the oil hole in each bearing in alignment with
the oil holes in the cylinder block and the joint in the bearing toward the center of the block and 8°
± 5° above horizontal. Install the bearings to the dimensions shown in the illustration at the bottom
of the page.

end by:
a) install oil pan
b) install camshaft
c) install hydraulic pump gear train
Tue Sep 17 12:01:43 UTC+0800 2019

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Connecting Rod Bearings
SMCS - 1219-10
Remove And Install Connecting Rod Bearings
start by:
a) remove oil pan plate
1. Turn the crankshaft until two pistons are at bottom center. Remove connecting rod caps (1)
from the two connecting rods. Remove the lower half of the bearings from the caps.
2. Push the connecting rods away from the crankshaft and remove the upper half of the bearings.

3. Clean the surfaces where the bearings fit. Install the upper half of the new bearings in the rods.
Put clean SAE 30 oil on the bearings and crankshaft journals. Put the connecting rods in position
on the crankshaft.
4. Clean the surfaces where the bearings fit. Install the lower half of the new bearings in the caps.
Put clean SAE 30 oil on the bearings, bolt threads and contact surfaces of the nuts.
NOTICE
When connecting rod caps are installed, make sure the number on the
side of the cap is next to and respective with the number on the side of
the connecting rod.
5. Check the bearing clearance with Plastigage. Put caps (1) in position on the connecting rods and
install the nuts. Tighten the nuts to a torque of 41 ± 4 N·m (30 ± 3 lb.ft.). Put a mark on each nut
and the end of each bolt. Tighten the nuts 90° more.
6. Remove the cap. Measure the thickness of the Plastigage. The rod bearing clearance (Plastigage
thickness) must be 0.076 to 0.168 mm (.0030 to .0066 in.) with new bearings. The maximum
permissible clearance is 0.25 mm (.010 in.) with used bearings.
7. Put the caps in position on the connecting rods and install the nuts. Tighten the nuts to a torque
of 30 ± 3 lb.ft.(40 ± 4 N·m). Put a mark on each nut and the end of each bolt. Tighten the nuts 90°
more.
8. Do Steps 1 through 7 again for the other bearings.

end by:
a) install oil pan
Tue Sep 17 12:02:32 UTC+0800 2019

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Crankshaft Main Bearings
SMCS - 1203-11
Remove And Install Crankshaft Main Bearings
start by:
a) remove oil pan
1. Remove the Nos. 1, 3 and 5 main bearing caps (1). Remove the crankshaft thrust bearings from
No. 5 main bearing. Remove lower halves of bearings from the caps.

2. Install tool (A) in the oil hole in the crankshaft journal and remove the upper halves of the main
bearings. As the crankshaft is turned the bearings is moved out of the cylinder block with tool (A).
3. Put clean SAE 30 oil on the upper halves of the new bearings. Install the upper halves of the
main bearings with tool (A).
4. Put clean SAE 30 oil on the new crankshaft thrust bearings and install the bearings with the
steel back, with identification "BLOCK SIDE" against the cylinder block and the tabs on the
thrust bearings in the machined area in the cylinder block.
5. Clean the main bearing caps and install new lower bearing halves (2). Put clean SAE 30 oil on
the bolt threads and surfaces that make contact with the washers.
NOTICE
Make sure part number on cap is toward front of engine, and number
on bottom of cap is the same as number on cap saddle when caps are
installed.
NOTE: The crankshaft must be held up against the upper halves of the bearings before the
clearance in the bearings can be checked.
6. Check the bearing clearance with Plastigage. Install the caps and tighten the bolts to a torque of
41 ± 4 N·m (30 ± 3 lb.ft.). Put a mark on each bolt head and the bearing caps. Tighten the bolts
90° more. Remove bearing caps and measure the width of the Plastigage. The main bearing
clearance (Plastigage width) with new bearings must be 0.076 to 0.165 mm (.0030 to .0065 in.).
Maximum permissible clearance with used bearings is 0.25 mm (.010 in.).
7. Put clean SAE 30 oil on the bottom half of the main bearings. Put caps (1) in position on the
engine and install the washers and bolts. Tighten the bolts to a torque of 41 ± 4 N·m (30 ± 3 lb.ft.).
Put a mark on each bolt head and the bearing caps. Tighten the bolts 90° more.
8. Remove the Nos. 2 and 4 main bearing caps. Do Steps 2, 3, 5, 6 and 7 for the Nos. 2 and 4 main
bearings.
9. Check the crankshaft end play with tooling (C). The end play is controlled by the thrust
bearings on the No. 5 main bearing. End play with new bearings must be 0.064 to 0.368 mm
(.0025 to .0145 in.). The maximum permissible end play with used bearings is 0.64 mm (.025 in.).
end by:

a) install oil pump
b) install oil pan
Tue Sep 17 12:03:22 UTC+0800 2019

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Crankshaft And Gear
SMCS - 1201; 1202; 1204-11; 1204-12
Remove Crankshaft And Gear
start by:
b) remove timing gear cover
c) remove pistons
1. Install a 3/4"-16 NC bolt in the gear end of the crankshaft. Install two 5/8"-18 NF bolts in the
flywheel end of the crankshaft. Fasten a hoist to the crankshaft.
2. Remove main bearing caps (1).

3. Remove the crankshaft from the cylinder block. Weight of the crankshaft is approximately 65
kg (145 lb.).
4. Remove main bearings (2) from the block and from the caps. Remove the thrust bearings.
5. Use tooling (A) to remove gear (3) from the crankshaft.
Install Crankshaft And Gear
TYPICAL EXAMPLE
TYPICAL EXAMPLE
1. Heat the crankshaft gear to a maximum temperature of 315°C (600°F). Install the gear on the
crankshaft with the "C" mark on the gear toward the pulley end of the crankshaft.

2. Clean the surfaces on the cylinder block for the main bearings. Install the upper halves of the
main bearings in the block. Put clean engine oil on the bearings.
3. Turn the camshaft so the "C" mark on the camshaft gear will be toward the "C" mark on the
crankshaft gear when the crankshaft is installed. Put the crankshaft in position in the cylinder
block with a hoist. Make sure the timing marks on the camshaft gear and crankshaft gear are in
alignment as shown.
4. Clean the Nos. 1 and 5 main bearing caps. Install new bearings in the caps. Put clean engine oil
on the bearings. Temporarily install the caps to hold the crankshaft in place.
NOTICE
Make sure part number on cap is toward front of engine, and number
on bottom of cap is the same as number on block when caps are
installed.
5. Clean the Nos. 2, 3 and 4 main bearing caps. Install new bearings in the caps. Put clean engine
oil on the bearings, bolts, threads and surfaces of the washers for the caps.
6. Check the bearing clearance with Plastigage (A). Install the caps and tighten the bolts to a
torque of 41 ± 4 N·m (30 ± 3 lb.ft.). Put a mark on each bolt head and the bearing caps. Tighten
the bolts 90° more. Remove the bearing caps and measure the width of the Plastigage. The main
bearing clearance (Plastigage width) with new bearings must be 0.076 to 0.165 mm (.0030
to .0065 in.). The maximum permissible clearance with used bearings is 0.25 mm (.010 in.).
7. Put the caps in position on the engine and install the washers and bolts. Tighten the bolts to a
torque of 41 ± 4 N·m (30 ± 3 lb.ft.). Put a mark on each bolt head and the bearing caps. Tighten
the bolts 90° more.
8. Remove the Nos. 1 and 5 main bearing caps. Follow the procedure in Steps 5 and 6 and check
the main bearing clearance for the Nos. 1 and 5 main bearings.
9. Follow the procedure in Step 7 and install the No. 1 main bearing cap.

10. Put clean engine oil on thrust bearings (1). Install the bearings with the steel back against the
cylinder block. Install the No. 5 main bearing cap. Tighten the bolts for the cap with the procedure
in Step 7.
11. Check the crankshaft end play with tool group (B). The end play is controlled by the thrust
bearings on the No. 5 main. The end play with new bearings must be 0.064 to 0.368 mm (.0025
to .0145 in.). The maximum permissible end play with used bearings is 0.64 mm (.025 in.).
NOTE: If a replacement has been made for any of the timing gears, it will be necessary to check
the engine timing to make sure it is correct. See INSTALL FUEL INJECTION PUMP HOUSING
AND GOVERNOR.
end by:
a) install pistons
b) install timing gear cover
c) install hydraulic pump gear train
Tue Sep 17 12:04:11 UTC+0800 2019

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Flywheel
SMCS - 1156-10
Remove And Install Flywheel
start by:
a) remove engine
b) remove drive coupling *
*
See POWER TRAIN section.
1. Fasten tool (A) and a hoist to the flywheel. Remove bolts (1) and remove the flywheel. Weight
is approximately 79 kg (176 lb.).
2. Install two 5/8"-18 NF guide bolts in the end of the crankshaft to hold the rear drive gear in
alignment and put the flywheel in alignment at installation.
NOTE: The bolt hole pattern in the rear drive gear and flywheel is not even so the rear drive gear
and flywheel can only be installed in one position.

3. Use tool (A) and a hoist to put flywheel (2) in position on the guide bolts. Install the bolts that
hold the flywheel in place and tighten them to the standard torque of 200 ± 25 N·m (150 ± 20
lb.ft.).
end by:
a) install drive coupling *
b) install engine
*
See POWER TRAIN section.
Tue Sep 17 12:05:00 UTC+0800 2019

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Flywheel Ring Gear
SMCS - 1158-10
Remove And Install Flywheel Ring Gear
start by:
a) remove flywheel
1. Use a punch and hammer to remove ring gear (1) from the flywheel.
2. Heat the ring gear to a maximum temperature of 315° C (600° F). Install the ring gear on the
flywheel with the tooth chamfer up or toward the engine when the flywheel is installed.
end by:
a) install flywheel
Tue Sep 17 12:05:50 UTC+0800 2019

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Flywheel Housing
SMCS - 1157-11; 1157-12
Remove Flywheel Housing
start by:
a) remove flywheel
b) remove starter
1. Fasten a hoist to the flywheel housing. Remove the bolts from the back side of the flywheel
housing, bolts (1), ten bolts (2) and nuts (4) across the bottom of the flywheel housing.
NOTICE
When the flywheel housing is removed, do not let gears (3) fall.
2. Carefully remove the flywheel housing. Weight is approximately 49.5 kg (110 lb.).

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3. Use tooling (A) to remove bearing (5) from the flywheel housing.
Install Flywheel Housing
1. Use tooling (A) to install the bearing in the flywheel housing as shown so the bearing is within
0.8 mm (.031 in.) of the back face of the bearing bore but does not extend beyond that face.
2. Clean the old gasket from the surfaces of the flywheel housing and the housing on the back of
the cylinder block. Install a new gasket on the housing. Put clean oil on the lip of the crankshaft
seal.
3. Install two 1/2"-13 NC guide bolts in the back of the cylinder block. Be sure gears (1) are in
position. Fasten a hoist and put the flywheel housing in position on the guide bolts. Carefully slide
the flywheel housing into position and install the 1/2 in. bolts in the flywheel housing. The two
short bolts go in positions No. 3 and No. 5 in the tightening sequence. When all the 1/2 in. bolts
are installed tighten them in the number sequence shown in picture B36011X1.

4. Install bolts (2) and the bolts on the back side of the housing.
5. Last, install the nuts on studs (3) and tighten them in sequence from the center out each way.
end by:
a) install flywheel
b) install starter
Tue Sep 17 12:06:39 UTC+0800 2019

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Crankshaft Rear Seal
SMCS - 1161-11; 1161-12
Remove Crankshaft Rear Seal
start by:
a) remove flywheel
1. Use tool (A) to remove crankshaft rear seal (1).
2. Inspect the rear drive gear for damage caused by the crankshaft rear seal. If the gear is damaged,
a replacement will be necessary. The flywheel housing must be removed if a replacement of the
rear drive gear is necessary.

Install Crankshaft Rear Seal
1. Install the crankshaft rear seal with tooling (A) as follows:
a) Put the 9S8871 Locator in position on the rear drive gear and install the bolts that hold it in
place.
b) Put clean engine oil on the seal lip and on the outside diameter of the rear drive gear.
c) Put the crankshaft rear seal on the 9S8871 Locator with the lip of the seal toward the engine as
shown. Start the seal on the rear drive gear.
d) Put lubrication on the threads of the stud in the locator and on the washer face of the 9S8858
Nut.
e) Install the 5P7298 Installer and the 9S8858 Nut on the stud of the locator. Tighten the nut until
the installer comes in contact with the face of the locator. The crankshaft rear seal will now be in
the correct location in the flywheel housing.
f) Remove tooling (A) and check the crankshaft rear seal for correct installation. The seal is in the
correct position when the outside face of the seal is 4.1 mm (.161 in.) beyond the outside face of
the rear drive gear.
end by:
a) install flywheel
Tue Sep 17 12:07:28 UTC+0800 2019

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