963D Track-Type Loader Power Train Caterpillar

Assembly Procedure

Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.

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Illustration 1	g00877519

1. Install ring (70) and guide ring (69).
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   Illustration 2	g00875604

2. Install O-ring seal (68) to cover (67).
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   Illustration 3	g00875602

3. Install cover (67) and bolts (66).
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   Illustration 4	g00875601

4. Install spring retainer (63) and rod (65). Install springs (61), (62), and (64). Install spring retainer (60). Install O-ring seal (58) and ring assembly (59).
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   Illustration 5	g00875599

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   Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

5. Use Tooling (A) and a suitable press to install retaining ring (57).
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   Illustration 6	g00875573

6. Install O-ring seal (56) to cover (55).
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   Illustration 7	g00875571

7. Install cover (55) and nut (54).
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   Illustration 8	g00875570

8. Install spring retainer (53). Install springs (50), (51), and (52). Install spring retainer (49).
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   Illustration 9	g00875569

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   Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened.

9. Use Tooling (C) and a suitable press to Install ring assembly (48).
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   Illustration 10	g00875568

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   Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

10. Use Tooling (A) and a suitable press to install retaining ring (47).
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    Illustration 11	g00875567

11. Install servo valve (46) and bolts (45).
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    Illustration 12	g00875539

12. Install bearings (42).
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    Illustration 13	g00875538

13. Install bearings (41), rods (40), and slide (39).
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    Illustration 14	g00875537

14. Install swashplate assembly (38).
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    Illustration 15	g00875564

15. Install joint pin (43) and plug assembly (44).

16. Repeat Step 15 for the opposite side.
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    Illustration 16	g03699124

17. Install Tooling (J) over shaft assembly (36) to protect the shaft during installation. Install shaft assembly (36) to housing (4). Remove Tooling (D) after installation.

18. Install retaining ring (35) to housing (4).
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    Illustration 17	g03699121

19. Install seal (34) to housing (4).
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    Illustration 18	g00875204

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    Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

20. Install retaining ring (33) to housing (4).
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    Illustration 19	g00875827

21. Use a suitable press to install washer (31), spring (32) and washer (31) in barrel assembly (27).

22. Install retaining ring (30).

23. Use the following steps to determine the correct shim thickness on the rotating group.
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    Illustration 20	g00875829

    1. Place port plate (11) onto a surface plate. The flat side of the port plate should rest on the surface plate.
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       Illustration 21	g00875830

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       Illustration 22	g00875832

    2. Place Tooling (E) on the inside diameter of port plate (11). The chamfered side faces upward.

    3. Install barrel assembly (27) onto Tooling (E) and port plate (11).
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       Illustration 23	g00875866

    4. Install Tooling (F) on top of the barrel assembly (27), as shown.
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       Illustration 24	g02996236

    5. Make sure that all the springs and shims have been removed from ball joint (26). Install the ball joint over Tooling (F).
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       Illustration 25	g00875876

    6. Install retainer plate (25) onto ball joint (26).
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       Illustration 26	g00875877

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       Illustration 27	g00875879

    7. Bolt Tooling (G) and Tooling (H) together. Place Tooling (G) and Tooling (H) on top of the retainer plate (25), as shown.
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       Illustration 28	g00875881

    8. Use a Vernier scale or a similar tool to measure the dimension in Step 23.i.
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       Illustration 29	g00586062

    9. Measure the distance from the top of the surface plate to the top of Tooling (G). Record this dimension as Dimension (X). Measure the distance from the top of Tooling (G) to the top of retainer plate (25). Record this dimension as Dimension (W).
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       Table 2

       CALCULATION

       Subtract Dimension (W) from Dimension (X) to obtain Dimension (Y).

       Dimension (Y) is the Lift Off Height.

       Note: The Lift-Off height is 131.000 + 0.0 & - 0.200 mm (5.1575 + 0.00 − 0.0079 inch) for standard machines. Call this height Dimension (Z).

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       Table 3

       CALCULATION

       Subtract Dimension (Y) from Dimension (Z) to obtain the thickness of shim (29). This will provide the correct Lift Off Height.

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    Illustration 30	g00875186

24. Install shim (29) onto barrel assembly (27). Refer to Step 23.i for the correct size. Install spring assembly (28) in the correct sequence.
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    Illustration 31	g00875182

25. Install ball joint (26) on the shim and barrel assembly (27).
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    Illustration 32	g00875175

26. Install pistons (24) and retainer plate (25).
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    Illustration 33	g00875902

27. Wrap a piece of nylon string around the pistons, as shown.
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    Illustration 34	g00875903

28. Lower rotating assembly (23) into the pump. Use the nylon string to hold the assembly together during installation. Remove the nylon string.
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    Illustration 35	g02994896

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    Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

29. Install control piston (18) to head (7).

30. Install retainer (19), spring (20) and retainer (21) to compensator valve (22).

31. Install compensator valve (22) and the O-ring seal to head (7).

32. Install test port (15) and the O-ring seal to head (7).

33. Install relief valves (16) and the O-ring seals to head (7).

34. Install O-ring seal (15) to head (7).
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    Illustration 36	g06221275

35. Install plug (12), pin (13), plug (14), and the O-ring seal to head (7).

    Note: Plug (12) will need to be installed in new head (7) if head (7) is replaced.

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    Illustration 37	g00875055

36. Install port plate (11) to head (7).

37. Install O-ring seal (9) to head (7).
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    Illustration 38	g01284387

38. Install coupler (9).

39. Install head (7) onto the housing.

40. Install bolts (8) to head (7).

41. Install O-ring seal (9A).
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    Illustration 39	g01284386

42. Install flange (6) to housing (4).

43. Install bolts (5) to flange (6).
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    Illustration 40	g01284385

44. Install the bevel washers, the O-ring seals, solenoids (1A), and bolts (1).

45. Install servo valve (2B) and bolts (3B).

46. Install the gasket, cover (3), and bolts (2).

End By:

1. Install the piston pump. Refer to Disassembly and Assembly, "Piston Pump (Hydrostatic) - Install".