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The CAT 963B and Its Hydraulic System
The Caterpillar 963B track loader, introduced in the late 1980s, was designed as a mid-sized crawler loader with hydrostatic drive and a robust hydraulic system. It featured a 3204 or 3116 diesel engine, depending on the year, and a load-sensing hydraulic system that powered the boom, bucket, and auxiliary functions. With thousands of units sold globally, the 963B became a staple in construction, demolition, and material handling.
Its hydraulic system includes a main implement pump, pilot pump, charge pump, and a series of valves and cylinders. The system is designed to maintain consistent pressure and flow under varying loads and temperatures. However, as these machines age, hydraulic performance can degrade due to wear, contamination, or component failure.
Symptoms of Hydraulic Weakness
A common issue reported with the 963B is progressive hydraulic weakness after several hours of operation. Initially, the boom and bucket functions perform normally, but after 3–4 hours, the boom becomes sluggish and eventually struggles to lift even an empty bucket. This degradation typically occurs gradually, worsening over 30 minutes until the machine becomes nearly inoperable.
Terminology Explained
Several potential causes can lead to this type of hydraulic failure:
In Georgia, a civil superintendent faced a similar issue with a 963B. After hours of troubleshooting and replacing the charge pump, the problem persisted. Eventually, they discovered a cracked weld inside the hydraulic tank near the suction line. This allowed air to enter the system, causing the pilot pump to fail. A replacement pump was sourced from a salvage yard in Missouri, and the machine returned to full function.
Recommended Diagnostic Steps
As the 963B ages, sourcing OEM parts becomes more difficult. For example:
Hydraulic weakness in the CAT 963B after extended use is often the result of internal pump wear, suction line leaks, or pilot system starvation. A methodical approach—starting with pressure testing and fluid analysis—can pinpoint the issue without unnecessary part replacement. With careful inspection and sourcing, even aging machines like the 963B can be restored to reliable performance.
The Caterpillar 963B track loader, introduced in the late 1980s, was designed as a mid-sized crawler loader with hydrostatic drive and a robust hydraulic system. It featured a 3204 or 3116 diesel engine, depending on the year, and a load-sensing hydraulic system that powered the boom, bucket, and auxiliary functions. With thousands of units sold globally, the 963B became a staple in construction, demolition, and material handling.
Its hydraulic system includes a main implement pump, pilot pump, charge pump, and a series of valves and cylinders. The system is designed to maintain consistent pressure and flow under varying loads and temperatures. However, as these machines age, hydraulic performance can degrade due to wear, contamination, or component failure.
Symptoms of Hydraulic Weakness
A common issue reported with the 963B is progressive hydraulic weakness after several hours of operation. Initially, the boom and bucket functions perform normally, but after 3–4 hours, the boom becomes sluggish and eventually struggles to lift even an empty bucket. This degradation typically occurs gradually, worsening over 30 minutes until the machine becomes nearly inoperable.
Terminology Explained
- Charge Pump: A small pump that supplies oil to the main hydraulic pump to maintain pressure and prevent cavitation.
- Pilot System: A low-pressure hydraulic circuit that controls the main valves via joystick or lever inputs.
- Cavitation: The formation of vapor bubbles in hydraulic fluid due to low pressure, which can damage pumps and reduce performance.
Several potential causes can lead to this type of hydraulic failure:
- Worn Implement Pump Over time, internal wear in the main pump can reduce its ability to maintain pressure, especially when hot. Seals may degrade, and internal bypassing increases, leading to pressure loss.
- Pilot Pump Starvation A pinhole leak in the suction line or a cracked weld inside the hydraulic tank can cause the pilot pump to cavitate. This results in erratic control and eventual failure of the pilot system.
- Heat-Related Viscosity Loss If the hydraulic oil is too thin or degraded, it may lose viscosity when hot, reducing system pressure. Using the wrong oil type or failing to change it regularly can exacerbate this.
- Clogged Filters or Screens Even after replacing filters, internal screens or suction strainers may remain clogged, restricting flow and starving the pump.
In Georgia, a civil superintendent faced a similar issue with a 963B. After hours of troubleshooting and replacing the charge pump, the problem persisted. Eventually, they discovered a cracked weld inside the hydraulic tank near the suction line. This allowed air to enter the system, causing the pilot pump to fail. A replacement pump was sourced from a salvage yard in Missouri, and the machine returned to full function.
Recommended Diagnostic Steps
- Test main and pilot system pressures using a hydraulic gauge
- Inspect suction lines for leaks or soft spots
- Remove and inspect the hydraulic tank for internal damage or contamination
- Analyze hydraulic oil for viscosity, contamination, and water content
- Verify that the correct oil type and viscosity are being used (e.g., CAT HYDO Advanced 10 or SAE 10W)
As the 963B ages, sourcing OEM parts becomes more difficult. For example:
- Pilot pump (part number 107-4321) may be unavailable from dealers
- Complete pump group (6E-6046) may require contacting remanufacturers or salvage yards
- Aftermarket or remanufactured pumps are available from suppliers in Morton and York, PA, ranging from $1,530 to $2,350
Hydraulic weakness in the CAT 963B after extended use is often the result of internal pump wear, suction line leaks, or pilot system starvation. A methodical approach—starting with pressure testing and fluid analysis—can pinpoint the issue without unnecessary part replacement. With careful inspection and sourcing, even aging machines like the 963B can be restored to reliable performance.
