Parts Manual

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF

CATERPILLAR OR IT’S SUCCESSORS. CATERPILLAR AND IT’S SUCCESSORS

ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS,

AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

Parts

Man

ual

963 Traxcavator

S/n 6Z1 & Up

CT-P-963TX6Z1

."

CONTE ALPHABE .. CALINDEXQF GROUPS __ 3 QU;ICK CONVERSION EQUIVALENT.' ." tAB~ES. ". "NSIDE SACK. COVER ORDERIN'~.;PA~rS~~ ..... ';'~~-~-_ ... ':' ___ 2

. QUICKREFE~ENCE -;, ,. "CHART'> ...•....... I.NSIDE.,FR()NT, COVER·

USINGTH ERAR"F$.aQ,AK:-~.:;-- ,... - -'- --2

PARTSB·OOK

. 963 TRACK LOADER POWERED BY 3304 ENGINE· SERIAL NUMBER 6Z1 .. UP (VEHJCLE) 7Z1055-UP(ENG INE)·

. 4TA1-UP (TRANSMISSION) 63Y·l-UP (RIPPER) ..

PUBLISHEO"IVIA Y1981 . CATERPfLlARTRACtORCO. PUBLICATIONS[)IV.--S~RVICE G.p. PEORIA,ILL."U.S.A.

:: . ." ~ .. . . :.: .Of:.·· .. ·

OC,:., .

··.~:z~

1 "':'J .-,

I

IN D EX ENGINE ARRANGEMENTS ARE LISTED STARTING ON PAGE 6

A

Name Page

Air Cleaner ....................... 41

Air Conditioner .................... 243 Air Conditioner Arrangement ....... 242 Air Conditioner Lines ............... 245 Air Conditioner Lines -Cab ........ 246

Air Conditioner Wiring ............. 244 Air Lines ...........•.............. 42

Air' Lines - Engine ................. .43

Alternator ... 0 . 0 0 •• 0 • 0 0 • 0 0 • 0 • 0 0 0 • 0 76 Axial Piston Pump - Variable

Displacement 0 • 0 0 •• 0 •• 0 •• 0 ••• 0 •• 118

B

Back-Up Warning 0 0 • 0 •• 0 ••••• 0 •••• 90 Balancer ... 0 • 0 ••• 0 •••• 0 •••• 0 ••• 0 • 0 ·12

Battery .0 00 0 • 0 •••••• 0.00 0 0 0 • 0 ••• 0. 57 Battery Box . 0 0 •••••• ; 0 ••••••• 0 0 • •• 74 Battery & Wiring ..... 0 • 0 •••• 0 • 0 • o. 66

Bearings - Camshaft . 0 0 • 0 0 • 0 •••• 0 •• 8

Bit & Cutting Edge ... 0 •••• 0 • 0 •••••• 222 Brake Control 0 0 •• 0 0 0 •• 0 • 0 0 •••••••• 132

Breather - Crankcase ...... 0 • • • • • •• 29 Bucket - General Purpose .... 0 •• 0 •• 221

Bucket Control ............. 0 • 0 ••••• 218

Bucket Cylinder o. 0 0 0 0 0 0 0 • 0 ••••••••• 215

c Cab Heater ... 0 . 0 ••• 0 • 0 •• 0 .•••• 0 •• 248

Name Page

Cab Heater Arrangement .. 0 0 • 0 0 •• 0 0242

Cab Heater Lines ... 0 •• 0 0 • 0 0 0 0 0 0 •• 0247

Cab Pressurizer o. 0 0 0 •• 0 0 ••• 0 ••• 0 0 •• 234

Camshaft 0 0 0.0 • 0 0 •••• 0 •••••••••••• '. 11

Condenser - Air Conditioner .. 0 .0. 0.250

Connecting Rod & Piston . 0 0 . 0 • 0 •• • . .12

Control - Speed & Direction ','" 0 • 0 0 1 O~ ,.

Cover - Cylinder Block . - . ,. ........ " ... . Cover - Cylinder Head 0 •••• 0 •• 00.0 l4

Cover - Open ROPS. 0 0 '0 0 • 0 ••• 0 • •• 86

Cover - ROPS .. 0 0 0 •••• o •• 0 ••• 0 0 •. ~,231

Crankshaft ................. 0 •• 0 0 •• 9

Crankshaft Bearing Replacements o. 0 0 11

Crankshaft Pulley 0.0 •••••••• 0 •••• o. 21

Crankshaft Seal ..... 0 • 0 0 0 •••• 0 0 0 •• , 10

Cutting Edge - Bucket .. 0 • 0 •••• 0 ••• 222

Cylinder Block 0 0 • 0 • 0 • o •••• 0 0 •• 0 •• 0 6

Cylinder Head 0 0 o •••• o ••• 00 •••• 0 o. 13

Cylinder - Hydrostatic Power Control 115

Cylinder Mounting -Multi Purpose Bucket .,. 0 • 0 • 0 . 0 • 0 .216

D

Dash 0 0 ••••••• 0 •••••••• 0 •••••••••• 263

Dash Lamp .................. 0 • • •• 74

Dipstick - Transmission . 0 •••••••••• 93

Disconnect Switch .......... 0 ••••• , 75

Diverter Valve & Control - Hydraulic 193

Diverter Valve Lines .. 0 •• 000 ••••••. 0200

Name Page

Door -:- Cab ..................•... 232 Drain lines ......................• 62

E

Engine Arrangement ............... 4

Engine & Transmission Enclosure ..... 152

Engine Mounting .............. ~..... 17

Engine Support ..... .............. 16

Engine Trunnion •.......• " •. ~ • . . . .. 21

EqUdtizer Bar ...... ',~ ............. 151

Ether Starting Aid ... >. ~". . . . . . .. . . .. 88

E~:ry¢lust Manifold .................. 40

Exhaust Manifold Fastener .......... 41

F

Fan - Blower ............ "......... 34

Fan Drive ........................ 20

Fan Pulley ........................ 20

Fc;stener - Engine •........ " ....... e· '4 Filter - Air Cleaner ............... 41

Filter - Cab Pressurizer ............ 234

Filter - Engine Oil ...............•. 28

Filter - Fuel ..... . . . . . . . . . . . . . . . .• 64

. Filter - Main - Hydrostatic Power Control ....•..•.....•..... 113

Filter - Oil ........ < • . . . . . . . . . . • .. 28

Filter - Secondary . • • . . . • . • . . . . . • •. 64

FiHer Tank .......•..• ' ••• '" ••.•.• ' .. ,.170 FiI'lQ! Drive ............•..•..•..• , .• 130 .

Flood. Lamp .•.....•••....••.•.. ',,, ., 87

Flywheel ....................... " .. 0 ••• ,.',22

Page

Flywheel Housing .................. 22 Front Guard ...................... 147

Front Housing Cover .. 0 ••••••• 0 • • •• 18

Front Housing - Engine ......... .. 18

Front Housing Fastener ...... 0 0 •• 0 o. 19

Front Idler ... 0 o ••••••••••••••• 0 ••• 154

Front Timing Gear ... 0 •• 0 •••••••• o. 19

Fuel Injection lines 0 •• 0 •• o. 0 o ••••• o. 56

Fuel Injection Pump ...... 0 • 0 ••••••••• 54

Fuel Lines . 0 • 0 ••••••••••••••••••• '. 58

Fuel Priming P,ump ........ 0 •• 0 0 •••• 61

Fuel Ratio Control ..... 0 • • • • • • • • • •• 62

Fuel Tank . 0 ••••••••• 0 ••••• 0 • • • • • •• 59

Fuel Transfer Pump . 0 •• o. 0 •••• 0 0 • • •• 55

Fumes Disposal .................... 30

G

Gasket Kits .......•............... 265 General Purpose Bucket ............. 221

Governor ............... 0 • 0 • • • • • •• 49

Governor Control .................. 52

Governor & Fuel Injection Pump ...... 46

Grease Gun ................. , .... 265

Guard - Bottom ... " .............. 149

Guard - Front .•..... 0 •••••••••••• 147

Guard - Radiator .......•. 0 ••••••• 148

Guard - Tilt Lines ... 0 •••••••••••• 0 146

Guard - Track Roller & Sprocket .... 159

Guard - Vandalism . 0 ••••••••••••• 261

H

Hand Pump - Brake Control ........ 138

Name Page

Handle - Hydraulic Control ........ 186

Harness- Battery & Wiring ........ 65

Harness - ROPS .......•........ ~ .237 Hitch ........•..................•• 141

Horn - Electric . . . . . . • . . • . . . . . •. .• 87

Housing & Regulator ............... 38

Hydraulic Arrangements ~ ..........• 167

Hydraulic Control - Pilot Op~rated .. 182 Hydraulic Oil Cooler Implement Lines. 39

. ,

Hydraulic Tank Mounting •.......... 173 Hydrostatic Drive ........•......... '9l Hydrostatic Lines .. ' .. ' .. ~ l . ......... 112

Hydrostatic Power Case ............ 96"

Hydrostatic Power Case Lines ........ 110 Hydrostatic Power Case Linkage. ; ... 102

Hydrostatic Power Control Arrangement 95

Implement Cooler .................. 37

K

Key - Cab Door .................. 232

Kit - Alternator Repair 80

L

Lift Cylinder .......... : ..•.......• 212 Lift Cylinder Lines ........ : .......... 196

Lifting - Engine ..................• 16

Name "Page

Lighting ................................................ Lighting Arrangement ............... 84

Lines - Engine Oil ................. 27

Lines - Heater .................... 247 Lines - Multi-Purpose Bucket ........ 209 Linkage - Governor Control •....... 52

Loader Frame ..................... 139

M

Motor - Link - Hydrostatic ... ~.~ •. " .ll6·' Mounting & Condenser - .' '" ".

Air Conditioner .......•. ; .. .', .... 249 Muffler ....................... ,... 45

Muffler Mounting .................. 45

Multi-Purpose Bucket .....•......... 220

Multi-Purpose Bucket Arrangement .. 219 Multi-Purpose Bucket Lines ........... 209

N

Name Plates & Transfers ............ 266 Non-ROPS Conversion Arrangement .. 146 Nozzle - Fuel Injection ............ 57

o

Oil Cooler - Engine ............... 31

Oil Filler .............•.......•.... 28

Oil Level Gauge .....•....... ; .... : . "29 Oil Pan ........................ '. .. 24:'

r Name Page

c,~ ... ~,~.':.:_; .. : .. ,J .•... l °0' ~'II ppan FasteEner ....................... 2245 ;l lump - ngme ......•.........

~~ Operator Warning ................. 89

~ ':'j

<I '..:.~

:l ~:, "

.... J

! i

p

Padlock - Fuel Tank Cap ........... 60

Padlock - Radiator Cap ............ 30

Padlock - Vandalism Arrangement ... 260

Parking Brake ............ : ........ 134

Pedal - Retarder Brake' Valve ....... 135

Pedal - Steering Control ........... 137

Pilot Lines & Pump ................. 207

Piston Rings ....................... 12

Pivot Bar .......•............... ,. 158

Platform Tilt ...................... 144

Positioner & Kickout ................ 217

Power Train Cooler Lines ............ 91

Power Train Schematic .............. 2B

Precleaner - Air Cleaner ........... 41

Protection Cover - Fuel Tank Cap ... 60

Protection Cover - Hydraulic Tank Cap . ~ ..................... 206

Pump - Charge - Fixed Displacement .................... 115

Pump - Fuel Priming & Primary Filter . 60

Pump - Gear ..................... 208

Pump Lines ........................ 202

R

Radiator .......................... 32

Radiator Protection Cover ........... 30

Rear Attachment Lines ........ : ..... 199

Name Page

Rear Bumper •..................... 138

Rear Gear - Accessory Drive ....... 23

Rear View Mirror .................. 238

Rear Wiper ....................... 239

Refrigerant Compressor ....... , ..... 251

Ripper ...........................• 224

Ripper Arrangement ................ 223

Ripper Cylinder .................... 213

Ripper Lines ....................... 210

Ripper Mounting ................... 224

Ripper Mounti.ng & Cylinder ......... 225

Ripper Tooth ...................... 225

Rockerarm - Valve Mechanism ...... 15

RaPS Arrangement - Open ......... 230

RaPS - Enclosed .................. 228

RaPS Mounting .................... 146

s

Safety Brace ...................... 150

Seals - Fuel Injection Housing ....... 56

Seat ............................. 253

Seat Adjuster ...................... 258

Seat Belt .......................... 253

Seat Cover ........................ 259

Seat Suspension ...... , ............. 256

Secondary Filter ................... 64

Sender - Transmission ............. 262

~rvo Linkage - Hydrostatic Power Case ..................... 104

Specifications ..................... 268

Speed & Direction Control .......... 1 08

Sprocket Segment .................. 129

Starting Motor - Electric ........... 75

Name Page

Steering Control ................... 136

Step - Track Roller Frame .......... 150 Suspension Seat .................... 253

Suspension Seat Adjuster ............ 258

Switch - Disconnect ............... 75 Switch - Engine Oil Pressure ........ 89

Switch - Starter ......... .; ..... ;... 73 Switch - Transmission Oil Temperature 89 Switch - Water Temperature ........ 89

T

Tilt Cylinder ................. ~ ..... 211 Tilt Cylinder lines .................. 198

Tilt Platform ....................... 140 Tilt Support ....................... 141 Tip - Bucket Tooth ................ 227

Tools - Hand ..................... 264 Tooth ............................ 226

Torque Control .................... 4~ Track ............................ 165 Track Carrier Roller ................ 161

Track Guiding Guard .............. 162

Track Roller ....................... 163 Track Roller Frame .................. 160 Transmission Control ............... 106 Transmission & Drive Motor Fastener .. 92

Transmission Oil Cooler ............ 37 Transmission & Pump Drive Filler ..... 93

Turbocharger ...................... 45

Turbocharger Oil lines ............ 45A

v

Valve - Actuator - Hydrostatic ..... 126

Name Page

Valve - By-Pass - Hydrostatic ...... 127

Valve - Charge & Main Relief-Hydrostatic ..................... 122

Valve - Charge Relief - Hydrostatic . 121

Valve - Control - Hydraulic Tank ... 178

Valve - Diverter - Hydraulic ....... 194

Valve - Intake & Exhaust .....•..... 13

Valve - Mechanism .'. . . . . . . . . . . . .. 15

Valve Mechanism Cover ............. 15

Valve - Pilot - Hydrostatic ......... 127

Valve-Pilot Operated Control ..... 174

Valve - Retarder Brake ............ 135

Valve - Servo - Hydrostatic ......• 128

Valve - Servo Relief - Transmission· .120

Valve - Shuttle - link Motor ....... 120

Valve - Underspeed Over:..ride ...... 121

Vandalism Arrangement ............ 260

Vee Belt - Air Conditioner .......... 251

Vee Belts - Fan Drive .............. 20

w

Warning Gauge ................... 262

Water lines ....................... 36

Water Pump ...................... 35

Windshield Washer ................ 240

Windshield Washer Tank ........... 241

Windshield Wiper ................. 238

Wiring - Cab Pressurizer ........... 236

INDEX ALPHABETIQUE

Designation

Moteur de base (Page 4)

Arbre a carnes ........ . Bielles et pistons ........... . B loc-cyl indres ............. . Bloc-cylindres (couvercle) ..... . Bride de levage ............ . Carter: avant . . . . . . . . . • . .• • . Carter avant (boulonnerie) .... . Carter avant (couvercle) ...... . Carter de volant .......... ~ . Coussinets de

rechange de vilebrequin .... . Culasse ................. . Culasse (couvercle) ....... . Engrenage arriere

(entrainements secondaires). Engrenage de

distribution avant ...... . Ensemble moteur ........ . Entrainement de ventilateur .. .

Page

11 13

6 9

16 18 19 18 22

11 13 15

23

19 4

20 £quilibreur dynamique ...... . . 12 Fixation ............... . Joint de vilebrequin ........ . Pieces de fixation du moteur ... . Poulie de ventilateur ........ . Poulie de vilebrequin ........ . Soupapes (couvercle) ........ . Soupapes et train de commande .. Support moteur ......... . Tourillon .............. . Volant ................ .

Circuit de graissage (Page 24)

14 10 17 20 21 15 15 16 21 22

Canalisations d'huile moteur . . .. 27 Carter inferieur. . . . . . . . . . . .. 24 F iltre a hu ile . . . . . . . .. . . . .. 28 Fixation du carter inferieur. . . .. 24 Jauge de niveau d'huile. . . . . . .. 29 Pompe a hu ile. . . . . . . . . . . . .. 25 Reniflard. . . . . . . . . . . . . . . .. 29 Tubulure de

remplissage d'hu ile. . . . . . . .. 28 Tuyauterie d'evacuation

de vapeurs . . . . . . . . . . . . .. 30

Designation

Circuit de refro id issement

(Page 30)

Bouchon a

Page

cadenas (radiateur) . . . . . . .. 30 Pompe a eau. . . . . . . . . . . . . 35 Radiateur. . . . . . . . . . . . . . . .. 32 Refroidisseur d'huile

de transmission. . . . . . . . . .. 37 Refroidisseur d'huile

hydraulique . . . . . . . . . . . .. 37 Refroidisseur d'huile

hydraulique (canalisations) . .. 39 Refroidisseur d'huile moteur . . . . 31 Thermostat et boitier. . . . . . . .. 38 Tuyauterie d'eau . . . . . . . . . . .. 36 Ventilateur soufflant . . . . . . . .. 34

Admission et echappement (Page 40)

Canalisations d'air . . . . . . . .. 42 Canalisations d'huile

(tu rbocomp resseu r) . . . . . . . . 45A Collecteur d'echappement. . . . .. 40 Collecteur d'echappement

(boulonnerie) . . . . . . . . . . .. 40 Filtre a air. . . . . . . . . . . . . . .. 41 Silencieux d'echappement. . . . .. 44 Silencieux d'echappement

(groupe de montage) . . . . . .. 44 Turbocompresseur. . . . . . . . 45

Alimentation en carburant et regulateur

(Page 47)

Canalisations de carburant. . . . .. 58 Canalisations de retour. . . . .. . .. 62 Filtre secondaire. . . . . . . . . . .. 64 Limiteur d'injection. . . . . . . . ... 62 Pompe d'amorc;age et prefiltre . .. 60 Regulateur

(timonerie exterieure) . . . . .. 52 Regulateur et pompe d'inJection.. 47 Reservoir de carburant . . . . . . .. 59

Installation electrique et demarrage

(Page 65)

Designation Page

Alternateur . . . . . . . . .. . . 76 Avertisseur de recul . . . . . . 90 Avertisseur sonore

e lectrique. . . . . . . . . . . 87 Batterie et cablage. . . . . . . . . .. 66 Circu it d 'avertissement. . . . . . .. 89 Coffre a batterie .......... " 74 Demarreur electrique .. . . . . . .. 75 Ecla irage . . . . .. . . . . . . . . . .. 85

Train de transmission

(Page 91)

Barbotin (segment) .......... 129 Bloc de

commande hydrostatique . . .. 95 Canalisations hydrostatiques .... 112 Commande de sens de

marche et de vitesse . Reducteu rs laterau x .. . Schema. . . . . . . ... . Transmission et moteur

... 108

... 130 2B

de translation (fixation) . . 92 Transm ission hydrostatique. . .. 91 Tubulure de remplissage

(transmission et entrainement de pompe) .... , 93

Tuyauterie du refro id isseu r d 'hu i Ie (train de transmission) . . . . .. 91

Embrayages et freins de direction

(Page 132)

Direction (commande) ............. 136

Frein de stationnement ........ 134 Freins

(commande) ............. 132 Soupape de ralentisseur ....... 135

Designation

Bati et train de rou lement

(Page 138)

Page

Arbre porteur. . . . ....... 158 Balancier de suspension ....... 151 Barre d'accouplement

de securite . . . . ....... 150 Bati de I'appareil

de levage . . . . . . . . . . . . 139 Bouclier de

protection inferieur ...•.... ·149 Capot avant ........... " .. 147 Carenage moteur

et transmission ... , •...... 156 Chaines de roulement ......... 165 Chassis porteurs ............ 160 Galets inferieurs ............ 163 Galets superieurs ............ 161 Grilles pour

compartiment moteur ... 152 Groupe de pose pour

bati de protection . . . . ... 146 Gu ides-protecteurs

de chaines .............. 162 I nclinaison de plate-forme ...... 144 Marchep ied . . . . . . . . ....... 150 Pare-chocs arriere ........... 138 Plate-forme inclinable ......... 140 Plate-forme inclinable

(support) ............... 141 Protege-radiateur. . . . . . . ... 148 Roues A V ................. 154

Circuit hydraulique (Page 167)

Arret en fin de levage et retour a I'angle d'anaque automatiques ..... 217

Canalisations de pompe .....•. 202 Commande a circuit pilote ..... 182 Commande hydrau I ique . . . . . .. 167 Distributeur commande

par circuit pilote .......... 174 Pompe a engrenages. . . . . . . . . . 208 Pompe et canalisations

de circuit pilote ........... 207 Reservoir

(groupe de montage) ....... 173 Reservoir et filtre ........... 170

Designation Page

Verin de levage ............. 212 Verin de levage

(canal isations) ............ 196 Verin d'inclinaison ........... 211 Verin d'inclinaison

(canalisations) ............ 198

Equipement de travail . (Page 218)

Bras et bielles de godet ......... 218-Godet normal .............. 221 Rjpper ................... 223

Cabine, instruments de contro Ie at accesso ires

(Page 228)

Bati de protection ........... 228 Cablage (surpresseur) ......... 236 Essu ie-glace ............... 238

Designation Page

Essuie-glace (lunette arriere) .... 239 Lave-glace . . . . . . . . . . . . . . . . 240 L~ve-glace

. (reservoir) .............. 241 Siege ....................... 253 Surpresseur d'air

de cabine. . . . . . . . . . . . . . . 234 Tablier .................. 263

Divers (Page 264)

Caracteristiques ............. 269 Jeux de joints ............... 265 Plaques signahhiques

et instructions sur decalcomanies ............ 266