Caterpillar Cat 963K TRACK LOADER (Prefix YDR) Service Repair Manual (YDR00001 and up).pdf

Service Repair Manual
Models
963K TRACK LOADER

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Product: TRACK LOADER
Model: 963K TRACK LOADER YDR
Configuration: 963K Track-Type Loader YDR00001-UP (MACHINE) POWERED BY C7.1 Engine
Disassembly and Assembly
963K Track Type Loader Machine Systems
Media Number -M0086958-00 Publication Date -01/02/2018 Date Updated -27/02/2018
i06552519
System Pressure - Release
SMCS - 5050-553-PX
Pressure Release Procedure
Personal injury can result from hydraulic oil pressure and hot oil.
Hydraulic oil pressure can remain in the hydraulic system after the
engine has been stopped. Serious injury can be caused if this pressure is
not released before any service is done on the hydraulic system.
Make sure all of the work tools have been lowered to the ground, and
the oil is cool before removing any components or lines. Remove the oil
filler cap only when the engine is stopped, and the filler cap is cool
enough to touch with your bare hand.
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.
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963K Track-Type Loader YDR00001-UP (MACHINE) POWERED BY C7.1 Engine(...
2019/9/8
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Dispose of all fluids according to local regulations and mandates.
1. Move the machine to a smooth, horizontal location that is away from operating machines
and away from personnel.
Note: Permit only one operator on the machine. Keep all other personnel away from the
machine or in the sight of the operator.
2. Place the steering control lever in the NEUTRAL position.
3. Engage the parking brake.
4. Lower the attachments to the ground.
5. Stop the engine.
6. Turn the key to the ON position, but do not start the engine.
7. Verify that the implement shutoff control is not activated.
8. Move the control levers through the full range of travel several times. This step will relieve
any pressure that may be present in the implement hydraulic system.
9. Loosen the filler cap on the hydraulic tank so that the pressure in the tank is released.
10. Tighten the filler cap on the hydraulic tank.
11. The pressure in the hydraulic system has been released and lines or components can be
removed.
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
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Sun Sep 8 16:20:56 UTC+0800 2019
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i06791428
Ripper - Remove and Install
SMCS - 6310-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
1U-9200 Lever Puller Hoist 1
386-6031(1)
Lever Puller Hoist 1
(1)
This part number complies with European requirements.
Start By:
a. Release the system pressure.
Illustration 1 g01017886
Typical Example
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1. Remove bolt (2) and pin (3). Repeat for the other side.
2. Start the engine and retract ripper lift cylinders (1).
Typical Example
3. Secure ripper lift cylinders (1) away from the ripper.
Typical Example
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Typical Example
4. Attach Tooling (A) and a suitable lifting device to ripper (4). The weight of ripper (4) is
approximately 600 kg (1323 lb). Raise ripper (4) off the ground.
5. Remove locknuts (5) from both sides of ripper (4). Remove ripper (4).
Typical Example
6. Remove dowels (6) from both sides of the machine, if necessary.
Installation Procedure
1. Install ripper (4) in the reverse order of removal.
Sun Sep 8 16:21:37 UTC+0800 2019
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i06298578
Ripper Lift Cylinder - Remove and Install
SMCS - 5352-010
Removal Procedure
Start By:
a. Release the hydraulic system pressure.
Cylinders equipped with lock valves can remain pressurized for very
long periods of time, even with the hoses removed.
Failure to relieve pressure before removing a lock valve or
disassembling a cylinder can result in personal injury or death.
Ensure all pressure is relieved before removing a lock valve or
disassembling a cylinder.
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1. Disconnect tube assembly (1) and hose assembly (2) from ripper lift cylinder (3).
Typical Example
2. Attach a suitable lifting device to ripper lift cylinder (3). The weight of ripper lift cylinder (3) is
approximately 54 kg (120 lb).
3. Remove bolt (4) and pin (5).
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Typical Example
4. Position ripper lift cylinder (3) in the horizontal position.
5. Remove bolt (6) in order to remove ripper lift cylinder (3).
Disassembly and Assembly Information
Table 1
Required Tools
A 152-4252 Repair Stand 1
B 195-4609 Seal Pick 1
C - Loctite 609 Retaining Compound -
D 8H-8541 Socket 1
E - Loctite ViperLube High Performance Synthetic Grease -
Cylinders equipped with lock valves can remain pressurized for very
long periods of time, even with the hoses removed.
Failure to relieve pressure before removing a lock valve or
disassembling a cylinder can result in personal injury or death.
Ensure all pressure is relieved before removing a lock valve or
disassembling a cylinder.
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(1) Use Tooling (D) in order to install bolt (1). Tighten nut (1) to a torque of 2100 ± 250 N·m
(1550 ± 185 lb ft).
(2) Apply Tooling (C) to wiper seal groove (2) prior to assembly.
(3) Apply lubrication to the threads of crown (3) with Tooling (E). Tighten crown (3) to a torque of
600 ± 130 N·m (440 ± 95 lb ft).
Note: Lubricate sealing lips with a thin covering of the lubricant that is being sealed.
1. Attach a suitable lifting device to ripper lift cylinder (3).
2. Position ripper lift cylinder (3). The weight of ripper lift cylinder (3) is approximately 54 kg
(120 lb).
3. Install bolt (6).
4. Position ripper lift cylinder (3).
5. Install pin (5) and bolt (4).
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6. Connect tube assembly (1) and hose assembly (2) onto ripper lift cylinder (3).
Sun Sep 8 16:22:18 UTC+0800 2019
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i06293787
Bucket - Remove and Install
SMCS - 6101-010
Removal Procedure
Table 1
Required Tools
A
350-7768 Electric Hydraulic Pump Gp (115V) 1
6V-3175 Double Acting Cylinder 1
9U-6832 Nut 1
4C-9634 Puller Stud 1
9U-5266 Sleeve 1
4K-0684 Hard Washer 1
When you are using hydraulic cylinders and puller studs, always ensure
that the rated capacity of the puller stud meets or exceeds the rated
capacity of the hydraulic cylinder. If the puller stud does not meet or
exceed the rated capacity of the hydraulic cylinder, a sudden failure of
the puller stud could occur. The sudden failure of the puller stud could
result in personal injury or death.
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1. Lower lift arm assembly (1) to suitable cribbing. Rest bucket (2) on the ground.
2. Release the hydraulic system pressure.
3. Attach a suitable lifting device to link and bearing assembly (3).
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4. Remove bolt (5), the washer, and the spacer. Attach Tooling (A) to pin assembly (4). Use
two people in order to remove pin assembly (4) and Tooling (A). The weight of pin
assembly (4) and Tooling (A) is approximately 36 kg (80 lb).
5. Attach a suitable lifting device to bucket (2).
6. Remove bolt (6), the washer, and the spacer. Remove pin assembly (7) and washers (8).
7. Repeat Step 6 for the opposite side.
8. Remove bucket (2). The weight of bucket (2) is approximately 1406 kg (3100 lb).
Table 2
Required Tools
B - Loctite ViperLube High Performance Synthetic Grease -
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NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Coat all the bores for the pin assemblies with Tooling (B).
2. Attach a suitable lifting device to bucket (2) and position bucket (2) to the machine. The
weight of bucket (2) is approximately 1406 kg (3100 lb).
3. Install pin assembly (7) and washers (8). Install bolt (6), the washer, and the spacer.
4. Repeat Step 3 for the opposite side.
Note: Install a minimum amount of one washer (8) on each side. Install additional washers
(8) in order to obtain 1.8 mm (0.07 inch) maximum clearance.
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5. Attach a suitable lifting device to link and bearing assembly (3) and position link and
bearing assembly (3) to bucket (2).
6. Install pin assembly (4). Install bolt (5), the washer, and the spacer.
7. Remove suitable cribbing from lift arm assembly (1).
Sun Sep 8 16:22:59 UTC+0800 2019
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i06293862
Bucket Lever and Link - Remove and Install
SMCS - 6107-010
Removal Procedure
Table 1
Required Tools
A
9U-5266 Sleeve 1
9U-6832 Nut 1
3H-0467 Puller Washer 1
B 350-7768 Electric Hydraulic Pump Gp (115V) 1
9U-6832 Nut 1
4K-0684 Hard Washer 1
9S-5431 Puller Sleeve Assembly 1
5P-8677 Adapter 1
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9S-5433 Puller Adapter 3
5H-6197 Pin 3
8S-6377 Lock pin bolt 3
When you are using hydraulic cylinders and puller studs, always ensure
that the rated capacity of the puller stud meets or exceeds the rated
capacity of the hydraulic cylinder. If the puller stud does not meet or
exceed the rated capacity of the hydraulic cylinder, a sudden failure of
the puller stud could occur. The sudden failure of the puller stud could
result in personal injury or death.
1. Stop the engine with the bucket flat on the ground. Use a suitable lifting device in order to
support link and bearing assembly (1). Remove bolt (3), the washer, and the spacer.
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2. Install Tooling (A). Use a suitable lifting device in order to prevent the Tooling from falling
after the pin assembly is removed. Remove pin assembly (2). Lower the link and bearing
assembly to the ground.
3. Start the engine. Extend or retract the tilt cylinder until the lever and bearing assembly is
vertical.
4. Use a suitable lifting device in order to support tilt cylinder (6). Remove bolt (4), the
washer, and the spacer that holds pin assembly (5) in place. Install Tooling (A) to the pin
assembly. Use a suitable lifting device in order to support Tooling (A). Remove pin
assembly (5). Lower tilt cylinder (6).
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5. Attach a suitable lifting device to the top of the lever and bearing assembly. Remove bolt
(7), the washer, and the spacer from pin assembly (8).
6. Install Tooling (B) to pin assembly (8). Use a suitable lifting device to support Tooling (B)
and the pin assembly (8) to prevent Tooling (B) and pin assembly (8) from falling. Remove
pin assembly (8). Remove bucket lever (9) and the link. The weight of bucket lever (9) and
the link assembly is approximately 288 kg (635 lb).
Table 2
Required Tools
C 9S-5561 Pin Driver Cap 1
D 9S-5562 Pin Driver Cap 1
E - Loctite ViperLube High Performance Synthetic Grease -
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1. Fasten a suitable lifting device to bucket lever (9) and the link assembly. Use a suitable
lifting device in order to install bucket lever (9) and the link assembly. Move bucket lever
(9) and the link assembly into position on the arm and bearing assembly. The weight of
bucket lever (9) and the link assembly is 288 kg (635 lb).
Note: Coat the bore for pin assembly (8) with Tooling (E). Lubricate the lip seals lightly
with the lubricant that is being sealed.
2. Install pin assembly (8) with Tooling (C).
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3. Position pin assembly (8). Install the spacer, the washer, and bolt (7).
4. Fasten a suitable lifting device to tilt cylinder (6) and move the tilt cylinder into position.
5. Start the engine. Extend or retract the tilt cylinder until the hole in the cylinder and the hole
in the lever and bearing assembly are in alignment.
6. Use Tooling (D) in order to install pin assembly (5).
7. Install the spacer, the washer, and bolt (4).
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8. Use a suitable lifting device in order to raise and position link and bearing assembly (1).
Install pin assembly (2), the spacer, the washer, and bolt (3).
Sun Sep 8 16:23:41 UTC+0800 2019
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i06757747
Bucket Lever and Link - Disassemble
SMCS - 6107-015
Disassembly Procedure
Table 1
Required Tools
A 1P-0520 Driver Group 1
Start By:
a. Remove the bucket lever and link.
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1. Remove bolt (4), the washer, and pin assembly (2) to disconnect link and bearing assembly
(3) from bucket lever (1).
2. Remove lip-type seal (5) from both ends of link and bearing assembly (3). Use Tooling (A)
and a suitable press to remove bushings (6) from both ends of link and bearing assembly
(3).
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3. Remove lip-type seal (7) on both sides of bucket lever (1). Use Tooling (A) and a suitable
press to remove bearing (8) from bucket lever (1).
Sun Sep 8 16:24:22 UTC+0800 2019
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2019/9/8

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i06757758
Bucket Lever and Link - Assemble
SMCS - 6107-016
Assembly Procedure
Table 1
Required Tools
A 1P-0520 Driver Gp 1
B - 3% Moly Grease -
1. Lower the temperature of the new bearing. Use Tooling (A) and a suitable press to install
bearing (8) in bucket lever (1).
Note: Lubricate lip-type seals (7) with the lubricant that is being sealed.
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2. Use Tooling (A) to install lip-type seal (7) on both sides of bucket lever (1).
3. Lower the temperature of the new bushings. Use Tooling (A) and a suitable press to install
bushings (6) on both ends of link and bearing assembly (3).
Note: Lubricate lip-type seals (5) with the lubricant that is being sealed.
4. Use Tooling (A) to install lip-type seals (5) on both ends of link and bearing assembly (3).
Note: Use Tooling (B) to coat pin assembly (2) before installation.
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5. Place link and bearing assembly (3) in position in bucket lever (1). Install pin assembly (2)
with the washer and bolt (4).
End By:
a. Install the bucket lever and link.
Sun Sep 8 16:25:03 UTC+0800 2019
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Caterpillar Cat 963K TRACK LOADER (Prefix YDR) Service Repair Manual (YDR00001 and up).pdf

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