Caterpillar 963D BROCHURE

Engine

Engine Model Cat®C6.6 ACERT™
Flywheel Power 141 kW 189 hp

Buckets

Capacity – General 2.45 m

3

3.2 yd

3

Purpose
Capacity – 1.9 m

3

2.48 yd

3

Multi-Purpose

Weights

Operating Weight 20 220 kg 44,577 lb

963D

Track Loader

®

®

2

963D Track Loader

The 963D has increased horsepower, excellent maneuverability and a redesigned operator
cab for operator comfort.

Increased horsepower, excellent
maneuverability, redesigned operator cab
for comfort, the revolutionary SystemOne™
undercarriage and the new implement
system increase your productivity, drastically
reduce your operating costs and make the
new 963D unsurpassed in versatility.

Versatility

A large choice of buckets, Ground
Engaging Tools (GET), and attachments,
allow configuration of the 963D for
maximum performance in any job.

pg. 14

SystemOne™ Undercarriage

The revolutionary Cat SystemOne
Undercarriage provides maximum
undercarriage life and reliability no
matter the application, environment
or underfoot conditions. Built to last
longer and require less maintenance,
it ensures a dramatic drop in owning
and operating costs. pg. 12

Monitoring System

The 963D incorporates a new smooth,
rounded gauge cluster with integral
defroster vents. Together with the
optional Cat®Messenger, it displays
all necessary information within the
operator’s normal line of sight. pg. 8

✔

Operator Station

Experience a high level of efficiency,
comfort and productivity with the new
D-series cab. The cab features a new
gauge cluster, a fully air-suspension
seat, the new seat mounted controls,
an automatic air climate control and
provides excellent visibility. pg. 6

✔

Engine

The Cat®C6.6 ACERT engine utilizes
the Caterpillar®Common Rail fuel
delivery system. Designed for
performance, durability, serviceability,
and fuel economy, it meets EPA Tier 3,
EU Stage IIIa and Japan Ministry of
Land, Infrastructure & Transport Step 3
emission standards. pg. 4

✔

✔ New Feature

3

Special Application Arrangements

Special arrangements – Waste Handling,
Wide Gauge and more, are available or
can be designed on request, to allow the
963D to work in special applications.

pg. 18

Serviceability and Customer Support

The new 963D is equipped with a tiltable
cab that allows complete service of the
hydraulic system. Daily maintenance
checks are performed from the machine’s
right side. pg. 16

✔

Structure

The D-series Main Frame and Loader
Tower provide durability, resistance
to twisting, and a solid base for all
components. The Z-bar linkage offers
high breakout force and fast dump
speed for enhanced productivity. pg. 11

✔

Implement System

The 963D features a load sensing
implement pump which reduces engine
power consumption. The new electro­hydraulic implement controls lower the
operator’s effort. And the new position
sensing cylinders allow setting kickouts
at any position from the cab. pg. 10

✔

Hydrostatic Drive

The closed loop hydrostatic drive with
electronic control provides precise
modulation for quick, smooth operation
and superior maneuverability. Shorter
cycle times, high efficiency, and excellent
maneuverability results in increased
productivity. pg. 9

✔

Cooling module architecture. The cooling
system is a single cooling unit, which
includes Radiator, ATAAC, Oil cooler
and Fan installation. The cooling module
is located at the rear of the loader, away
from dust and debris stirred up by the
bucket while the machine is working.
The radiator has 6.5 fins per inch (fpi)
which helps reduce plugging.

Cat C6.6 ACERT™. The Cat

®

C6.6 is
a 6.6 liter (403 in3) displacement,
six-cylinder, in-line configured engine
that utilizes the Caterpillar®Common
Rail fuel system for fuel delivery. It uses
ACERT™ Technology, a series of
Caterpillar engineered innovations that
provide advanced electronic control,
precision fuel delivery and refined air
management, resulting in outstanding
performance and lower emissions.

The C6.6 with ACERT Technology
offers a compact design with big,
heavy-duty engine features for
outstanding durability, reliability and
performance. The C6.6 incorporates
a new cross flow cylinder head design,
4 valve head and an ADEM™ A4
electronic controller. The C6.6 also
features proven cylinder block, pistons
and crankshaft and incorporates the
common rail fuel system. ACERT™
technology enables the C6.6 engine to
meet the U.S. EPA Tier 3, European
Union Stage IIIa and Japan Ministry of
Land, Infrastructure & Transport Step 3
emissions standards, which dramatically
reduce nitrous oxides (NOx) and other
emissions.

4

Provides power, reliability and acts as a working counterweight in the rear of the machine,
for optimum machine balance.

Engine

ACERT™ technology used on the
C6.6 consists of three basic building
block systems: electronic control, fuel
delivery, and air management. These have
been refined to control the combustion
process to a higher degree than ever
before possible.

Electronic control ADEM™ A4.

The Advanced Diesel Engine
Management – Electronic Control
Module continuously monitors important
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, self­diagnosis, 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.
Injecting fuel in this way allows for
precise shaping of the combustion cycle.
The ADEM™ A4 module directs the
injectors to deliver precise quantities of
fuel at exactly the right times during the
combustion cycle.

This process provides precise control
over a range of combustion variables,
which can be regulated to produce
higher performance with fewer emissions.
Fuel is delivered at high pressure to
each combustion chamber through a
Caterpillar designed injector linked
to a Common Rail fuel system.

Air Management. Air management
is a key concept in optimizing engine
performance and controlling emissions.
Engines must breathe clean cool air in
order to perform. To aid this, the C6.6
uses a turbocharger fitted with a smart
waste gate to give precise and reliable
control of the boost pressure. A new
cross-flow design in the cylinder head
facilitates air movement, while tighter
tolerances between the piston and
cylinder liner reduce blow-by gases.

Fuel pump. The C6.6 uses an oil­lubricated high-pressure fuel pump
to feed the common rail.

Fuel Priming Pump. An electrical fuel­priming pump, standard, is located
between the fuel tank and the combined
water separator/primary fuel filter.
The triple fuel filters, water separator
design, provides protection to the
injection system against low-quality
or contaminated fuel.

Starting System. The Electronic Speed
Selector Switch (A), a “rocker” switch
located on the right console, sets the
engine rpm. The ADEM A4 engine
controller will always start the engine
in low idle. The engine rpm can be seen
on the digital display of the instrument
cluster in the gage cluster or in the
performance menu in Messenger.

Air-to-Air After cooler (ATAAC).

The air-to-air after cooler is a single
pass, aluminum, heat exchanger or
cooling system for the pressurized air
coming from the turbocharger, before
it enters the engine intake manifold.
Cooling the pressurized air from the
turbocharger increases the density of
the engine’s intake air. The increased
air density in the cylinders results in
more power, improved combustion,
and reduced exhaust emissions.

Serviceability. Unit injectors can be
serviced individually, without the need
to service the whole fuel system.

Engine Installation. The engine is
installed using rubber mounts to reduce
the transfer of engine vibration to the
frame and cab, lowering operator
vibration, sound levels, and fatigue.

Rear Engine Location. Rear engine
location allows excellent forward
visibility, while serving as a working
counterweight. It also helps reduce
radiator plugging while providing easy
service access to the engine and other
major components.

Hydraulic on-demand fan. The fan is
a hydraulic demand type with optional
reversible function, and operates normally
in suction mode.

The complete cooling package has been
designed for a very easy maintenance
with a complete accessibility to the cores
for cleaning. Rear grill and fan door
swings out and latches.

5

6

Designed for operator comfort, convenience, and ease of operation throughout the workday.

Operator Station

Working lights. Eight working lights are

available on the 963D. Four (2 front and
2 rear) are standard, four additional
lights are optional.

Storage spaces. Storage spaces include
space for lunch box, a beverage/ashtray
holder, and a coat hook.

Viewing Area. Large windows use
tinted glass to reduce glare and provide
an excellent view to the bucket, tracks,
and around the engine enclosure to
the rear.

Side windows slide top down to allow
the operator to let fresh air into the cab
and communicate.

Kickout settings. Automatic kickouts
are part of the electro-hydraulic
controls; adjustable from inside the cab
with a simple rocker switch. Kickout
stops are hydraulically cushioned for
greater operator comfort and less
material spillage.

Armrests. The right hand side console
features an adjustable armrest, wrist rest
and joystick mount. The left side console
is tiltable for improved ingress/egress
and features adjustable armrest and
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, temperature­controlled air to the operator and
windows through 10 louvered vents.

Caterpillar Air-suspension Seat.

The Caterpillar air-suspension seat, with
side-to-side isolator, is ergonomically
designed and fully adjustable for
maximum operator comfort and control.
Retractable seat belt is 75 mm (3 in)
wide for positive, comfortable restraint.

Seat mounted controls. Seat mounted
controls provide less vibration for the
operator and provide a combined seat
and controls adjustment.

Messenger. Messenger is a new
electronic monitoring system with real­time, visual feedback on engine and
machine operating conditions. It provides
information on diagnostic data,
maintenance, and allows operating
settings such as implement reactions.

Electro-hydraulic implements controls.

The new electro hydraulic implement
controls on the 963D provide the
operator with responsive, smooth and
precise control of bucket and lift arms.
Choice of joystick or two-lever control
is available for bucket lift and dump.

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.

A Caterpillar heavy-duty (AM/FM)
radio/CD player and satellite radios
are available from dealers.

Door release lever. The door’s release
lever is accessible from the ground to
unlock the door conveniently, as well
as from inside the cab.

Machine Security System. Eliminate
machine theft and unauthorized usage
with the Cat Machine Security System
(MSS). It is integrated into the machine’s
electronic system and can protect most
brands of equipment by requiring a
uniquely coded key to start the machine.

7

The 963D gauge cluster display.

The gauge cluster displays all vital
functions and alerts the operator to
the nature of any abnormalities.

The 963D gauge cluster display includes:

• Four direct reading gauges

• Fifteen alert indicators

• A numeric message display

Alert indicators. The fifteen alert
indicators used on the 963D are:

1. Reversible fan

2. Water separator

3. Fuel filters

4. Fuel level

5. Engine air filter

6. Machine security system

7. Either starting aid

8. Action lamp

9. Parking brake

10. Operator presence

11. Hydraulic lockout

12. Hydraulic oil filter

13. Bucket float

14. Lift kickout/lower kickout

15. Bucket leveler

Gauge cluster-self test. The gauge
cluster self-test verifies that the main
display module is operating properly
every time the key start switch is turned
from the “off” to the “on” position.

8

Monitoring System

The gauge cluster provides all necessary functions and information within the operator’s
normal line of sight.

3

2

1

8

6

5

4

9

11

12

13

14

15

7

10

The electronically controlled hydrostatic
drive system automatically matches
machine travel speed to the combined
travel and implement loads on the
machine, enabling maximum travel
speed, up to the speed selected by
the operator.

Electronic Hydrostatic Control (EHC).

Hydrostatic system has integrated
electro-hydraulic controls (EHC),
which provide optimum performance
and efficiency.

Variable Displacement Pumps and
Drive Motors. Variable displacement

pumps and drive motors are electronically
controlled by the EHC, offering high
efficiency and precise travel. Each track
is independently driven by a separate
hydraulic circuit consisting of one pump,
connected by Cat XT-6™ hydraulic
hose and couplings to a piston motor.

Fuel Management System. This system
allows the operator to select a lower
RPM setting for reverse. Three selections
are available in Messenger to match the
engine speed in reverse to the application.
Full speed is achievable in all settings.

Travel Speeds. Travel speeds are
infinitely variable between zero and top
speed. Two speed modes “work” and
“travel”, provide two different speed
ranges to best match machine speed and
torque to the job conditions for maximum
productivity. Maximum travel speed is
10 kph (6.2 mph) when the switch is
set in the travel position.

Hydrostatic Drive System Controls.

The control systems allow quick speed
and directional changes. Two power train
control options are available:

1. The V-lever system includes a single
speed direction control lever and
steering pedals that can be adjusted
from 35° to 50° depending on operator
preference and allow precise control
of each track independently
and on-demand counter rotation.
An emergency brake pedal is located
between the two steering pedals.

2. The joystick system features an
S-lever pattern steering including
a single joystick handle for speed,
direction and steering functions, foot
rests and an emergency brake pedal.
Counter rotation is possible from
moving or immobile machine.
This power train control system
is comparable to the drive system
known from the Cat Multi Terrain
and Skid Steer Loaders. A black
button is located on the top to activate
the horn.

Speed Switches. Both systems include
speed mode switches.

For the V-lever system a “work mode”
and “travel mode” switch allows to best
match the machine speed to various job
conditions. Switching between travel
and work mode takes effect immediately.

The joystick includes two yellow
buttons for maximum transmission
speed setting. It features three machine
travel speed limits, to best match
application and controllability
requirements. Limit increase and
decrease take effect immediately.

Steering. Steering is accomplished by
changing relative pump flows and/or
motor displacements, which causes
one track to rotate slower than the
other track.

Maneuverability. The hydrostatic drive
train also offers independent power
and control of each track, with fast
acceleration, infinitely variable speeds,
and automatic, on-the-go, direction
changes for each track. The operator
can command smooth “power turns”
or even counter-rotation of the tracks
by simply pushing one of the steering
pedals, if the machine is equipped with
a V-lever, or moving the joystick in
the right/left axis while the machine is
stationary. The Caterpillar hydrostatic
drive system manages itself, freeing
the operator to concentrate on using
the Cat track loader’s superb agility,
speed, and maneuverability to do
more productive work.

9

Hydrostatic Drive

The electronically controlled hydrostatic drive helps provide quick response for shorter cycle
times and increased productivity.

Electro-hydraulic Implement Controls.

Electro hydraulic implement controls
on the 963D provide the operator with
responsive, smooth and precise control
of bucket and lift arms. They also
allow the operator to set personal
parameters through Messenger such
as implement reactions.

Load sensing hydraulics. The 963D
features a load sensing hydraulic system
that automatically adjusts to operating
conditions to provide only the hydraulic
flow required by the implement for
improved fuel efficiency.

Automatic kickouts. The standard
programmable automatic kickouts
provide flexibility and productivity for
precise load and dump target heights.
Tilt and lift kickouts are set by positioning
the bucket or work tool and setting a
rocker switch in the cab.

Position sensing cylinder. Position
sensing cylinders allows you to:

• Set lift and tilt kickouts at any
positions according to the
applications without operator
leaving the cab

• Advanced automatic features as
feather catch (accelerate and stop
smoothly) and snubbing (smooths
start and stop cylinder motion)

• Sensing of the cylinder end of stroke

• Prevent unintended motion

10

Implement System

Work smart and move more.

Mainframe and Loader Tower.

The 963D Main Frame and Loader Tower
is a single, slab rails with reinforced
cross members, with castings and
forgings incorporated at points of high
stress, to distribute those stresses over
wider areas for long structural life.

Design. The part of the frame below the
engine and operator’s station consists of
two Slab-section side-frame rails, which
are joined at the rear by a box-section
cross member. The Slab-section 963D
frame resists twisting and impact forces
to provide a solid foundation for all the
components it supports. Mounting
points for the final drives, pivot shafts,
and platform are built into each
mainframe side rail.

Frame side plates. The frame side plates
are made of mild steel, which provides
strength and resists shock and bending
stresses. “Deep penetrating”, “Backed up”
welds are used for maximum strength.

Loader tower. The loader tower is
integral with the basic main frame.
The one slab plate continues forward to
become one side of the loader tower in
order to provide a smooth transition to
loads from linkages to the mainframe
rails. The loader tower provides a solid
mount for lift arms, lift cylinders, and
Z-bar tilt cylinder. A box-section cross
member is welded below the two inboard
loader tower plates to add strength.
The equalizer bar, which connects the
track roller frames to the main frame,
is mounted below the loader tower.
The result is an integrated main frame
and loader tower assembly which will
accommodate maximum load capability.
The engine is at the rear, where its weight
serves as a “working counterweight”
to balance the machine for full bucket
loads without adding inefficient
“dead” weight.

Z-Bar linkage. Breakout force is
exceptionally high due to mechanical
advantage of Z-bar linkage design, and
hydraulic pressure applied to the head
end of the tilt cylinder. Using a single
tilt cylinder and linkage provides the
operator a better view of the work area,
bucket, and cutting edge.

Sealed Loader Linkage. The 963D
linkage has fewer grease points compared
to other linkage designs because every
pin joint is sealed to keep grease in
and dirt out. Fewer grease points and
sealed pins means less downtime for
maintenance allowing more working
hours between servicing.

Lift Arms. The two arms are welded into
a single unit, using a weld-fabricated
cross-tube. The fabricated cross-tube
and tilt lever use forging at high stress
points to spread the loads for long life.

The tilt link (Dog Bone) is a single
forging. The 963D linkage design
combines the advantages of strength
and durability with minimum structural
weight, so that productivity is not
penalized by excess weight in the linkage.

11

Structure

Durable Slab section Frame and Loader Front End: Durable with increased space
for larger components.

Revolutionary Undercarriage.

SystemOne™ is the latest innovation
in a century of undercarriage leadership.
It was designed to reduce customers’
operating costs and maintenance intervals.

The revolutionary Cat SystemOne™
Undercarriage provides maximum
undercarriage life and reliability no
matter the application, environment or
underfoot conditions. Built to last longer
and require less maintenance it ensures
a dramatic drop in operating costs.

Track Roller Frames. The track roller
frames are a welded, box section
design, which provides strength and
resistance to bending without adding
extra weight. The track roller frames
are pinned at the rear to the loader main
frame with pivot shafts, which allow the
front of the track roller frames to swing
or oscillate about the pivot shafts at
the rear.

Guiding System. Better, more rigid
guiding. The guiding system contacts
link rails instead of pin ends and helps
keep the track within the roller system.

Carrier Rollers. The 963D has seven
track rollers, which spread machine
weight over a large area and two upper
carrier rollers on each side mounts to
the machine mainframe.

12

The SystemOne undercarriage was designed exclusively for Caterpillar machines to reduce
customers’ operating costs, downtime and maintenance intervals.

SystemOne™ Undercarriage

The rollers and carrier rollers have
been redesigned to run with the system.
This will lead directly to better guiding.
All rollers in this new system are single
flange rollers with increased flange
diameter. The increased flange diameters
increase guiding capability.

Idlers. Idlers provide superior structural
support and rebuild capabilities. Special
heat treatment of the idler rim ensures
proper hardness levels, which provides
wear resistance. Cat’s Duo-Cone®seals
give lifetime lubrication, which eliminates
idler maintenance and lowers
operating costs.

Cartridge Joints. Factory-sealed
cartridge joints are welded to control
end play. They offer improved seal
integrity through an innovative new
sealing system and do not depend on the
link interface to remain sealed. As with
all new Cat undercarriage products,
they are filled with special oils.

Track Shoes. The shoes for SystemOne™
are unique to this system. Several track
shoe types tailor your machine for
work in all underfoot conditions.
The SystemOne links have a straight
rather than offset bolt hole pattern.

Double grouser standard or narrow
track shoes are available. The standard
shoe can be fitted with center hole to
reduce material packing.

Long-life Sprockets. The rotating
bushing design of the SystemOne track
greatly reduces wear on the sprocket
teeth, allowing the sprockets to be used
over the lives of multiple
undercarriages.

Oscillating Undercarriage. The
undercarriage on the 963D features an
“oscillating track roller frame design”
which decreases ground shock to the
machine, increases machine stability,
and provides a smoother, more
comfortable ride for the operator.
Oscillating track roller frames keep
more of the track on the ground when
operating on uneven terrain, which
increases machine stability, felt by
the operator, allowing faster machine
operation, increased machine productivity
and reduced operator fatigue.

Track Adjuster. The track adjuster and
mechanical recoil system uses a large
recoil spring and grease filled adjustment
cylinder, which allows the idler to move
forward and back to maintain proper
track tension as it absorbs undercarriage
shock loads.

Equalizer Bar. The equalizer bar is
pinned in its center to the machine
mainframe and at the ends to each track
roller frame. This allows the forward
ends of the track roller frames to
oscillate, or move vertically, to keep
more track on the ground in uneven
underfoot conditions. The equalizer
bar also provides a more stable work
platform for the operator, who will be
comfortable working at faster speeds
for increased productivity.

13

General Purpose Bucket. The General
Purpose (GP) bucket is designed for
excellent loadability and long life in a
broad range of applications such as hard
bank excavating, stripping and stockpile
loading. High-strength, low-alloy steel
helps the bucket resist dents and
abrasions. Rear edge of bucket is
designed for improved efficiency
when backdragging.

The shell-tine design in the bucket back
and floor offers increased structural
strength.

Multi-Purpose Bucket. The Multi­Purpose (MP) bucket combines the
performances of a standard bucket,
dozer blade and clamp. The bucket
provides maximum versatility combined
with strength to handle a broad range of
applications, such as loading, stripping
topsoil, clearing, bulldozing, picking up
debris and grading.

General Purpose Landfill Bucket.

With the integrated trash-rack, the
General Purpose Landfill (GP Landfill)
bucket becomes ideal for digging,
loading and carrying as well as dozing
and spreading material at landfills, or
loading refuse at a transfer station.

Multi-Purpose Landfill Bucket.

The Multi-Purpose Landfill (MP Landfill)
bucket combines the versatility of
a Multi-Purpose bucket with the
performance of a landfill design.
Constructed with a trash-rack for
increased capacity, extra strength
and better load retention. Ideal for
applications in the harsh refuse market,
whether digging or spreading material
at the landfill or grasping and loading
refuse at a transfer station.

Bucket Protection Options. Caterpillar
offers several types of adapters, tips,
and cutting edges, which increase
bucket life and maximize performance.

K Series™ Tooth System. The K-Series
tooth system provides longer tip and
adapter life, faster cycle time with
greater bucket fills and reduced machine
strain. Therefore, it contributes to the
reduction of operating costs.

Easy and convenient during the
installation, this new system provides
a very good response to the need of
reliability and durability of such
components.

Longer Tooth Life. Tips are installed
with a slight twist and secured with a
one-piece retainer, providing less tip
movement and nose wear.

Stable System Geometry. Opposing,
sloped rails on the adapter provide
full length stabilization with minimal
movement. The tip bears directly on the
end of the adapter nose to absorb thrust
loads, leading to better tip retention and
a longer adapter life.

Easy Installation and Removal.

Opposing sloped side rails and flanks
keep the tip on the nose as the retainer
is being installed and removed.
The one-piece vertical retainer requires
low force and no special tools, allowing
faster and easier removal and installation,
amounting to less machine down time
for tip changes.

Sharper Digging Profile. Lower height
at the front and the back of the nose
provides a sharper profile. This provides
more production, less machine strain
and lower cost of machine operation.

14

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.

Versatility

Reversible Tips. Each tip ear has a

retainer groove with a locking recess.
Tips can be run in one direction,
then “flipped,” or reversed, to get the
maximum use of wear material from
the tip.

Tip Options. Caterpillar GET offers a
variety of tips to better accommodate
your needs in any working environment,
whether that is high impact or general­purpose applications.

These and other GET options are
available from your Caterpillar Dealer.

Penetration Tips. Penetration tips are
extremely strong and are for use in high
impact and pry-out work such as rock.

General Duty Tips. General duty tips
are for use in most general applications
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
standard tip. Provides increased
strength, extended service life, and
low cost-per-hour.

Ripper-Scarifier. A radial ripper-scarifier
is available for the 963D as an
attachment. It is mounted with two pins
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
do not require lubrication.

The 963D ripper-scarifier is intended
for ripping frozen ground, asphalt and
easily ripped rock.

Additional Work Tools. Beyond the GP
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

Tiltable Cab. The 963D is equipped
with a tiltable cab. This new feature
makes the maintenance and the repairs
easier. By tilting the cab, you can access
to the drive train and perform complete
service of the hydraulic system.

Right side compartments.

• The two maintenance-free batteries,
the machine ECM and the window
washer reservoir are located on the
right side compartment, accessible
from the ground.

• The engine compartment has large
hinged openings with latches. On the
door, you can clip a grease gun.

You can access to the following
maintenance and service points:

Primary and secondary Engine Air filter

Engine air pre-cleaner

Water in fuel separator

Fuel filters

Engine crankcase breather filter

Engine oil filter

The Electric fuel-priming pump

The dipstick for the oil level in the
engine crankcase and the fill tube.

The electrical disconnect switch.

16

Grouped service points and excellent accessibility make the 963D easy to maintain.

Serviceability and Customer Support

Fuel fill. The fuel tank and the optional

quick fill port are located on the right
side compartment, below the cab access.

Cooling System. The fan and the grill
swing open, providing excellent access
for clean-out and maintenance. The heavy
duty latched grill minimizes debris
build-up.

Ground Level Shutdown. The Engine
Control ECM monitors the status of a
switch that is mounted behind a cover
at the rear of the machine, allowing the
machine to be shut down from ground
level in emergency situations.

Shovel holder. As an optional attachment,
a shovel holder, located on the rear right
side of the machine, is available for
undercarriage cleaning.

Left side compartments. The lower part
of the compartment door can be used as
a step to access the shunt tank fill, the
air pre-cleaner (if equipped) and allows
easy cleaning of the rear window.

Cab Air Filter. The cab air filter, the
grouped pressure taps, the cab tilt
locking bar, the optional cab tilt cylinder,
the tool box, and the hydraulic oil filters
are conveniently located below the left­side cab window.

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
self-diagnosing Electronic Hydraulic
Control (EHC) work together to warn
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 quick­connect hydraulic grouped pressure taps
allow quick diagnosis of the hydrostatic
drive and the implement hydraulic
systems.

Product Link. This attachment allows
a customer or dealer to remotely obtain
machine diagnostics. Product Link
provides updates on service meter hours,
machine condition, machine location,
and integrated mapping/route planning.

Complete Customer Support. Cat field
service technicians have the experience
and tools necessary to service your
loader on site. Technical experts at the
dealership and Caterpillar can provide
additional assistance to field service
technicians as needed. When on-site
repair isn’t enough, Cat dealerships
are fully equipped to service your
loader quickly.

SAFETY.CAT.COM™.

17

With the addition of certain special
modifications, the capabilities of the
963D can be further expanded to handle
some very harsh working conditions.

Waste Handling/Demolition
Arrangements. Waste Handling

arrangements provide added protection
and are designed to make the 963D

perform well in landfills, or any waste
handling or demolition applications
where the machine spreads, compacts,
sorts, shreds and crushes materials.

Shiphold Arrangement. The 963D with
its low ground pressure and excellent
stability works well on top of loose
materials, cleaning the cargo from the
sides of the holds and moving it into
position for the unloading system.
Lifting eyes are included so that the
963D can be lifted from the dock to
the hold.

Wide Gauge. For underfoot conditions
that require even lower ground pressure
than the standard 963D undercarriage
the gauge of the machine can be widened
by 250 mm (9.8 inches) and the track
shoe width increased to 800 mm
(31.5 inches). The ground pressure
is decreased to 53 kPa (7.7 psi).

Custom Products Arrangements.

Other arrangements beyond those
shown here are available. For other
custom-designed arrangements for
specific applications, contact your
Caterpillar Dealer.

18

Special Application Arrangements

Special arrangements improve the 963D’s performance in special applications.

19

963D Track Loader specifications

Service Refill Capacities

Fuel Tank 400 L 105.6 gal
Cooling System 31.5 L 8.3 gal
Crankcase (with Filter) 16.5 L 4.4 gal
Final Drives (each) 15 L 4 gal
Hydraulic Tank 90 L 23.7 gal
Pivot Shaft 1.8 L 0.5 gal

Weights

Operating Weight 20 220 kg 44,577 lb

Buckets

Capacity – General Purpose 2.45 m

3

3.2 yd

3

Capacity – Multi-Purpose 1.9 m

3

2.48 yd

3

Bucket Width – General Purpose 2612 mm 102.8 in
Bucket Width – Multi-Purpose 2575 mm 101.3 in

Ripper Specifications

Type Radial
Number of pockets 3
Overall Width/Beam 1950 mm 76.7 in
Shank cross section 58.5 mm  50 in 

138 mm 5.4 in
Ground Clearance 595 mm 23.4 in
Penetration 295 mm 11.6 in
Ripping Width 1836 mm 72.3 in
Cylinders – Bore 114.3 mm 4.49 in
Cylinders – Stroke 289 mm 11.3 in
Addition to Machine Length due 610 mm 24 in

to Ripper (in Transportation
Position)

Hydraulic System – Equipment

Type Closed center,

load sensing/piston
Output 209 L/min 55.2 gal/min
Main Relief Valve Setting 27 500 kPa 3,989 psi

Engine

Engine Model Cat®C6.6 ACERT™
Flywheel Power 141 kW 189 hp
Net Power – Caterpillar 141 kW 189 hp
Net Power – ISO 9249 141 kW 189 hp
Net Power – SAE J1349 141 kW 189 hp
Net Power – EEC 80/1269 141 kW 189 hp
Bore 105 mm 4.13 in
Stroke 127 mm 5 in
Displacement 6.6 L 403 in

3

Undercarriage

Track Shoe Type Double Grouser
Track Shoe Width – Standard 550 mm 21.6 in
Track Shoe Width – Optional 450 mm 17.7 in
Track Rollers – Each Side 7
Number of Shoes – Each Side 38
Track on Ground 2542 mm 100 in
Ground Contact Area – 2.8 m

2

4,340 in

2

Standard Shoe
Ground Contact Area – 2.3 m

2

3,565 in

2

Optional Shoe
Ground Pressure – 70.9 kPa 10.3 psi

Standard Shoe
Ground Pressure – Optional Shoe 85.5 kPa 12.4 psi
Grouser Height – Double Grouser 42 mm 1.65 in
Track Gauge 1850 mm 72.8 in

Drive System

Track Motor Two, variable

displacement,
bent axis motors

Drive System Hydrostatic drive with

infinite machine speeds
to 10.0 km/h (6.2 mph)

Drive Pump Two, variable-

displacement,
slipper-type axial
piston pumps

Track Motor Two, variable-

displacement,
bent axis motors

Relief Valve Setting 47 500 kPa (6,890 psi)

20

963D Track Loader specifications

Bucket Cycle Times

Lift – Seconds 5.7
Power Down – Seconds 3.7
Float Down – Seconds 2.0
Dump at Max Height 1.3

from full rackback – Seconds
Rackback at Max Height 1.5

from full dump – Seconds

Standards

ROPS/FOPS
Brakes
Cab

• ROPS (Rollover Protective Structure) offered by Caterpillar
for the machine meets ROPS criteria SAE J1040 MAY94,
ISO 3471:1994 DLV criteria SAE J397B, ISO 3164:1995.

• FOPS (Falling Object Protective Structure) meets
SAE J/ISO 3449 APR98 Level II, ISO 3449:1992 Level II
DLV criteria SAE J397B, ISO 3164:1995.

• Brakes meet SAE J/ISO 10265 MARCH99 ISO 10265:1998.

• The operator sound exposure Leq (equivalent sound
pressure level) measured according to the work cycle
procedures specified in ANSI/SAE J1166 OCT 98 is 80 dB(A),
for cab offered by Caterpillar, when properly installed and
maintained and tested with the doors and windows closed.

• The operator sound pressure level measured according to
the procedures specified in ISO 6396:1992 is 76 dB(A) for
the cab offered by Caterpillar, when properly installed and
maintained and tested with the doors and windows closed.

• Hearing protection is recommended when operating with
an open operator station and cab (when not properly
maintained or doors/windows open) for extended periods
or in noisy environment.

• The exterior sound pressure level for the standard machine
measured at a distance of 15 meters according to the test
procedures specified in SAE J88 APR 95, mid-gear-moving
operation, is 80 dB(A).

• The labeled sound power level is 111 dB(A) measured
according to the test procedure and conditions specified
in 2000/14/EC.

21

963D Track Loader specifications

Dimensions

All dimensions are subject to change without notice.

3

18

17

13

16

14

11

15

12

9

8

2

6

1

4

5

1 Overall machine width without bucket:

with standard tracks – 550 mm (21.6 in) shoes 2280 mm (89.7 in)

with narrow tracks – 450 mm (17.7 in) shoes 2180 mm (85.8 in)

2 Ground clearance 471 mm (18.5 in)
3 Machine height to top of cab 3335 mm (131.3 in)
4 Length to front of track 4749 mm (187 in)
5 Overall machine length* 6941 mm (273.3 in)
6 Carry position approach angle 15°
7 Digging depth* 138 mm (5.4 in)
8 Maximum rollback at ground 43°
9 Maximum rollback at carry position 50°
10 Bucket height in carry position 457 mm (18 in)
11 Reach at full lift height and 45° dump* 1373 mm (54 in)
12 Clearance at full lift height and 45° dump* 2915 mm (114.8 in)
13 Maximum rollback, fully raised 52°
14 Maximum dump, fully raised 53°

Grading angle 63°

15 Height to bucket hinge pin 3940 mm (155.1 in)
16 Overall machine height, bucket fully raised 5402 mm (212.7 in)
17 Height to top of seat with headrest 2790 mm (109.8 in)
18 Height to top of stack 2953 mm (116.3 in)

10

7

* With general purpose bucket and extra duty teeth.

Dimensions vary with bucket. Refer to Operating Specifications chart.

22

963D Track Loader specifications

Flush
General purpose Multi purpose mounted
bucket bucket teeth

Attachments on Long teeth Bolt-on Long teeth Bolt-on Long
bucket cutting edge None & segments edge None & segments edge teeth

Bucket weight kg 1508 1866 1721 1942 2236 2155 1619

lb 3,324.5 4,113.8 3,794.1 4,281.3 4,929.5 4,750.9 3,569.2

Rated load nominal heaped § kg 3958 4214 4214 3216 3388 3440 4214

lb 8,721.4 9,290.2 9,290.2 7,090 7,469.2 7,583.8 9,290.2

Rated capacity nominal m

3

2.3 2.45 2.45 1.9 2 2 2.45

heaped yd

3

3 3.2 3.2 2.4 2.6 2.6 3.2

Struck capacity m

3

2 2.14 2.14 1.6 1.7 1.7 2

yd

3

2.61 2.79 2.79 2.09 2.22 2.22 2.61

Bucket width overall * # mm 2508 2612 2539 2482 2575 2515 2583

in 98.7 102.8 99.9 97.7 101.3 99 101.6

Teeth

none

8 bolt-on with

none none

8 bolt-on with

none

8 bolt-on with

replaceable tips replaceable tips replaceable tips

Dimensions and weights

Overall height mm 3335 3335 3335 3335 3335 3335 3335

in 131.3 131.3 131.3 131.3 131.3 131.3 131.3

Overall operating height * mm 5402 5402 5402 5308 5308 5308 5402

in 212.6 212.6 212.6 208.9 208.9 208.9 212.6

Clearance at 45° dump max lift * mm 3155 2915 3068 3000 2772 2909 2951

in 124.2 114.7 120.7 118.1 109.1 114.5 116.1

Reach at 45° dump max lift * mm 1160 1373 1215 1079 1253 1119 1397

in 45.7 54.1 47.8 42.5 49.3 44 55

Reach at 45° dump mm 1784 1899 1806 1598 1650 1607 1940

2133 mm (84 in) clearance * in 70.2 74.8 71.1 62.9 65 63.3 76.4

Bottom dump clearance mm

———

3450 3450 3450

—

at 45° dump max lift in 135.8 135.8 135.8

Bottom dump reach mm

———

627 627 627

—

at 45° dump max lift in 24.7 24.7 24.7

Reach with lift arm horizontal mm 2289 2604 2386 2346 2622 2447 2601

and bucket level in 90.1 102.5 93.9 92.4 103.2 96.4 102.4

Overall length – mm 6584 6941 6706 6698 7013 6820 6907

bucket level on ground * in 258.2 273.3 264 263.7 276.1 268.5 271.9

Digging depth * mm 80 138 115 161 209 191 95

in 3.1 5.4 4.5 6.3 8.2 7.5 3.7
Full dump at max lift * Deg 53 53 53 43 43 43 53
Carry height * mm 457 457 457 540 540 540 457

in 18 18 18 21.6 21.6 21.6 18
Rackback at carry * Deg 50 50 50 52 52 52 50
Rackback at ground * Deg 43 43 43 45 45 45 43
Grading angle max * Deg 63 63 63 63 63 63 63
Static tipping load min * *** kg 14 969 14 462 14 685 14 487 14 124 14 208 14 815

lb 33,001 31,883.1 32,375 31,938.3 31,138 31,323.3 32,661.5
Breakout with tilt cylinders N 208 658 203 868 206 184 193 265 189 538 190 769 207 438

level at ground * lbf 46,908 45,831 46,352 43,447 42,609 42,886 46,634

Lift capacity to full lift – kg 8803 8479 8609 8382 8152 8203 8703

bucket racked * lb 19,407 18,693 18,979.57 18,479 17,972 18,084.5 19,186.8

Lift capacity at ground line – kg 18 574 18 655 19 031 18 559 17 888 18 082 19 300

bucket racked * lb 40,948.6 41,127 41,956 40,915.5 39,436.2 39,863.9 42,549

Shipping weight without bucket ** kg 18 330 18 330 18 330 18 385 18 385 18 385 18 330

lb 40,410.7 40,410.7 40,410.7 40,532 40,532 40,532 40,410.7
Operating weight with bucket *** kg 20 220 20 592 20 433 20 710 20 975 20 911 20 332

lb 44,577.4 45,397.5 45,047 45,657.7 46,241.9 46,100.8 44,824.3

* SAE J732 JUN92

** With 10% fuel. All other fluid compartments full. No operator, no bucket pins.

*** Full fuel, 75 kg (165 lb) operator, standard machine.

# Width at cutting edge

§ Calculation based on 1602 kg/m3(2,700 lb/yd3) of loose dirt.

Operating Specifications

23

963D Track Loader specifications

Standard Equipment

Standard equipment may vary. Consult your Caterpillar dealer for details.

UNDERCARRIAGE

Caterpillar SystemOne track (38 sec.) 1850 mm (72.8 in)

track gauge
Final drive, standard
Track, 550 mm (21.6 in), double grouser
Track adjuster, hydraulic
Sprocket rims, with replaceable bolt-on segments
7 single flange track rollers per side, with two upper carrier

rollers, lifetime lubricated
Conventional idlers, lifetime lubricated
Idler, scrapper
Oscillating track roller frames

HYDRAULIC

Oil change, standard
Hydraulic oil
Hydraulic, 2 way valve

GUARDS

Guard, front
Guard, rear
Guards, full bottom

OTHER STANDARD EQUIPMENT

Cab, tilt, locking bar
Sound Suppression, Exterior
Z-bar loader linkage
Caterpillar Product Link 321 (for selected territories)
Load sensing variable displacement implement pump
Implement cylinders with integrated positioning sensors
Operator programmable lift and tilt kickouts
Engine enclosure with lockable doors
Radiator core 6.5 fpi, debris resistant
Hinged Radiator Guard and swing out fan
Ecology grains on hydraulic tank
Product Link ready
Oil sampling valves
Hydraulic hoses, Caterpillar®XT
Hydraulic Oil, HYDO Advanced 10

WARNING DECALS

Warning decals, ANSI, for NACD
Warning decals, ISO

SERVICE INSTRUCTIONS

English Instructions included in North America and

Canada only

ELECTRICAL

Alternator, 24 volt, heavy duty brushless
Alarm, backup
Horn, electric
2 heavy duty batteries, high output, maintenance free,

1120 CCA
Switch, main disconnect
Starter, electric (heavy duty, 24 volt)
Four halogen lights, two forward facing, roof mounted;

two rearward facing, integrated in A/C unit

OPERATOR ENVIRONMENT

Pressurized, sound suppressed, ROPS/FOPS cab
Cab, windows, glued
Cat Messenger
Side sliding windows
Air conditioning and heater/ defroster with temperature control
Seat, fabric-covered, air suspended, adjustable, with

side-to-side isolator
Seat belt, retractable
Electro Hydraulic Seat mounted control levers
Control, joystick, bucket gp
Electronic Monitoring System with gauges for:

• Engine coolant temperature

• Hydraulic oil temperature

• Engine oil pressure

• Fuel level

Mirror, rearview, inside
Radio-ready. Includes 24 to 12 volt converter, speakers,

antenna and 12 volt power outlet
12 volt outlets (2)
Coat hook
Storage compartments under left armrest
Document holder on right console
Floor mat, rubber, heavy duty
Windshield washers and wipers, front and rear
Durable metal roof
Parking brake switch and “brake-on” indicator light

POWER TRAIN

Caterpillar C6.6 ACERT engine diesel engine, turbo

charged with ATAAC
Modular cooling system for engine air intake, oil and water
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

Optional Equipment

Optional equipment may vary. Consult your Caterpillar dealer for details.

BUCKET ATTACHMENTS

Cutting edge, bolt-on
Segments, bolt-on
Edge, segments, bolt-on
Edge, segments, heavy duty
Teeth, general duty, K80
Teeth, penetration, K80
Teeth, extra duty, K80
Teeth, general duty, K90
Teeth, extra duty, K90
Tips, general duty, flush adapter

OTHER ATTACHMENTS

Cab tilt jack, hydraulic
Shovel holder
Bumper
Ripper, multi-shank
Hitch, drawbar
Hitch, standard
Striker bars, rear
Sediment pump, fuel tank
Heater, engine coolant, 120V
Heater, engine coolant, 240V
Counterweight, light
Counterweight additional
Antifreeze, –50° C (–58° F)

GUARDS

Guard front heavy duty
Lines GP-brake – M
Lines GP-Brake – Wide Gauge

ELECTRICAL

Beacon, rotating
Lights, four, extra

IMPLEMENT CONTROLS

Control, joystick, GP bucket
Control, joystick, MP bucket
Control, two levers, GP bucket

OPERATOR ENVIRONMENT

Cat®Messenger
Seat, air suspended, heated
Cab windows, front sealed

POWER TRAIN

Fan, demand, reversing
Tank fuel, fast fill
Air inlet, pre-cleaner, turbine
Oil change, high speed

UNDERCARRIAGE

Track, 450 mm (17.7"), DG, narrow
Track, 550 mm (21.6"), DG, center hole
Track, 450 mm (17.7"), DG, center hole
Track, 560 mm (22"), SG, extreme service
Track, 450 mm (17.7"), center hole, SG, extreme service
Track, 800 mm (31.5"), DG, wide gauge
Track, 560 mm (22"), center hole, SG, extreme service
Idler, with seal protection

GUARDS

Guard, idler
Guard, track roller
Guard, cab lights
Guard, lift lines
Screen, windshield

HYDRAULIC

Hydraulic oil, bio
Hydraulic, MP bucket, lines front
Hydraulic, ripper, lines rear
Hydraulic, MP bucket and ripper, lines front and rear

BUCKET

General purpose
General purpose, flush mounted adapter
General purpose, landfill
Multi purpose
Multi purpose, extreme service
Multi purpose, landfill
Refuse

24

963D Track Loader specifications

25

963D Track Loader specifications

Notes

963D Track Loader specifications

26

Notes

963D Track Loader specifications

27

Notes

For more complete information on Cat products, dealer services,

and industry solutions, visit us on the web at www.cat.com

© 2008 Caterpillar

All Rights Reserved

Printed in U.S.A.

Materials and specifications are subject to change without notice.

Featured machines in photos may include additional equipment.

See your Caterpillar dealer for available options.

CAT, CATERPILLAR, ACERT, SystemOne, SAFETY.CAT.COM, their respective logos,

“Caterpillar Yellow,” and the POWER EDGE trade dress, as well as corporate and product

identity used herein, are trademarks of Caterpillar and may not be used without permission.

AEHQ5827-02 (9-08)

Replaces AEHQ5827-01

963D Track Loader

R