Bobcat 963 Skid-Steer Loader Repair Service Manual - 6900988

(S/N: 562215001 & Above) - (S/N: 516515001 & 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: 562215001 & Above)
(S/N: 516515001 & Above)


TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS 
SERIAL NUMBER LOCATIONS 
DELIVERY REPORT
BOBCAT LOADER INDENTIFICATION 
SAFETY & MAINTENANCE 
HYDRAULIC SYSTEM 
HYDROSTATIC SYSTEM 
DRIVE SYSTEM 
MAIN FRAME 
ELECTRICAL SYSTEM & ANALYSIS
ENGINE SERVICE 
HEATING, VENTILATION, AIR CONDITIONING 
SPECIFICATIONS
SERVICE MANUAL REVISIONS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6900988 (3-06)
Total Pages : 640


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
    BOBCAT LOADER INDENTIFICATION
    
SAFETY & MAINTENANCE
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
        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 Loaders With Advanced Hand Controls (AHC)
    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
    HAND-LEVER BOB-TACH
        Inspection And Maintenance
    POWER BOB-TACH (OPTION)
        Inspection and Maintenance
    OPERATOR CAB
        Description
        Raising The Operator Cab
        Lowering The Operator Cab
        Emergency Exit
    SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)
        Description
        Inspecting The Seat Bar
        Maintaining The Seat Bar
    SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)
        Description
        Inspecting The Seat Bar
        Maintaining The Seat Bar
    REMOTE START
        Procedure for Loader Without, Attachments Control Harness
        Procedure for Loader With Attachments Control Harness
        Procedure
    SERVICE SCHEDULE
    FUEL SYSTEM
        Fuel Specifications
        Filling the Fuel Tank
        Fuel Filters
        Removing Air From The Fuel System
    AIR CLEANER SERVICE
        Replacing Filter Element
    ENGINE LUBRICATION SYSTEM
        Checking Engine Oil
        Replacing OIl and Filter
    ENGINE COOLING SYSTEM
        Cleaning The Cooling System
        Checking The Coolant Level
        Replacing The Coolant
    HYDRAULIC/HYDROSTATIC SYSTEM
        Checking And Adding Fluid
        Replacing The Hydraulic/Hydrostatic Filters
        Replacing The Hydraulic Fluid
        Breather Cap
    TIRE MAINTENANCE
        Wheel Nuts
        Tire Rotation
        Tire Mounting
    LUBRICATING THE BOBCAT LOADER
        Procedure
        
HYDRAULIC SYSTEM
    HYDRAULIC/HYDROSTATIC SCHEMATICS
    HYDRAULIC SYSTEM INFORMATION
        Glossary of Hydraulic/Hydrostatic Symbols for Loaders
        Troubleshooting Chart
        Tighten Procedures
    CYLINDER(S)
        Checking The Lift Cylinder(s)
        Removal And Installation Of Lift Cylinder(s)
        Checking The Tilt Cylinder(s)
        Removal And Installation Of Tilt Cylinder(s)
        Tilt Cylinder Base End Pivot Pin
        Lift Cylinder Parts Identification
        Tilt Cylinder Parts Identification
        Disassembly
        Assembly
    MAIN RELIEF VALVE
        Checking Main Relief Valve At Front Auxiliary Hydraulics
        Checking Main Relief Valve At Control Valve.
        Removal And Installation
        Adjustment
    MAIN RELIEF VALVE (ADVANCED HAND CONTROL) (AHC)
        NOT AVAILABLE AT TIME OF PRINTING
    HYDRAULIC CONTROL VALVE (FOOT CONTROL)
        Removal And Installation
        BICS™ Valve, Removal And Installation
        BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly
        BICS™ Valve, Check Valve Disassembly And Assembly
        BICS™ Valve, Lock Valve Disassembly And Assembly
        BICS™ Valve, Solenoid Disassembly And Assembly
        BICS™ Valve, Solenoid Testing
        Identification Chart
        Load Check Valve
        Main Relief Valve
        Port Relief Valve, Tilt Spool (Linkage End)
        Port Relief Valve, Lift Spool (Bonnet End)
        Anti-Cavitation Valve/Port Relief Valve, Tilt Spool (Bonnet End)
        Anti-Cavitation Valve, Lift Spool (Linkage End)
        Rubber Boot
        Lift And Tilt Lock Block
        Lift Spool and Detent
        Tilt Spool Removal And Installation
        Auxiliary Spool Removal And Installation (Bonnet End)
        Auxiliary Spool Removal And Installation (Linkage End)
        Auxiliary Plug Removal And Installation
        Auxiliary Electric Solenoid Disassembly
        Port Relief-Auxiliary Section Disassembly
        Cleaning And Inspection
    HYDRAULIC CONTROL VALVE (ADVANCE HAND CONTROL) (AHC)
        NOT AVAILABLE AT TIME OF PRINTING
    LIFT ARM BY-PASS CONTROL VALVE
        Removal And Installation
        Disassembly And Assembly
    HYDRAULIC PUMP
        Checking the Output of the Pump
        Removal And Installation
        Disassembly and Assembly
    HYDRAULIC PUMP
        Disassembly And Assembly
        Inspection
    HYDRAULIC/HYDROSTATIC FILTER
        Removal And Installation
    COOLING FAN FILTER
        Removal And Installation
    HYDRAULIC FLUID RESERVOIR
        Removal And Installation
    CONTROLS
        Control Pedal Removal And Installation
        Control Pedal Adjustment
        Control Pedals Mounting Panel Removal And Installation
    BUCKET POSITION VALVE
        Removal And Installation
        Disassembly And Assembly
    TILT JUNCTION BLOCK
        Removal And Installation
    REAR AUXILIARY DIVERTER
        Removal And Installation
        Disassembly
        Inspection
        Solenoid Testing
        Assembly
        
HYDROSTATIC SYSTEM
    HYDROSTATIC SYSTEM INFORMATION
        Troubleshooting Chart
        Replenishing Valve Function
    CONTROL PANEL
        Removal And Installation
    STEERING
        Lever Removal And Installation
        Disassembly And Assembly
        Neutral Adjustment
    HYDROSTATIC MOTOR
        Removal and Installation
        Throttle Control
        Shuttle Check Valve
        Flushing Valve
        Disassembly
        Inspection
        Assembly
        Cover Removal And Installation
        Neutral Adjustment
    CHARGE PRESSURE
        Checking The Charge Pressure
    HYDROSTATIC PUMP
        Removal And Installation
        Replenishing/High Pressure Relief Valve
        Charge Relief Valve
        DA Controller
        Disassembly
        Inspection
        Assembly
        Hydrostatic Pump Start-Up
        Neutral Adjustment
        Timing Procedure
    DRIVE BELT
        Shield Removal And Installation
        Replacement
        Adjustment
        Tensioner Pulley Removal And Installation
        Tensioner Tension Spring
        Tensioner Pulley Disassembly And Assembly
        Tensioner Pivot Shaft
        Idler Pulley Removal And Installation
    OIL COOLER
        Removal And Installation
        
DRIVE SYSTEM
    BRAKE
        Pedal Removal And Installation
        Pedal Disassembly And Assembly
        Two Speed Block Removal And Installation
        Two Speed Block Disassembly And Assembly
        Parking Brake Removal And Installation
        Parking Brake Disassembly And Assembly
    DRIVE COMPONENTS
        Axle Seal Removal And Installation
        Axle, Bearings And Sprocket Removal And Installation
        Drive Chains Removal And Installation
    CHAINCASE
        Checking And Adding Oil
        Front Chaincase Cover Removal And Installation
        Rear Chaincase Cover Removal and Installation
        Reduction Gearcase Removal And Installation
        Reduction Gearcase Disassembly And Assembly
        Removing The Oil 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 Bracket Disassembly And Assembly
        Removal And Installation
    OPERATOR SEAT
        Removal And Installation
        Slide Rail Removal And Installation
        Cushion Removal And Installation
        Back Removal And Installation
        Shock Removal And Installation
    BOB-TACH
        Removal And Installation
        Bob-Tach Lever And Wedge
        Bob-Tach Stops
    POWER BOB-TACH
        NOT AVAILABLE AT TIME OF PRINTING
    LIFT ARMS
        Removal And Installation
    REAR GRILL
        Gas Cylinder Removal And Installation
    REAR DOOR
        Removal And Installation
        Adjusting The Rear Door Latch
        Door Latch Removal And Installation
        Door Brace Removal And Installation
    FUEL TANK
        Front Removal And Installation
        Fuel Level Sender
        Rear Removal And Installation
        Pick-up Tube Screen
        
ELECTRICAL SYSTEM & ANALYSIS
    ELECTRICAL SCHEMATICS
    ELECTRICAL SYSTEM INFORMATION
        Troubleshooting Chart
        Description
        Fuse Location
        Relay Switch Location
        Solenoid Test
    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
    INSTRUMENT PANEL
        Left Panel
        Right Panel - Standard Instrument Panel (With Key Switch)
        Right Panel - (Deluxe) (With Keyless Start)
        Right Panel Set Up Display Options (Deluxe)
        Passwords
        Option And Field Accessory Panels
        Standard Panel Removal And Installation (Right Side)
        Standard Panel Removal And Installation (Right Side) (Cont'd)
        Deluxe Panel Removal And Installation (Right Side)
        Standard And Deluxe Panel Removal And Installation (Left Side)
    LIGHTS
        Front Removal And Installation
        Rear Removal And Installation
    BOBCAT CONTROLLER
        Identification Chart
        Removal And Installation
    DIAGNOSTICS SERVICE CODES
        Display
    BICS™ SYSTEM
        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 Loaders With Advanced Hand Controls (AHC)
        Troubleshooting Chart
        Troubleshooting Guide
    SEAT BAR SENSOR
        Troubleshooting Chart
        Test
        Removal And Installation
        BICS™ Circuit Test
    TRACTION LOCK
        Troubleshooting Chart
    ADVANCED HAND CONTROL (A.H.C.) SYSTEM
        Components Identification
        Troubleshooting Guide
        Parts Identification
        A.H.C. Controller Removal And Installation
        Handle Control Unit Connector
        Switch Handle Removal and Installation
        Actuators Disassembly and Assembly
    PROPORTIONAL CONTROL (PWM)
        Troubleshooting Chart
        Control Handle Testing
        Electric Solenoid Coil Testing
    ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
        Controls Identification Chart
        
ENGINE SERVICE
    TROUBLESHOOTING
        Chart
    ENGINE SPEED CONTROL
        Removal And Installation
        Disassembly And Assembly
    MUFFLER
        Spark Arrestor Cleaning Procedure
        Removal And Installation
        Exhaust Extension Pipe.
    AIR CLEANER
        Housing Removal And Installation
    RADIATOR
        Coolant Recovery Tank Removal And Installation
        Removal And Installation
    COOLING FAN
        Removal And Installation
        Disassembly And Assembly
        Blower Housing Removal And Installation (Cont'd)
    ENGINE COMPONENTS AND TESTING
        Fuel Injection Pump Removal And Installation
        Fuel Injector Removal and Installation
        Fuel Injector Checking
        Checking The Fuel Lift Pump
        Removal And Installation
    ENGINE AND ENGINE MOUNTS
        Removal And Installation
        Mounting Brackets Removal And Installation
    FLYWHEEL AND HOUSING
        Flywheel Removal And Installation
        Ring Gear Removal
        Ring Gear Installation
    RECONDITIONING THE ENGINE
        Intake Manifold Removal and Installation
        Exhaust Manifold Removal and Installation
        Cylinder Head Disassembly
        Cylinder Head Removal
        Cylinder Head Inspection
        Cylinder Head Installation
        Rocker Shaft Disassembly And Assembly
        Valve Removal
        Valve Springs Checking
        Valve Depth Checking
        Valve Guides Checking
        Valve Guide Removal
        Valve Guide Installation
        Valves Checking
        Cutting A Valve Seat
        Valve Seat Assembly
        Changing Valve Springs (With Cylinder Head Installed)
        Valve Clearance Adjustment
        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
        Camshaft And Tappets Installation
        Pistons And Connecting Rods Description
        Pistons And Connecting Rods Removal
        Pistons And Connecting Rods Disassembly
        Piston Ring End Gap
        Piston Ring Installation
        Piston Ring Groove Clearance
        Connecting Rod Inspection
        Connecting Rod Bushing Replacement
        Piston And Connecting Rod Assembly
        Piston And Connecting Rod Installation
        Checking Piston Height
        Crankshaft And Bearings Description
        Crankshaft And Bearings Removal
        Inspection Of Crankshaft And Bearings
        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
        Engine Oil Cooler Disassembly And Assembly
        Engine 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
        Engine Block 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
        Turbo Charger Troubleshooting
        Turbo Charger Description
        Turbo Charger Removal and Installation
        
HEATING, VENTILATION, AIR CONDITIONING
    AIR CONDITIONING SYSTEM FLOW
        Principals
        Chart
    COMPONENTS
        Identification
    SAFETY
        Safety Equipment
    REGULAR MAINTENANCE
        Filter Elements Removal And Installation
        Compressor Drive Belt Inspection
        Cleaning The Condenser
    BASIC TROUBLESHOOTING
        Poor A/C Performance
        Cleaning The A/C Evaporator Coil & Heater Coil
        Compressor Drive Belt Inspection:
        Checking The Electrical System
        Engine Coolant By-Passing The Heater Valve
        Heater Valve Not Opening Or Closing
    GENERAL AIR CONDITIONING SERVICE GUIDELINES
        Compressor Oil
        Compressor Oil Check
        Component Replacement And Refrigeration Leaks
    SYSTEM TROUBLESHOOTING CHART
        Gauge Pressure Related Troubleshooting
    TEMPERATURE/PRESSURE
        Chart
    AIR CONDITIONING SERVICE
        Chart
    SYSTEM CHARGING AND RECLAMATION
        Reclamation Procedure
        Charging Procedure With A Manifold Gauge Set
        Charging Procedure
    COMPRESSOR
        Removal And Installation
        Compressor Clutch Disassembly
    CONDENSER
        Removal And Installation
    RECEIVER/DRIER
        Removal And Installation
    PRESSURE RELIEF VALVE
        Removal And Installation
    PRESSURE SWITCH
        Removal And Installation
    EVAPORATOR/HEATER UNIT
        Removal And Installation
        Disassembly And Assembly
    THERMOSTAT
        Removal And Installation
    EXPANSION VALVE
        Removal And Installation
    EVAPORATOR
        Removal And Installation
    HEATER COIL
        Removal And Installation With A/C
        Removal And Installation Without A/C
    HEATER/AC FAN
        Removal And Installation
        Disassembly And Assembly
        Wire Connector Removal and Installation
    HEATER VALVE
        Removal and Installation
        Disassembly And Assembly
        
SPECIFICATIONS
    LOADER SPECIFICATIONS
        Loader Dimensions
        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
        Specifications
    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
        Specifications
    CONVERSIONS
        Decimal And Millimeters Equivalents
        U.S. To Metric Conversion
        
SERVICE MANUAL REVISIONS
    Revision No: 963-1
    Revision No: 963-2
    
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