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Track Loader
Engine Weights
®
Engine Model Cat C6.6 ACERT™ Operating Weight 20 220 kg 44,577 lb
Flywheel Power 141 kW 189 hp
Buckets
Capacity – General 2.45 m3 3.2 yd3
Purpose
Capacity – 1.9 m3 2.48 yd3
Multi-Purpose
963D Track Loader
The 963D has increased horsepower, excellent maneuverability and a redesigned operator
cab for operator comfort.
the Caterpillar® Common Rail fuel comfort and productivity with the new rounded gauge cluster with integral
delivery system. Designed for D-series cab. The cab features a new defroster vents. Together with the
performance, durability, serviceability, gauge cluster, a fully air-suspension optional Cat® Messenger, it displays
and fuel economy, it meets EPA Tier 3, seat, the new seat mounted controls, all necessary information within the
EU Stage IIIa and Japan Ministry of an automatic air climate control and operator’s normal line of sight. pg. 8
Land, Infrastructure & Transport Step 3 provides excellent visibility. pg. 6
emission standards. pg. 4
2
Hydrostatic Drive Implement System Structure
✔ The closed loop hydrostatic drive with ✔ The 963D features a load sensing ✔ The D-series Main Frame and Loader
electronic control provides precise implement pump which reduces engine Tower provide durability, resistance
modulation for quick, smooth operation power consumption. The new electro- to twisting, and a solid base for all
and superior maneuverability. Shorter hydraulic implement controls lower the components. The Z-bar linkage offers
cycle times, high efficiency, and excellent operator’s effort. And the new position high breakout force and fast dump
maneuverability results in increased sensing cylinders allow setting kickouts speed for enhanced productivity. pg. 11
productivity. pg. 9 at any position from the cab. pg. 10
✔ New Feature
3
Engine
Provides power, reliability and acts as a working counterweight in the rear of the machine,
for optimum machine balance.
4
ACERT™ technology used on the Fuel pump. The C6.6 uses an oil- Engine Installation. The engine is
C6.6 consists of three basic building lubricated high-pressure fuel pump installed using rubber mounts to reduce
block systems: electronic control, fuel to feed the common rail. the transfer of engine vibration to the
delivery, and air management. These have frame and cab, lowering operator
Fuel Priming Pump. An electrical fuel-
been refined to control the combustion vibration, sound levels, and fatigue.
priming pump, standard, is located
process to a higher degree than ever
between the fuel tank and the combined
before possible.
water separator/primary fuel filter.
Electronic control ADEM™ A4. The triple fuel filters, water separator
The Advanced Diesel Engine design, provides protection to the
Management – Electronic Control injection system against low-quality
Module continuously monitors important or contaminated fuel.
engine conditions and functions. It uses
sensors throughout the engine to regulate
fuel delivery and all other engine systems
that require input to manage load and
performance. ADEM™ A4 is the brain
behind engine responsiveness, self-
diagnosis, controlling emissions, and
fuel economy.
Fuel System. Through multiple injection
fuel delivery, fuel is introduced in the
combustion chamber in a number of
precisely controlled microbursts. Starting System. The Electronic Speed
Injecting fuel in this way allows for Selector Switch (A), a “rocker” switch
precise shaping of the combustion cycle. located on the right console, sets the
The ADEM™ A4 module directs the engine rpm. The ADEM A4 engine Rear Engine Location. Rear engine
injectors to deliver precise quantities of controller will always start the engine location allows excellent forward
fuel at exactly the right times during the in low idle. The engine rpm can be seen visibility, while serving as a working
combustion cycle. on the digital display of the instrument counterweight. It also helps reduce
cluster in the gage cluster or in the radiator plugging while providing easy
This process provides precise control
performance menu in Messenger. service access to the engine and other
over a range of combustion variables,
which can be regulated to produce Air-to-Air After cooler (ATAAC). major components.
higher performance with fewer emissions. The air-to-air after cooler is a single Hydraulic on-demand fan. The fan is
Fuel is delivered at high pressure to pass, aluminum, heat exchanger or a hydraulic demand type with optional
each combustion chamber through a cooling system for the pressurized air reversible function, and operates normally
Caterpillar designed injector linked coming from the turbocharger, before in suction mode.
to a Common Rail fuel system. it enters the engine intake manifold.
Cooling the pressurized air from the The complete cooling package has been
Air Management. Air management
turbocharger increases the density of designed for a very easy maintenance
is a key concept in optimizing engine
the engine’s intake air. The increased with a complete accessibility to the cores
performance and controlling emissions.
air density in the cylinders results in for cleaning. Rear grill and fan door
Engines must breathe clean cool air in
more power, improved combustion, swings out and latches.
order to perform. To aid this, the C6.6
and reduced exhaust emissions.
uses a turbocharger fitted with a smart
waste gate to give precise and reliable Serviceability. Unit injectors can be
control of the boost pressure. A new serviced individually, without the need
cross-flow design in the cylinder head to service the whole fuel system.
facilitates air movement, while tighter
tolerances between the piston and
cylinder liner reduce blow-by gases.
5
Operator Station
Designed for operator comfort, convenience, and ease of operation throughout the workday.
6
Working lights. Eight working lights are Electro-hydraulic implements controls.
available on the 963D. Four (2 front and The new electro hydraulic implement
2 rear) are standard, four additional controls on the 963D provide the
lights are optional. operator with responsive, smooth and
precise control of bucket and lift arms.
Storage spaces. Storage spaces include
Choice of joystick or two-lever control
space for lunch box, a beverage/ashtray
is available for bucket lift and dump.
holder, and a coat hook.
Rearview Mirror. The rearview mirror
is located above the front windshield,
maximizing the operator’s visibility.
Dome Light. A dome light is located
in the cab headliner.
Radio Installation Arrangement.
A standard feature in the cab is a
Radio Installation Arrangement, which
includes a 24-volt to 12-volt converter
and speakers.
Viewing Area. Large windows use A Caterpillar heavy-duty (AM/FM)
tinted glass to reduce glare and provide radio/CD player and satellite radios
an excellent view to the bucket, tracks, Caterpillar Air-suspension Seat. are available from dealers.
and around the engine enclosure to The Caterpillar air-suspension seat, with Door release lever. The door’s release
the rear. side-to-side isolator, is ergonomically lever is accessible from the ground to
Side windows slide top down to allow designed and fully adjustable for unlock the door conveniently, as well
the operator to let fresh air into the cab maximum operator comfort and control. as from inside the cab.
and communicate. Retractable seat belt is 75 mm (3 in)
wide for positive, comfortable restraint. Machine Security System. Eliminate
Kickout settings. Automatic kickouts machine theft and unauthorized usage
are part of the electro-hydraulic Seat mounted controls. Seat mounted with the Cat Machine Security System
controls; adjustable from inside the cab controls provide less vibration for the (MSS). It is integrated into the machine’s
with a simple rocker switch. Kickout operator and provide a combined seat electronic system and can protect most
stops are hydraulically cushioned for and controls adjustment. brands of equipment by requiring a
greater operator comfort and less Messenger. Messenger is a new uniquely coded key to start the machine.
material spillage. electronic monitoring system with real-
Armrests. The right hand side console time, visual feedback on engine and
features an adjustable armrest, wrist rest machine operating conditions. It provides
and joystick mount. The left side console information on diagnostic data,
is tiltable for improved ingress/egress maintenance, and allows operating
and features adjustable armrest and settings such as implement reactions.
control lever mount. Total adjustability
lets the operator customize the armrests
to the most comfortable position.
Heating and Air Conditioning.
Air conditioning is standard on 963D.
Both the air conditioning and the heater
deliver filtered, pressurized, temperature-
controlled air to the operator and
windows through 10 louvered vents.
7
Monitoring System
The gauge cluster provides all necessary functions and information within the operator’s
normal line of sight.
6 8 9 11
5 12
4 13
3 14
2 15
1 7 10
The 963D gauge cluster display. 2. Water separator 11. Hydraulic lockout
The gauge cluster displays all vital
3. Fuel filters 12. Hydraulic oil filter
functions and alerts the operator to
the nature of any abnormalities. 4. Fuel level 13. Bucket float
The 963D gauge cluster display includes: 5. Engine air filter 14. Lift kickout/lower kickout
• Four direct reading gauges 6. Machine security system 15. Bucket leveler
• Fifteen alert indicators 7. Either starting aid Gauge cluster-self test. The gauge
cluster self-test verifies that the main
• A numeric message display 8. Action lamp
display module is operating properly
Alert indicators. The fifteen alert 9. Parking brake every time the key start switch is turned
indicators used on the 963D are: from the “off” to the “on” position.
10. Operator presence
1. Reversible fan
8
Hydrostatic Drive
The electronically controlled hydrostatic drive helps provide quick response for shorter cycle
times and increased productivity.
9
Implement System
Work smart and move more.
10
Structure
Durable Slab section Frame and Loader Front End: Durable with increased space
for larger components.
11
SystemOne™ Undercarriage
The SystemOne undercarriage was designed exclusively for Caterpillar machines to reduce
customers’ operating costs, downtime and maintenance intervals.
12
The rollers and carrier rollers have Track Shoes. The shoes for SystemOne™ Track Adjuster. The track adjuster and
been redesigned to run with the system. are unique to this system. Several track mechanical recoil system uses a large
This will lead directly to better guiding. shoe types tailor your machine for recoil spring and grease filled adjustment
All rollers in this new system are single work in all underfoot conditions. cylinder, which allows the idler to move
flange rollers with increased flange The SystemOne links have a straight forward and back to maintain proper
diameter. The increased flange diameters rather than offset bolt hole pattern. track tension as it absorbs undercarriage
increase guiding capability. shock loads.
Double grouser standard or narrow
Idlers. Idlers provide superior structural track shoes are available. The standard Equalizer Bar. The equalizer bar is
support and rebuild capabilities. Special shoe can be fitted with center hole to pinned in its center to the machine
heat treatment of the idler rim ensures reduce material packing. mainframe and at the ends to each track
proper hardness levels, which provides roller frame. This allows the forward
Long-life Sprockets. The rotating
wear resistance. Cat’s Duo-Cone® seals ends of the track roller frames to
bushing design of the SystemOne track
give lifetime lubrication, which eliminates oscillate, or move vertically, to keep
greatly reduces wear on the sprocket
idler maintenance and lowers more track on the ground in uneven
teeth, allowing the sprockets to be used
operating costs. underfoot conditions. The equalizer
over the lives of multiple
bar also provides a more stable work
undercarriages.
platform for the operator, who will be
Oscillating Undercarriage. The comfortable working at faster speeds
undercarriage on the 963D features an for increased productivity.
“oscillating track roller frame design”
which decreases ground shock to the
machine, increases machine stability,
and provides a smoother, more
Cartridge Joints. Factory-sealed comfortable ride for the operator.
cartridge joints are welded to control Oscillating track roller frames keep
end play. They offer improved seal more of the track on the ground when
integrity through an innovative new operating on uneven terrain, which
sealing system and do not depend on the increases machine stability, felt by
link interface to remain sealed. As with the operator, allowing faster machine
all new Cat undercarriage products, operation, increased machine productivity
they are filled with special oils. and reduced operator fatigue.
13
Versatility
The large variety of tasks an operator can perform with the standard machine and
Work Tools has lead to the Caterpillar Track Loader’s reputation for versatility.
14
Reversible Tips. Each tip ear has a Penetration Tips. Penetration tips are
retainer groove with a locking recess. extremely strong and are for use in high
Tips can be run in one direction, impact and pry-out work such as rock.
then “flipped,” or reversed, to get the
General Duty Tips. General duty tips
maximum use of wear material from
are for use in most general applications
the tip.
where breakage is not a concern.
Extra-duty, Tips. Extra-duty long tips
are for use in general loading and
excavation work. They have thirty-six
percent more wear material than on Ripper-Scarifier. A radial ripper-scarifier
standard tip. Provides increased is available for the 963D as an
strength, extended service life, and attachment. It is mounted with two pins
low cost-per-hour. pressed into each side of the main frame.
Two cylinders raise and lower the ripper.
The ripper beam has three pockets for
holding ripper shanks. The linkage pins
Tip Options. Caterpillar GET offers a do not require lubrication.
variety of tips to better accommodate
your needs in any working environment, The 963D ripper-scarifier is intended
whether that is high impact or general- for ripping frozen ground, asphalt and
purpose applications. easily ripped rock.
These and other GET options are Additional Work Tools. Beyond the GP
available from your Caterpillar Dealer. and MP buckets and the Ripper-scarifier
your Cat dealer offers: Side-Dump
Buckets, Landfill Buckets, Straight
Trim Blades, Pallet Forks, Extendible
Material Handling Arms, and Quick
Couplers.
15
Serviceability and Customer Support
Grouped service points and excellent accessibility make the 963D easy to maintain.
16
Hydraulic Tank. The hydraulic tank is
located in the front of the machine. It is
accessible without raising the lift arms.
A site gauge allows oil level check from
the ground.
Fuse Panel. The fuse panel is located
to the inside of the cab, on the rear right
side console. It includes the ET port.
Easy Diagnosis. The gauge cluster and
Fuel fill. The fuel tank and the optional self-diagnosing Electronic Hydraulic
quick fill port are located on the right Control (EHC) work together to warn
side compartment, below the cab access. against faults to reduce downtime.
S·O·S Fluid Taps. Simplifies drawing
fluid samples for Scheduled Oil Sampling
and reduces sample contamination.
Quick-Connect Fittings. The quick-
connect hydraulic grouped pressure taps
allow quick diagnosis of the hydrostatic
drive and the implement hydraulic
Left side compartments. The lower part systems.
of the compartment door can be used as Product Link. This attachment allows
a step to access the shunt tank fill, the a customer or dealer to remotely obtain
air pre-cleaner (if equipped) and allows machine diagnostics. Product Link
easy cleaning of the rear window. provides updates on service meter hours,
Cooling System. The fan and the grill
swing open, providing excellent access machine condition, machine location,
for clean-out and maintenance. The heavy and integrated mapping/route planning.
duty latched grill minimizes debris Complete Customer Support. Cat field
build-up. service technicians have the experience
Ground Level Shutdown. The Engine and tools necessary to service your
Control ECM monitors the status of a loader on site. Technical experts at the
switch that is mounted behind a cover dealership and Caterpillar can provide
at the rear of the machine, allowing the additional assistance to field service
machine to be shut down from ground technicians as needed. When on-site
level in emergency situations. Cab Air Filter. The cab air filter, the repair isn’t enough, Cat dealerships
grouped pressure taps, the cab tilt are fully equipped to service your
Shovel holder. As an optional attachment, loader quickly.
locking bar, the optional cab tilt cylinder,
a shovel holder, located on the rear right
the tool box, and the hydraulic oil filters SAFETY.CAT.COM™.
side of the machine, is available for
are conveniently located below the left-
undercarriage cleaning.
side cab window.
17
Special Application Arrangements
Special arrangements improve the 963D’s performance in special applications.
18
Engine Service Refill Capacities
Engine Model Cat® C6.6 ACERT™ Fuel Tank 400 L 105.6 gal
Flywheel Power 141 kW 189 hp Cooling System 31.5 L 8.3 gal
Net Power – Caterpillar 141 kW 189 hp Crankcase (with Filter) 16.5 L 4.4 gal
Net Power – ISO 9249 141 kW 189 hp Final Drives (each) 15 L 4 gal
Net Power – SAE J1349 141 kW 189 hp Hydraulic Tank 90 L 23.7 gal
Net Power – EEC 80/1269 141 kW 189 hp Pivot Shaft 1.8 L 0.5 gal
Bore 105 mm 4.13 in
Stroke 127 mm 5 in
Displacement 6.6 L 403 in3 Weights
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11
15
3
17 18 12
9
8
10
2
6
1 4
7
5
ELECTRICAL UNDERCARRIAGE
Alternator, 24 volt, heavy duty brushless Caterpillar SystemOne track (38 sec.) 1850 mm (72.8 in)
Alarm, backup track gauge
Horn, electric Final drive, standard
2 heavy duty batteries, high output, maintenance free, Track, 550 mm (21.6 in), double grouser
1120 CCA Track adjuster, hydraulic
Switch, main disconnect Sprocket rims, with replaceable bolt-on segments
Starter, electric (heavy duty, 24 volt) 7 single flange track rollers per side, with two upper carrier
Four halogen lights, two forward facing, roof mounted; rollers, lifetime lubricated
two rearward facing, integrated in A/C unit Conventional idlers, lifetime lubricated
OPERATOR ENVIRONMENT Idler, scrapper
Pressurized, sound suppressed, ROPS/FOPS cab Oscillating track roller frames
Cab, windows, glued HYDRAULIC
Cat Messenger Oil change, standard
Side sliding windows Hydraulic oil
Air conditioning and heater/ defroster with temperature control Hydraulic, 2 way valve
Seat, fabric-covered, air suspended, adjustable, with GUARDS
side-to-side isolator Guard, front
Seat belt, retractable Guard, rear
Electro Hydraulic Seat mounted control levers Guards, full bottom
Control, joystick, bucket gp OTHER STANDARD EQUIPMENT
Electronic Monitoring System with gauges for: Cab, tilt, locking bar
• Engine coolant temperature Sound Suppression, Exterior
• Hydraulic oil temperature Z-bar loader linkage
• Engine oil pressure Caterpillar Product Link 321 (for selected territories)
• Fuel level Load sensing variable displacement implement pump
Mirror, rearview, inside Implement cylinders with integrated positioning sensors
Radio-ready. Includes 24 to 12 volt converter, speakers, Operator programmable lift and tilt kickouts
antenna and 12 volt power outlet Engine enclosure with lockable doors
12 volt outlets (2) Radiator core 6.5 fpi, debris resistant
Coat hook Hinged Radiator Guard and swing out fan
Storage compartments under left armrest Ecology grains on hydraulic tank
Document holder on right console Product Link ready
Floor mat, rubber, heavy duty Oil sampling valves
Windshield washers and wipers, front and rear Hydraulic hoses, Caterpillar® XT
Durable metal roof WARNING DECALS
Parking brake switch and “brake-on” indicator light Warning decals, ANSI, for NACD
POWER TRAIN Warning decals, ISO
Caterpillar C6.6 ACERT engine diesel engine, turbo SERVICE INSTRUCTIONS
charged with ATAAC English Instructions included in North America and
Modular cooling system for engine air intake, oil and water Canada only
Fan radiator, electronically controlled, hydraulically driven,
temperature sensing, on demand
Electro Hydrostatic Control (EHC) for transmission with
travel and work modes
Fuel priming pump, electric
Water separator
Air inlet
Air cleaner dry-type, axial seal with integral pre-cleaner
and dust ejection system, electronic filter condition indicator
Muffler, under hood
Starting aid ether injection
Caterpillar extended life coolant
Fuel, tank
© 2007 Caterpillar
All Rights Reserved
Printed in U.S.A.