Caterpillar cat 963 track loader (prefix 21 z) service repair manual (21z00001 and up)

Service Repair Manual
Models
963 TRACK LOADER

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Product: TRACK LOADER
Model: 963 TRACK LOADER 21Z
Configuration: 963 LGP TRACK LOADER 21Z00001-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
Engine Oil Cooler
SMCS - 1264-15; 1264-16
Remove And Install Engine Oil Cooler
start by:
a) remove oil filter element
1. Drain the coolant from the engine.
2. Loosen clamp (1).
3. Remove four bolts (2) that hold the oil cooler to the water pipe.
4. Remove four bolts (3) that hold the oil filter base to the oil cooler.
1/3963 LGP TRACK LOADER 21Z00001-UP (MACHINE) POWERED BY 3304 ENGI...
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5. Move the oil cooler (4) up and away from the engine.
6. Remove the nut (one) and bolts (three) that holds the cover (5) to the oil cooler body.
7. Clean the tubes of the engine oil cooler with a 4 mm (.157 in.) diameter rod.
8. Inspect the gasket and make a replacement if necessary. Put cover (5) on oil cooler body and
install nut (one) and bolts (three).
9. Put O-ring seals (6) on oil filter base.

10. Inspect gasket (7) and make a replacement if necessary. Put oil cooler into hose and move oil
cooler toward engine.
11. Install the bolts (2) that hold the oil cooler to the water pipe.
12. Fill the cooling system with coolant to the correct level. See the MAINTENANCE GUIDE.
end by:
a) install oil filter element
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Thu Sep 19 01:50:02 UTC+0800 2019

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Oil Filter Base
SMCS - 1306-15; 1306-16
Disassemble Oil Filter Base
Cover (1) is under spring tension.
1. Remove cover (1) for the oil cooler bypass valve.
2. Remove oil cooler bypass plunger (2) and spring (3).

Cover (4) is under spring tension.
3. Remove cover (4) for the oil filter bypass valve.
4. Remove oil filter bypass plunger (5) and spring (6).
Assemble Oil Filter Base
1. Make an inspection of the parts and make a replacement if necessary.
2. Put clean engine oil on each plunger and install in the original bore.
NOTE: The plungers must move freely in their respective bores.
3. Install the remainder of parts.
Thu Sep 19 01:51:02 UTC+0800 2019

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Oil Pan And Oil Pan Plate
SMCS - 1302-11; 1302-12
Remove Oil Pan And Oil Pan Plate
1. Remove the guard below the engine. Weight is approximately 32 kg (70 lb.).
2. Remove drain plug (2) and drain the oil from the oil pan. Oil volume is approximately 15 liter
(4 U.S. gal.).
3. Loosen the lower fitting (1) that holds oil level gauge tube to the oil pan.
4. Loosen primary fuel filter mounting bracket (3) to let oil pan clear mounting bracket.
5. Remove bolts holding oil pan to oil pan plate. Remove oil pan.

6. Disconnect scavenge tube assembly (4) from the oil pump.
7. Remove the remainder of the bolts that hold oil pan plate (5) to the engine block. Remove the
oil pan plate.
Install Oil Pan And Oil Pan Plate
1. Inspect the oil pan plate gasket (1) and make a replacement if necessary. Inspect the scavenge
tube gasket (2) and make a replacement if necessary.
2. Put the oil pan plate in position and install the bolts. Connect the scavenge tube to the oil pump.
3. Inspect the oil pan gasket and make a replacement if necessary.
4. Put oil pan (3) in position and install bolts.

5. Put fuel filter mounting bracket in position and install oil pan bolts.
6. Tighten oil level gauge connection.
7. Install the guard below the engine. Weight is approximately 32 kg (70 lb.).
end by:
a) fill the crankcase with oil to the correct level (see MAINTENANCE GUIDE)
Thu Sep 19 01:52:01 UTC+0800 2019

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Oil Pump
SMCS - 1304-15; 1304-16; 1304-11; 1304-12

Remove Oil Pump
start by:
a) remove oil pan

1. Loosen bolts (1) and tube assembly (2) from oil pump.
NOTICE
The larger gear is not fastened to the pump.
2. Remove four bolts (3), locks and remove the oil pump (4). The weight of the oil pump is 16 kg
(35 lb.).
Install Oil Pump
1. Turn the crankshaft until the No. 1 piston is at the top center compression position. See
INSTALL FUEL INJECTION PUMP HOUSING AND GOVERNOR.
2. 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) 11/2" 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.
3. Put the oil pump (3) in position on the engine block and install the locks (left side only) and
bolts that hold the oil pump in place.

NOTE: Surface (2) of the oil pump must be free of lock tabs.
4. Remove bolts (1). 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 the top center compression position.
5. Put tube assembly (4) in place on oil pump and install bolts.
end by:
a) install oil pan
Disassemble Oil Pump
start by:
a) remove oil pump
1. Remove idler gear (2).
2. Remove bearing (1) from gear (2) with tooling (B).

3. Remove the bolt and the washer from the oil pump drive gear.
4. Remove the drive gear from the shaft with tooling (A).
5. Remove the key from the pump shaft.
6. Remove bolts (3) from the pump body.
7. Remove body (8), two gears (7), keys and spacer (4) from the pump.
8. Remove two shafts (5) and the gears.
9. Remove bolts (6), the cover and the pressure relief valve from the body.
10. Remove the bearings from the oil pump body assembly and the scavenge pump body assembly
with tooling (C).
Assemble Oil Pump

1. Install the bearings in the scavenge pump body assembly with tooling (A) as follows:
a) Put bearings (1) in position on the inside of the scavenge pump body assembly with the
chamfer on the bearing toward the outside of the pump body. Install the bearing until it is .060 in.
(1.52 mm) below the inside machined surface of the scavenge pump body assembly. Make sure
the joints in the bearings are at an angle of 30° ± 15° from the center line through the bores in the
scavenge pump body and toward the outlet passage of the pump. The outlet passage has a cavity
between the bearing bores.
2. Install the bearings in oil pump body assembly with tooling (A) as follows:

a) Put bearings (2) in position on the inside of the oil pump body assembly with the chamfer on
the bearings toward the outside of the pump body. Install the bearings until they are even with the
outside of the pump body. Make sure the joints in the bearings are at an angle of 30° ± 15° from
the centerline through the bearing bores and toward the outlet passage of the pump. The outlet
passage has a cavity between the bearing bores.
3. Check the condition of the relief valve. Check the condition and specifications for all the parts
of the oil pump before it is assembled. See OIL PUMP (2P1785) in SPECIFICATIONS.
4. Put clean engine on all of the parts of the oil pump.

5. Install pressure relief valve (3), cover (4) and bolt (5) in the oil pump body assembly.
6. Install gears and shafts (6) in the oil pump body assembly.
7. Install spacer (7) and the two keys in shafts (6).
8. Install two gears and scavenge pump body assembly (8).
9. Install key (9), drive gear (11), the washer and bolt (10). Tighten the bolt to a torque of 43 ± 7
N·m (32 ± 5 lb.ft.).
10. Install the bearing in the idler gear with tooling (B) until it is even with the outside surface of
the gear.
11. Install the idler gear (13) and suction bell (12).

NOTICE
The oil pump must turn freely by hand after it is assembled.
end by:
a) install oil pump
Thu Sep 19 01:53:00 UTC+0800 2019

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Piston Cooling Orifices
SMCS - 1307-10
Remove And Install Piston Cooling Orifices
start by:
a) remove crankshaft and gear
NOTE: The piston cooling orifices are installed in the No. 2 and 4 main bearing bosses in the
cylinder block.

FOUR CYLINDER ENGINE
1. Use a soft punch to remove the orifices from the cylinder block.
2. Use tool (A) to install the orifices in main bearing bosses No. 2 and 4 until they are against the
counterbore. Be sure the orifices are open after they are installed.
end by:
a) install crankshaft and gear
Thu Sep 19 01:53:59 UTC+0800 2019

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Engine
SMCS - 1000-11; 1000-12
Remove Engine
start by:
a) remove radiator and guard
b) remove air cleaner housing
c) lift cab *
See Vehicle Systems section.
1. Remove the guards below the engine. Weight is approximately 33 kg (72 lb.) each.
2. Drain the hydraulic tank. Capacity is approximately 98 liter (26 U.S. gal.).

3. Remove oil fill tube and oil level gauge tube (1) from the engine.
4. Disconnect the wire harness connectors at location (2).
5. Disconnect oil inlet line (3) and oil outlet lines (4) from the hydraulic pump. Put plugs in the
openings.
6. Disconnect air cleaner indicator line (5) from the air pipe.
7. Disconnect heater hoses (6) from the engine and remove the bolt from the clip that holds the
heater hoses to the cylinder head.
8. Remove clip (7) that holds the oil line to the support.
9. Remove two bolts (8) and move pilot pump (9) away from the flywheel housing.

10. Remove brace (10).
11. Remove bolts (11) and the lower half of the mounts from both sides of the engine front
support.
12. Put identification on wires (12) and disconnect them from the starter.
13. Disconnect refrigerant lines for the air conditioner at quick-disconnect fittings (13). Install
plugs (14) in the refrigerant lines to keep dirt out.
NOTE: Refrigerant will not be lost when the refrigerant lines are disconnected at quick-
disconnect fittings (13).
14. Disconnect connector (15) in the wire harness for the clutch on the air conditioner compressor.

15. Remove bolt (16) from the bracket that holds the transmission oil cooler line to the engine.
16. Disconnect governor linkage (17) and (18) from the bellcrank.
17. Remove the bolts that hold bracket (19) to the flywheel housing and move the bracket and
linkage clear of the flywheel housing.
18. Disconnect connector (20) in the wire harness for the transmission.
19. Loosen the hose clamps and disconnect fuel lines (21). Put plugs in the fuel lines.

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20. Disconnect rod end (22) from the speed-brake lever on the transmission.
21. Loosen the setscrews in knobs (23). Hold the pump and valve stems and loosen knobs (23) and
remove.
22. Remove nuts (24) and hand pump (25) for the track brake release from the bottom of the cab.
23. Disconnect ground wire (26) from the cab.
24. Disconnect the connectors at location (27) in the wire harness for the cab.

25. Install plate and bracket (28) on the front of the cab and frame as shown. The plate and bracket
are kept in the tool box on the machine.
26. Remove one bolt and install tool (A) on the side of the cab as shown. Fasten a hoist to tool
(A). Lift the hoist so the hoist will hold the weight of the cab. Remove support bracket (29) and
remove the pin from eye (30) on the jack.
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.
NOTICE
To prevent damage to the pilot oil lines to the cab when the cab is tilted
to the 90° position, remove the clamps from the oil lines. Also the

bucket must be flat on the ground to prevent damage to the windshield
by the tilt cylinder.
27. Tilt the cab to the 90° position with a hoist as shown. Install the bolt and nut in plate and
bracket (28) to hold the cab in the 90° position.
NOTE: On machines that do not have a ROPS or enclosed cab it will be necessary to use tool (B)
in addition to a hoist to pull the cab platform completely forward so the bolt and nut can be
installed in plate and bracket (28). Still use a hoist to lift the cab platform as far as possible.
28. Fasten tooling (C), chains and a hoist to the engine.
29. Remove bolts (31) that hold the flywheel housing to the transmission. Slide the engine straight
back to disengage the drive coupling from the transmission. Carefully remove the engine from the
machine. Weight is approximately 1730 kg (3833 lb.).
Install Engine

1. Fasten tooling (C), chains and a hoist to the engine. Be sure the O-ring seal is in position on the
drive coupling. Carefully put the engine in position in the machine. The splines on the drive
coupling must engage in the splines of the gear in the pump drive in the transmission. Weight of
the engine is approximately 1730 kg (3833 lb.).
2. Install bolts (1) that hold the flywheel housing to the transmission. Start with the top bolts.
3. Be sure the top halves of rubber mounts (4) are in position under both sides of the engine front
support. Install bolts (2), sleeves (3), bottom halves of rubber mounts (4) and the nuts on both
sides of the engine front support. Tighten bolts (2) to a torque of 875 ± 100 N·m (640 ± 80 lb.ft.).
Do not start the engine with the cab platform tilted to the 90° position.
All controls are disconnected which can cause uncontrolled lift arm or
machine movement. Injury or component damage can be the result. To
prevent injury always lower the cab to the 24 ° position and connect the
speed-brake control rod before the engine is started.

Caterpillar cat 963 track loader (prefix 21 z) service repair manual (21z00001 and up)

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