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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