Bobcat 963 Skid-Steer Loader Service Manual – 6900988 (3-06)

(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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