Caterpillar cat 963 track loader (prefix 29 s) service repair manual (29s01211 and up)

Service Repair Manual
Models
963 TRACK LOADER

Shutdown SIS
Previous Screen
Product: TRACK LOADER
Model: 963 TRACK LOADER 29S
Configuration: 963 TRACK TYPE LOADER 29S01211-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
Transmission
SMCS - 3200-11; 3200-12
Remove Transmission
start by:
a) lift the cab
NOTICE
Be sure the bucket is flat on the floor to prevent possible damage to the
cab when it is tilted.
1. Remove the front guard from under the fuel tank and the guards under the transmission. Weight
of the fuel tank guard is approximately 60 kg (134 lb.). Weight of each transmission guard is
approximately 33 kg (72 lb.).
2. Remove the drain plug and install a 1 in. pipe nipple in the oil pan and drain the oil out of the
transmission. Capacity is approximately 83.5 liter (22 U.S. gal.).
NOTICE
1/16963 TRACK TYPE LOADER 29S01211-UP (MACHINE) POWERED BY 3304 EN...
2019/9/18https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

Put plugs or caps on all oil line openings to keep dirt and foreign
material out of the transmission.
3. Disconnect oil line (1) from the front of the oil pan on the transmission.
4. Disconnect high pressure oil lines (2) for the track motors from both sides of the transmission.
5. Disconnect oil cooler line (3) and case drain line (4) from the rear of the transmission on the left
side.
6. Disconnect case drain line (5) and oil cooler line (6) from the rear of the transmission on the
right side.

7. Install plate and bracket (7) on the front of the cab and frame as shown. The plate and bracket
are kept in the tool box on the machine.
8. Disconnect rod (8) from the lever on the speedbrake control valve stem.
9. Loosen the setscrews in knobs (9) and remove the knobs from the track brake release pump in
the cab. Remove nuts (10) and hand pump for the track brake release from the bottom of the cab.
Disconnect the ground wire from the cab.
10. Disconnect refrigerant lines for the air conditioner at quick-disconnect fittings (11). Install
plugs (12) in the refrigerant lines to keep dirt out.
NOTE: Refrigerant will not be lost if the refrigerant lines are disconnected at quick-disconnect
fittings (11).

11. Disconnect connector (13) in the wire harness for the clutch on the air conditioner compressor.
12. Close the water cocks on the engine and disconnect heater hoses (14) from the tubes on the
cab.
13. Disconnect wire harnesses (15) on the right side of the cab.
The cab must first be put in the 24° position before it is lifted to the 90°
position. Too much load will be put on the tooling if the cab is lifted to
the 90° position from the fully lowered position.
NOTICE
Remove the clamps from pilot oil lines (18) to prevent damage when
the cab is tilted to the 90° position. The bucket must be flat on the
ground to prevent damage to the windshield.
14. If a hoist is available, use the procedure that follows to lift the cab to the 90° position.

a) Remove one bolt and install tooling (A) on the side of the cab as shown. Fasten a hoist to
tooling (A).
Do not fasten a hoist vertically to the lifting eyes on the top of the cab to
tilt the cab to the 90° position. A hoist can overload the lifting eyes and
cause a failure of the eyes which would permit the cab to fall. To
prevent injury always fasten the hoist to tooling (A) on the side of the
cab.
b) Lift the hoist so the hoist will hold the weight of the cab. Remove bolt (17) from the support
bracket and remove the pin from eye (16) on the jack.
c) Tilt the cab to the 90° position with a hoist as shown. Install the bolt and nut in plate and
bracket (7) to hold the cab in the 90° position.
15. If a hoist is not available, use the procedure that follows to lift the cab to the 90° position.
a) Fasten tooling (B) to the bucket and to straps fastened to the front lifting eyes on the cab.
NOTE: The load on tooling (B) will be approximately 900 kg (2000 lb.).
b) Tighten tooling (B) so the tooling will hold the weight of the cab. Remove bolt (17) from the
support bracket and remove the pin from eye (16) on the jack.

c) Install tooling (C) on the back of the cab as shown to hold the cab back so it does not fall
forward when it goes over center.
d) Tilt the cab to the 90° position with tooling (B) and (C) as shown. Install the bolt and nut in
plate and bracket (7) to hold the cab in the 90° position.
16. Disconnect fuel line (19) from the fuel tank and move it to the left.
17. Disconnect oil line (20) from the transmission.
18. Disconnect connector (21) in the wire harness. Remove clip (22) that holds the wire harness to
the transmission and move the wire harness out of the way.
19. Disconnect fuel supply and return lines (23) at the engine.
20. Disconnect rods (24), (25) and (26) from the bellcrank on bracket (27). Remove bracket (27)
from the transmission.

21. Remove clamp (28) and move the suction line for the hydraulic pump out of the way.
22. Remove fill tube (29) for the pump drive and fill tube (30) for the transmission.
23. Use a piece of wire to hold oil lines (32) for the pilot pump out of the way.
24. Remove bolts (31) from both sides of the transmission and remove the top halves of the
transmission mounts.
NOTICE
Be sure the chain and hoist do not damage the linkage on the bottom of
the cab.
25. Loosen the front engine mounting bolts.
26. Fasten chains, tooling (C) and a hoist to the transmission. Lift the transmission just enough to
remove the lower halves of the transmission mounts and the sleeves.

27. Install wood blocks (33) under the flywheel housing. Lower the transmission so the wood
blocks hold the weight of the engine.
28. Remove bolts (34) that hold the transmission to the flywheel housing. Slide transmission (35)
away from the engine and remove from the machine. Weight is approximately 770 kg (1700 lb.).
Install Transmission

1. Be sure O-ring seal (1) is in position on the drive coupling and put clean oil on the O-ring seal.
NOTICE
Use extra care when the transmission is installed so O-ring seal (1) is
not damaged.
2. Fasten chains, tooling (C) and a hoist to the transmission. Put the transmission in position in the
machine and slide into position on the flywheel housing with the splines on the drive coupling in
alignment with the splines in the drive gear in the pump drive housing. Weight of the transmission
is approximately 770 kg (1700 lb.).
3. Install bolts (2) that hold the transmission to the flywheel housing.

4. Lift the transmission and rear of the engine just enough to install the lower halves (3) of the
transmission mounts and the sleeves. Remove the wood blocks from under the flywheel housing.
Lower the transmission and engine on to the mounts.
5. Install the upper halves (4) of the transmission mounts and bolts (5) on both sides of the
transmission. Tighten bolts (5) and the engine front mounting bolts to a torque of 875 ± 100 N·m
(640 ± 80 lb.ft.).
6. Put clamp (6) and the hydraulic pump suction line in position on the transmission and install the
bolts that hold clamp (6) in place. Remove the wire from the pilot pump oil lines.
7. Install fill tube (7) on the pump drive housing and fill tube (8) on the transmission case.
8. Install bracket (12) on the flywheel housing. Connect governor control knobs (9) and (10) and
underspeed override valve control rod (11) to the bellcrank on bracket (12).
10/16963 TRACK TYPE LOADER 29S01211-UP (MACHINE) POWERED BY 3304 E...

9. Connect wire harnesses (13) and install the clip that holds the wire harness to the transmission.
10. Connect fuel supply and return lines (14) at the end.
11. Connect fuel line (15) to the fuel tank.
12. Connect oil line (16) to the transmission as shown. Oil line (16) is the oil pressure supply line
to automatically release the track brakes.
13. Connect case drain line (17) for the left track motor and oil cooler line (18) to the rear of the
transmission on the right side.
14. Connect lower oil cooler line (19) and case drain line (20) for the right track motor to the
transmission on the left side.

15. Connect high pressure oil lines (21) for the track motors to both sides of the transmission.
Tighten the bolts that hold the oil lines to the transmission to a torque of 100 ± 15 N·m (75 ± 10
lb.ft.).
NOTICE
It is very important that the bolts that hold the high pressure oil lines
to the transmission are tightened to the correct torque. A failure of the
seals on the oil lines will be the result if the bolts are not tightened
correctly.
16. Connect oil line (22) to the front of the oil pan on the transmission. Oil line (22) is the supply
line to the hand pump used to manually release the track brakes.
Do not start the engine with the cab platform tilted to the 90° position.
All controls are disconnected which could cause uncontrolled lift arm or
machine movement resulting in injury or component damage. To
prevent injury always lower the cab to the 24° position and connect the
speed-brake control rod before the engine is started.

17. Fasten a hoist to tooling (A).
18. Remove the bolt from bracket and plate (23).
19. Use the hoist to lower the cab. As the cab is lowered, hold bar (25) for the governor control in
alignment with tube (24) so the bar will slide into the tube.
20. Lower the cab until bolt (27) can be installed in the support bracket. Install the pin in eye (26)
to hold the jack to the cab.

21. Remove tooling (A) from the cab and install the original bolt in cab. Tighten the bolt to a
torque of 570 ± 80 N·m (420 ± 60 lb.ft.). Remove the plate and bracket from the front of the cab
and put the tooling in its storage location in the tool box on the machine.
NOTE: If a hoist is not available use tooling (B) and (C) to lower the cab platform.
22. Connect heater hoses (28) to the tubes on the cab and open the water cocks on the engine.
23. Connect wire harnesses (29) on the right side of the cab.

24. Remove the caps and plugs from the refrigerant lines. Connect refrigerant lines (30) to the
quick-disconnect fittings. Put the caps and plugs for the refrigerant lines in their storage locations
(31) on the cab platform.
25. Connect connectors (32) in the wire that goes to the electric clutch on the air conditioner
compressor.
26. Put the hand pump for the track brake release in position on the cab and install the washers and
nuts (33) to hold the pump in position. Install knobs (34) on the stems and tighten the setscrews
that hold the knobs in place. Connect the ground wire to the bottom of the cab.
27. Connect rod end (35) to the speed-brake lever on the transmission.
28. Fill the transmission to the correct level with oil as follows:
a) Fill the transmission filter housing.
b) Fill the transmission to the full mark. Fill the pump drive to the full mark.
c) Start the engine two times at low idle and stop it when the charge pressure gets to 400 kPa (58
psi).
d) Add oil to the transmission until the oil level is at the full mark. After normal start up
procedures, with engine at low idle and oil warm adjust oil level to full mark.
29. Install the front guard under the fuel tank and the guards under the transmission. Weight of the
fuel tank guard is approximately 60 kg (134 lb.). Weight of each transmission guard is
approximately 33 kg (72 lb.).
end by:
a) lower the cab
b) remove air from brakes *

*
For the procedure to remove air from the brakes see TESTING AND ADJUSTING.
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Sep 18 12:23:12 UTC+0800 2019

Shutdown SIS
Previous Screen
Drive Coupling
SMCS - 3279-11; 3279-12
Remove Drive Coupling
start by:
a) remove engine or transmission
1. Remove bolts (1) and drive coupling (2) from the flywheel.
2. Remove O-ring seal (3) from the shaft.

3. Use tool (A) to remove the snap ring from the hub.
4. Use a long punch or a 12.7 mm (.5 in.) bar (4) approximately 254 mm (10 in.) long to remove
the plate from the bottom of the hub.
5. Turn the hub over and use a press to remove shaft (5) from the hub.
Install Drive Coupling

1. Install the O-ring seal on shaft (1) and put clean oil on the O-ring seal. Use a press to install
shaft (1) in the hub as shown.
2. Put 7M7456 Bearing Mount on the outside diameter of plate (2). Use a press to install plate (2)
in the hub as shown.
3. Use tool (A) to install snap ring (3) in the hub.
4. Install O-ring seal (4) on the shaft.
5. Put drive coupling (5) in position on the flywheel and install the bolts that hold it in place.
end by:
a) install engine or transmission

Wed Sep 18 12:24:01 UTC+0800 2019

Shutdown SIS
Previous Screen
Oil Filter Housing
SMCS - 3164-11; 3164-12
Remove Oil Filter Housing
1. Remove bolt (1) that holds the clip to the filter housing.
2. Remove bolts (2) that hold the oil manifold to the filter housing.
3. Remove bolts (3) and filter housing (4). Weight of the filter housing is 18 kg (40 lb.).
Install Oil Filter Housing

1. Be sure O-ring seals (1) are in position on the main control valve, and the O-ring seal is in
position on the oil manifold.
2. Put the filter housing in position on the main control valve and install the bolts that hold it in
place.
3. Install bolts (2) that hold the oil manifold to the oil filter housing.
4. Install the bolt that holds clip (3) to the oil filter housing.
Wed Sep 18 12:24:50 UTC+0800 2019

Shutdown SIS
Previous Screen
Charge Pump (Fixed Displacement)
SMCS - 3204-11; 3204-12; 3204-15; 3204-16
Remove Charge Pump (Fixed Displacement)
NOTE: The removal of the charge pump is shown with the hydrostatic power control unit out of the
machine for better photo illustration only. The charge pump can be removed with the hydrostatic
power control unit in the machine.
1. Drain the oil from the hydrostatic power control unit. Capacity is approximately 60.0 liter (15.9
U.S. gal.).

2. Remove bolts (1) that hold the manifold to the oil filter housing.
3. Remove suction tube (2).
4. Remove two bolts (3) and charge pump (4) from the case.
5. Remove drive shaft (5) for the charge pump from the case.
6. Remove bolts (6) and oil manifold (7) from the charge pump.
Install Charge Pump (Fixed Displacement)

1. Be sure O-ring seal (2) and bolt (3) are in position on the charge pump. Put manifold (1) in
position on the charge pump and install the bolts that hold it in place.
2. Install drive shaft (4) for the charge pump in the case.
3. Be sure O-ring seal (5) is in position on the manifold. Put the charge pump in position on the case
and install the two bolts that hold it in place. Install the three bolts that hold the oil manifold to the
oil filter housing.
4. Install oil suction tube (6).
5. Fill the hydrostatic power control unit with oil to the correct level.
Disassemble Charge Pump (Fixed Displacement)

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start by:
a) remove the charge pump
1. Put identification on the pump for correct assembly.
2. Remove nuts and washers (1) and cover (2). Remove the seal assembly from the cover.
3. Remove wear plate (4) and gears (3) from the pump body.
4. Use a hammer and punch to push against the dowels and remove pump body (5) from the cover.
Remove wear plate (6). Remove the seal assembly from the cover.

5. Use tool (A) to remove snap ring (7) from the cover. Remove seal (8) from the cover.
Assemble Charge Pump (Fixed Displacement)
1. Use tooling (B) to install the seal in cover (2) with the lip in as shown. Use tool (A) to install snap
ring (1) in the cover.
2. Install seal assembly (3) in the cover with the black ring toward the cover.
3. Install wear plate (5) on body (4) with the brass side of the wear plate toward the gears and the
notch in the wear plate in alignment with the notch in the body.
4. Install body (4) on the cover with notches (6) in alignment.
5. Put clean oil on the pump gears and wear plates.

6. Install gears (7) in the pump body and cover with the grooves in the ends of the gears up as
shown.
7. Install wear plate (8) on the pump body with the brass side toward the gears and the notch in the
wear plate in alignment with the notch in the pump body.
8. Install seal assembly (9) in cover (10) with the black ring toward the cover.
9. Install cover (10) with notches (11) in alignment. Install the washers and nuts that hold the pump
together. Tighten the nuts to a torque of 81 ± 7 N·m (61 ± 5 lb.ft.).
end by:
a) install the charge pump
Wed Sep 18 12:25:39 UTC+0800 2019

Shutdown SIS
Previous Screen
Synch Shutoff Valve
SMCS - 3204-11; 3204-12; 3204-15; 3204-16
Remove And Install Synch Shutoff Valve
1. Disconnect balance line (2) from the synch shutoff valve.
2. Remove bolts (1) and synch shutoff valve (3).
3. Be sure O-ring seals (4) are in position on the charge and main relief valve.
4. Put the synch shutoff valve in position on the charge and main relief valve and install the bolts
that hold it in place.
5. Connect the balance line to the synch shutoff valve.
Disassemble And Assemble Synch Shutoff Valve

Caterpillar cat 963 track loader (prefix 29 s) service repair manual (29s01211 and up)

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Caterpillar cat 963 track loader (prefix 29 s) service repair manual (29s01211 and up)