Bobcat 963 Skid-Steer Loader Repair Service Manual - 6724545

(S/N: 562211001-11686 - S/N: 516511001-11065 - S/N: 562211687 and Above - S/N: 516511066 and Above) 
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This workshop repair service manual PDF download for the 963 Bobcat Skid-Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity. 


APPLICABLE MODELS :

Bobcat Loader 963 
S/N: 562211001-11686
S/N: 516511001-11065
S/N: 562211687 and Above 
S/N: 516511066 and Above


TABLE OF CONTENTS :

FOREWORD 
SAFETY INSTRUCTIONS 
SERIAL NUMBER LOCATIONS 
DELIVERY REPORT 
BOBCAT LOADER IDENTIFICATION 
PREVENTIVE MAINTENANCE 
HYDRAULIC SYSTEM 
HYDROSTATIC SYSTEM 
DRIVE SYSTEM 
MAIN FRAME 
ELECTRICAL SYSTEM 
ENGINE SERVICE 
SYSTEM ANALYSIS 
SPECIFICATIONS 
ADVANCED HAND CONTROL SYSTEM
SERVICE MANUAL REVISIONS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6724545 (11–97)
Total Pages : 500


This 963 Bobcat Loader Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!! 

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MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
    FOREWORD
    SAFETY INSTRUCTIONS
    FIRE PREVENTION
    SERIAL NUMBER LOCATIONS
    LOADER SERIAL NUMBER
    ENGINE SERIAL NUMBER
    DELIVERY REPORT
    963 BOBCAT LOADER IDENTIFICATION
    
PREVENTIVE MAINTENANCE
    SERVICE SCHEDULE
    LIFTING AND BLOCKING THE LOADER
        Procedure
    TRANSPORTING THE LOADER
        Procedure
    TOWING THE LOADER
        Procedure
    LIFT ARM SUPPORT DEVICE
        Engaging The Lift Arm Support Device
        Disengaging The Lift Arm Support Device
    OPERATOR CAB
        Description
        Raising The Operator Cab
        Lowering The Operator Cab
        Emergency Exit
    SEAT BAR RESTRAINT SYSTEM
        Description
        Inspecting The Seat Bar
        Maintaining The Seat Bar
    AIR CLEANER SERVICE
        Replacing Filter Elements
    FUEL SYSTEM
        Fuel Specifications
        Filling The Fuel Tank
        Fuel Filters
        Removing Air From The Fuel System
    ENGINE LUBRICATION SYSTEM
        Checking Engine Oil
        Replacing The Oil And Filter
    ENGINE COOLING SYSTEM
        Checking The Coolant Level
        Cleaning The Cooling System
        Replacing The Coolant
    ALTERNATOR BELT
        Adjusting The Alternator Belt
    HYDRAULIC/HYDROSTATIC SYSTEM
        Checking And Adding Fluid
        Hydraulic/Hydrostatic Filter Replacement
        Replacing The Hydraulic Fluid
    SPARK ARRESTOR MUFFLER
        Cleaning Procedure
    TIRE MAINTENANCE
        Wheel Nuts
        Tire Rotation
        Tire Mounting
    FINAL DRIVE TRANSMISSION (CHAINCASE)
        Checking And Adding Oil
    FAN GEARBOX
        Checking And Maintaining
    LUBRICATING THE LOADER
        Procedure
    BOB–TACH
        Inspection And Maintenance
    REMOTE START SWITCH
        Procedure
        
HYDRAULIC SYSTEM
    HYDRAULIC / HYDROSTATIC SCHEMATICS
    TROUBLESHOOTING
    HYDRAULIC SYSTEM INFORMATION
        Tighten Procedures
    LIFT CYLINDER
        Checking the Lift Cylinder(s)
        Removal and Installation
    TILT CYLINDER
        Checking The Tilt Cylinder(s)
        Removal And Installation
    HYDRAULIC CYLINDER
        Lift Cylinder Parts Identification
        Tilt Cylinder Parts Identification
        Disassembly
        Assembly
    TILT JUNCTION BLOCK
        Removal And Installation
    MAIN RELIEF VALVE
        Checking Main Relief Valve At Front Auxiliary Hydraulics
        Checking Main Relief Valve At Control Valve
        Removal And Installation
        Adjustment
    BICS™ VALVE
        Lift Arm By–Pass Orifice
        Lock Valve
        Check Valve
        BICS™ Valve Solenoid
        BICS Valve Removal And Installation
    HYDRAULIC CONTROL VALVE
        Removal And Installation
        Identification Chart
        Disassembly And Assembly
        Load Check Valve
        Main Relief Valve
        Port Relief Valve (Lift Section)
        Anti–Cavitation/Port Relief Valve
        Anti–Cavitation Valve
        Port Relief Valve (Tilt Section)
        Rubber Boot
        Lift Spool And Detent
        Tilt Spool And Centering Spring
        Auxiliary Spool
        Auxiliary Electric Solenoid
        H–Port – Auxiliary Section
        Inspection
        Spool Seal Installation
    LIFT ARM BY–PASS CONTROL VALVE
        Removal And Installation
        Disassembly And Assembly
    BUCKET POSITION VALVE
        Removal And Installation
        Disassembly And Assembly
    HYDRAULIC PUMP
        Checking the Output of the Pump
        Removal And Installation
        Disassembly And Assembly
        Inspection
    HYDRAULIC/HYDROSTATIC FILTER
        Removal And Installation
    HYDRAULIC FLUID RESERVOIR
        Draining The Hydraulic Fluid Reservoir
        Removal And Installation
    CONTROL PEDALS
        Removal And Installation
        Pedal Adjustment
    PEDAL INTERLOCK LINKAGE
        Removal And Installation
        Adjustment
    FRONT SIDE PANEL
        Removal and Installation
    CONTROL PEDALS MOUNTING PANEL
        Removal and Installation
        
HYDROSTATIC SYSTEM
    TROUBLESHOOTING
    HYDROSTATIC SYSTEM INFORMATION
        Replenishing Valve Function
        Checking The Charge Pressure
    CONTROL PANEL
        Removal And Installation
    STEERING LEVERS
        Disassembly And Assembly
    STEERING LINKAGE
        Neutral Adjustment
    HYDROSTATIC CONTROLLER
        Removal and Installation
        Disassembly and Assembly
        Adjustment
    HYDROSTATIC MOTOR
        Removal and Installation
        Throttle Control
        Shuttle Check Valve
        Flushing Valve
        Disassembly
        Inspection
        Assembly
    HYDROSTATIC PUMP
        Removal And Installation
        Hydraulic Pump Removal And Installation
        Replenishing/High Pressure Relief Valve
        Charge Relief Valve
        DA Controller
        Disassembly
        Inspection
        Assembly
        Hydrostatic Pump Start–Up
        Timing Procedure
    DRIVE BELT BELT SHIELD
        Removal And Installation
    DRIVE BELT
        Replacing The Drive Belt
        Adjusting The Drive Belt
    DRIVE BELT TENSIONER PULLEY
        Removal And Installation
        Tension Spring
        Disassembly And Assembly
        Pivot Shaft
    DRIVE BELT IDLER PULLEY
        Removal And Installation
    HYDROSTATIC MOTOR COVER
        Removal And Installation
    OIL COOLER
        Removal And Installation
        
DRIVE SYSTEM
    PARKING BRAKE PEDAL
        Removal And Installation
        Disassembly And Assembly
    BRAKE/TWO SPEED BLOCK
        Removal And Installation
        Disassembly And Assembly
    PARKING BRAKE 
        Removal And Installation
        Disassembly And Assembly
    AXLE SEAL
        Removal And Installation
    AXLE, BEARINGS AND SPROCKET
        Removal And Installation
    DRIVE CHAINS
        Removal And Installation
    FRONT CHAINCASE COVER
        Removal And Installation
    REAR CHAINCASE COVER
        Removal and Installation
    REDUCTION GEARCASE
        Removal And Installation
        Disassembly And Assembly
    CHAINCASE FLUID
        Removing The Fluid From The Chaincase
        
MAIN FRAME
    SEAT BAR
        Removal And Installation
        Assembling Components
        Compression Spring Disassembly And Assembly
    OPERATOR CAB GAS CYLINDER
        Removal And Installation
        Gas Cylinder Mounting Bracket
    OPERATOR CAB
        Removal And Installation
    OPERATOR SEAT
        Removal And Installation
    BOB–TACH
        Removal And Installation
        Bob–Tach Lever And Wedge
        Bob–Tach Stops
    LIFT ARMS
        Removal And Installation
    REAR GRILL
        Gas Cylinder Removal And Installation
        Removal And Installation
    REAR DOOR
        Removal And Installation
        Adjusting The Rear Door Latch
    FRONT FUEL TANK
        Removal And Installation
        Fuel Level Sender
    REAR FUEL TANK
        Removal And Installation
        Pickup Tube Screen
        
ELECTRICAL SYSTEM
    ELECTRICAL SCHEMATICS
    TROUBLESHOOTING
    ELECTRICAL SYSTEM INFORMATION
        Description
        Fuse Location
    RELAY SWITCHES
        Location
    BATTERY
        Removal And Installation
        Servicing The Electrical System
        Using A Booster Battery (Jump Starting)
    ALTERNATOR
        Alternator Output Test
        Rectifier (Diode) Test
        Alternator Regulator Test
        Removal And Installation
        Adjusting the Alternator Belt
        Disassembly
        Stator Continuity Test
        Stator Ground Test
        Rotor Continuity Test
        Rotor Ground Test
        Rectifier Continuity (Diode) Test
        Assembly
    STARTER
        Removal And Installation
        Parts Identification
        Disassembly And Assembly
        External Pinion
        Inspection And Repair
        Magnetic Switch Test
        No Load Test
    STANDARD INSTRUMENT PANEL
        Removal And Installation
    FRONT LIGHTS
        Removal And Installation
        
ENGINE SERVICE
    TROUBLESHOOTING
    ENGINE SPEED CONTROL
        Removal And Installation
    ENGINE MUFFLER
        Removal And Installation
        Exhaust Extension Pipe
    AIR CLEANER HOUSING
        Removal And Installation
    COOLANT RECOVERY TANK
        Removal And Installation
    RADIATOR
        Removal And Installation
    FAN DRIVE TENSION PULLEY
        Removal And Installation
    FAN GEARBOX/BLOWER HOUSING
        Removal And Installation
    BLOWER FAN
        Removal And Installation
    FAN GEARBOX
        Disassembly
        Assembly
        Checking Backlash
    FLYWHEEL
        Removal And Installation
        Ring Gear Removal
        Ring Gear Installation
    ENGINE MOUNTING BRACKET
        Removal and Installation
    VALVE CLEARANCE
        Adjustment
    FUEL LIFT PUMP
        Checking
        Removal And Installation
    FUEL INJECTION PUMP
        Removal And Installation
    FUEL INJECTOR NOZZLES
        Removal and Installation
        Checking
    ENGINE
        Removal And Installation
    INTAKE MANIFOLD
        Removal and Installation
    EXHAUST MANIFOLD
        Removal and Installation
    CYLINDER HEAD
        Removal
        Inspection
        Installation
    ROCKER SHAFT
        Disassembly And Assembly
    VALVES, VALVE GUIDES AND SPRINGS
        Valve Removal
        Checking Valve Springs
        Checking Valve Depth
        Checking Valve Guides
        Valve Guide Removal
        Valve Guide Installation
        Checking Valves
        Cutting A Valve Seat
        Assembly
        Changing Valve Springs (With Cylinder Head Installed)
    TIMING CASE AND DRIVE ASSEMBLY
        Description
        Timing Cover Removal
        Timing Cover Installation
        Front Oil Seal Removal
        Front Oil Seal Installation
        Timing Case And Gear Removal
        Timing Case And Gear Installation
    CAMSHAFT AND TAPPETS
        Removal
        Installation
    PISTONS AND CONNECTING RODS
        Description
        Removal
        Disassembly
        Piston Ring End Gap
        Piston Ring Installation
        Piston Ring Groove Clearance
        Connecting Rod Inspection
        Connecting Rod Bushing Replacement
        Assembly
        Installation
        Checking Piston Height
    CRANKSHAFT AND BEARINGS
        Description
        Removal
        Inspection Of Crankshaft And Bearings
        Installation
        Rear Oil Seal Removal
        Rear Oil Seal Housing Positioning
        Rear Oil Seal Installation
        Checking Crankshaft End Play
    COOLING SYSTEM
        Description
        Thermostat Removal and Installation
        Thermostat Testing
        Water Pump Removal
        Water Pump Installation
    ENGINE OIL COOLER
        Removal and Installation
        Disassembly and Assembly
    LUBRICATION SYSTEM
        Description
        Oil Filter Adapter Removal
        Oil Filter Adapter Installation
        Oil Pan Removal And Installation
        Oil Screen And Pick–up Tube
        Oil Pump Removal
        Oil Pump Installation
        Oil Pump Disassembly And Assembly
        Oil Pressure Relief Valve Disassembly And Assembly
    ENGINE BLOCK
        Description
        Disassembly And Assembly
        Piston Cooling Jet Removal
        Piston Cooling Jet Installation
        Piston Cooling Jet Alignment
        Inspection
        Cylinder Liner Inspection
        Cylinder Liner Removal
        Cylinder Liner Installation
    TURBOCHARGER
        Troubleshooting
        Description
        Removal and Installation
        
SYSTEMS ANALYSIS
    BICS™ (With Press To Operate Button)
        Inspecting The BICS™ Controller (Engine STOPPED – Key ON)
        Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)
        Inspecting The Seat Bar Sensor (Engine RUNNING)
        Inspecting The Traction Lock (Engine RUNNING)
        Inspecting The Lift Arm By–Pass Control
        Additional Inspection For Advanced Hand Controls
        Troubleshooting Chart
    BICS™ (Without Press To Operate Button)
        Inspecting The BICS™ Controller (Engine STOPPED – Key ON)
        Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)
        Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)
        Inspecting The Traction Lock (Engine RUNNING)
        Inspecting The Lift Arm By–Pass Control
        Maintenance
        Troubleshooting Chart
    SEAT SENSOR OVERRIDE ONLY (If Equipped)
    BICS™ SYSTEM CONTROLLER
        Troubleshooting Guide
        Removal And Installation
    SEAT BAR SENSOR
        Troubleshooting Guide
        Seat Bar Sensor Test
        Removal And Installation
        BICS™ Controller Seat Bar Sensor Circuit Test
    SEAT SENSOR
        Troubleshooting Guide
        Seat Sensor Test
        Removal And Installation
        BICS™ Controller Seat Sensor Circuit Test
    TRACTION LOCK
        Troubleshooting Guide
    BOSS® DIAGNOSTIC TOOL
        Procedure
    SENDER AND SENSOR
        Service Checks
        Components
        Adjustment
    MONITOR SERVICE CODES
    TROUBLESHOOTING THE BOSS® & LCD DISPLAY
    BOSS® UNIT
        Removal and Installation
    BOSS® INSTRUMENT PANEL
        Removal and Installation
    PWM MODULE
        Description
    PWM TROUBLESHOOTING
        Conditions
        Chart
    PWM CONTROL HANDLE
        Handle Testing
    PWM ELECTRIC SOLENOID
        Solenoid Coil Testing
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
        Controls Identification Chart
        
SPECIFICATIONS
    LOADER SPECIFICATIONS
        Performance
        Controls
        Engine
        Hydraulic System
        Electrical
        Drive System
        Capacities
        Tires
    ENGINE SPECIFICATIONS
        General
        Cylinder Head
        Valve Guides
        Exhaust Valves
        Intake Valves
        Valve Springs
        Rocker Shaft, Rockers And Bushings
        Pistons And Piston Rings
        Connecting Rods And Bearings
        Crankshaft
        Crankshaft Re–Grind Data
        Main Bearings
        Thrust Washers
        Camshaft And Thrust Washer
        Cylinder Block
        Cylinder Liners
        Fuel Injection Pump
        Fuel Injectors
        Fuel Lift Pump
        Timing Case And Timing Gears
        Oil Pump, Gear And Relief Valve
        Turbocharger
        Flywheel
        Water Pump And Thermostat
        Engine Torque
    LOADER TORQUE
    TORQUE SPECIFICATIONS FOR BOLTS
        Torque For General SAE Bolts
        Torque For General Metric Bolts
    HYDRAULIC CONNECTION SPECIFICATIONS
        O–ring Face Seal Connection
        Straight Thread O–ring Fitting
        Tubelines And Hoses
        Flare Fitting
        O–ring Flare Fitting
        Port Seal Fitting
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
    DECIMAL AND MILLIMETER EQUIVALENTS
    U.S. TO METRIC CONVERSION
    
ADVANCE HAND CONTROL SYSTEM (A.H.C)
    A.H.C. COMPONENTS
        Identification
    TROUBLESHOOTING (A.H.C.)
    ACTUATOR VOLTAGE TEST
        Procedure
    HANDLE CONTROL UNIT TEST
        Procedure
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
        Troubleshooting Chart
    SEAT SENSOR OVERRIDE ONLY
    ADVANCED HAND CONTROLS (AHC)
    A.H.C./PWM CONTROLLER
        Removal and Installation
        Description
        Conditions
        Troubleshooting Chart
        Handle Testing
        Solenoid Coil Testing
    HANDLE CONTROL UNIT
        Removal And Installation
        Control Unit Connector
    SWITCH HANDLE
        Removal and Installation
    A.H.C. HANDLE
        Removal and Installation
        Disassembly and Assembly
    A.H.C. STEERING LEVER
        Removal and Installation
        Steering Lever Boot
        Disassembly and Assembly
    BICS™ VALVE
        Lift Arm By–Pass Orifice
        Check Valve
        Lock Valve
        BICS™ Valve Solenoid
        Removal and Installation
    HYDRAULIC CONTROL VALVE
        Removal And Installation
        Mounting Plate
        Identification Chart
        Disassembly and Assembly
        Load Check Valve
        Main Relief Valve
        Port Relief Valve (Lift)
        Anti–Cavitation/Port Relief Valve
        Port Relief Valve (Tilt)
        Anti–Cavitation Valve
        Rubber Boot
        Lift and Tilt Spool
        Inspection
        Auxiliary Spool
        Auxiliary Electrical Solenoid
        H–Port Auxiliary Section
        Spool Seal Installation
        
SERVICE MANUAL REVISIONS
    963–1
    963–2
    963–3
    963–4
    
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