Bobcat 963 Loader Service Manual 6724545 (6-12) – PDF DOWNLOAD

Description

Bobcat 963 Loader Service Manual 6724545 (6-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 963 Loader Service Manual 6724545 (6-12) – PDF DOWNLOAD

Language : English
Pages : 502
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Bobcat 963 Loader Service Manual 6724545 (6-12) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
ALPHABETICAL INDEX 5
CONTENTS 7
FOREWORD 8
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 12
SERIAL NUMBER LOCATIONS 13
LOADER SERIAL NUMBER 13
ENGINE SERIAL NUMBER 13
DELIVERY REPORT 13
963 BOBCAT LOADER IDENTIFICATION 14
PREVENTIVE MAINTENANCE 15
SERVICE SCHEDULE 17
LIFTING AND BLOCKING THE LOADER 18
Procedure 18
TRANSPORTING THE LOADER 19
Procedure 19
TOWING THE LOADER 20
Procedure 20
LIFT ARM SUPPORT DEVICE 21
Engaging The Lift Arm Support Device 21
Disengaging The Lift Arm Support Device 22
OPERATOR CAB 23
Description 23
Raising The Operator Cab 23
Lowering The Operator Cab 24
Emergency Exit 25
SEAT BAR RESTRAINT SYSTEM 26
Description 26
Inspecting The Seat Bar 26
Maintaining The Seat Bar 26
AIR CLEANER SERVICE 27
Replacing Filter Elements 27
FUEL SYSTEM 29
Fuel Specifications 29
Filling The Fuel Tank 29
Fuel Filters 30
Removing Air From The Fuel System 30
ENGINE LUBRICATION SYSTEM 31
Checking Engine Oil 31
Replacing The Oil And Filter 31
ENGINE COOLING SYSTEM 32
Checking The Coolant Level 32
Cleaning The Cooling System 32
Replacing The Coolant 33
ALTERNATOR BELT 34
Adjusting The Alternator Belt 34
HYDRAULIC/HYDROSTATIC SYSTEM 35
Checking And Adding Fluid 35
Hydraulic/Hydrostatic Filter Replacement 35
Replacing The Hydraulic Fluid 36
SPARK ARRESTOR MUFFLER 37
Cleaning Procedure 37
TIRE MAINTENANCE 38
Wheel Nuts 38
Tire Rotation 38
Tire Mounting 38
FINAL DRIVE TRANSMISSION (CHAINCASE) 39
Checking And Adding Oil 39
FAN GEARBOX 39
Checking And Maintaining 39
LUBRICATING THE LOADER 40
Procedure 40
BOB–TACH 42
Inspection And Maintenance 42
REMOTE START SWITCH 43
Procedure 43
HYDRAULIC SYSTEM 45
HYDRAULIC / HYDROSTATIC SCHEMATICS 48
TROUBLESHOOTING 55
HYDRAULIC SYSTEM INFORMATION 56
Tighten Procedures 56
LIFT CYLINDER 57
Checking the Lift Cylinder(s) 57
Removal and Installation 57
TILT CYLINDER 60
Checking The Tilt Cylinder(s) 60
Removal And Installation 61
HYDRAULIC CYLINDER 64
Lift Cylinder Parts Identification 64
Tilt Cylinder Parts Identification 65
Disassembly 66
Assembly 68
TILT JUNCTION BLOCK 71
Removal And Installation 71
MAIN RELIEF VALVE 73
Checking Main Relief Valve At Front Auxiliary Hydraulics 73
Checking Main Relief Valve At Control Valve 75
Removal And Installation 77
Adjustment 77
BICS™ VALVE 79
Lift Arm By–Pass Orifice 79
Lock Valve 80
Check Valve 81
BICS™ Valve Solenoid 82
BICS Valve Removal And Installation 83
HYDRAULIC CONTROL VALVE 84
Removal And Installation 84
Identification Chart 86
Disassembly And Assembly 87
Load Check Valve 87
Main Relief Valve 88
Port Relief Valve (Lift Section) 89
Anti–Cavitation/Port Relief Valve 90
Anti–Cavitation Valve 91
Port Relief Valve (Tilt Section) 92
Rubber Boot 93
Lift Spool And Detent 94
Tilt Spool And Centering Spring 98
Auxiliary Spool 99
Auxiliary Electric Solenoid 100
H–Port – Auxiliary Section 101
Inspection 101
Spool Seal Installation 102
LIFT ARM BY–PASS CONTROL VALVE 103
Removal And Installation 103
Disassembly And Assembly 103
BUCKET POSITION VALVE 104
Removal And Installation 104
Disassembly And Assembly 105
HYDRAULIC PUMP 107
Checking the Output of the Pump 107
Removal And Installation 108
Disassembly And Assembly 110
Inspection 113
HYDRAULIC/HYDROSTATIC FILTER 114
Removal And Installation 114
HYDRAULIC FLUID RESERVOIR 115
Draining The Hydraulic Fluid Reservoir 115
Removal And Installation 115
CONTROL PEDALS 117
Removal And Installation 117
Pedal Adjustment 117
PEDAL INTERLOCK LINKAGE 118
Removal And Installation 118
Adjustment 119
FRONT SIDE PANEL 119
Removal and Installation 119
CONTROL PEDALS MOUNTING PANEL 120
Removal and Installation 120
HYDROSTATIC SYSTEM 123
TROUBLESHOOTING 125
HYDROSTATIC SYSTEM INFORMATION 126
Replenishing Valve Function 126
Checking The Charge Pressure 126
CONTROL PANEL 127
Removal And Installation 127
STEERING LEVERS 130
Disassembly And Assembly 130
STEERING LINKAGE 134
Neutral Adjustment 134
HYDROSTATIC CONTROLLER 136
Removal and Installation 136
Disassembly and Assembly 138
Adjustment 141
HYDROSTATIC MOTOR 142
Removal and Installation 142
Throttle Control 144
Shuttle Check Valve 144
Flushing Valve 145
Disassembly 146
Inspection 149
Assembly 151
HYDROSTATIC PUMP 156
Removal And Installation 156
Hydraulic Pump Removal And Installation 157
Replenishing/High Pressure Relief Valve 158
Charge Relief Valve 159
DA Controller 159
Disassembly 160
Inspection 168
Assembly 171
Hydrostatic Pump Start–Up 181
Timing Procedure 182
DRIVE BELT BELT SHIELD 184
Removal And Installation 184
DRIVE BELT 185
Replacing The Drive Belt 185
Adjusting The Drive Belt 185
DRIVE BELT TENSIONER PULLEY 186
Removal And Installation 186
Tension Spring 187
Disassembly And Assembly 188
Pivot Shaft 189
DRIVE BELT IDLER PULLEY 190
Removal And Installation 190
HYDROSTATIC MOTOR COVER 191
Removal And Installation 191
OIL COOLER 192
Removal And Installation 192
DRIVE SYSTEM 193
PARKING BRAKE PEDAL 195
Removal And Installation 195
Disassembly And Assembly 196
BRAKE/TWO SPEED BLOCK 197
Removal And Installation 197
Disassembly And Assembly 199
PARKING BRAKE 201
Removal And Installation 201
Disassembly And Assembly 202
AXLE SEAL 205
Removal And Installation 205
AXLE, BEARINGS AND SPROCKET 208
Removal And Installation 208
DRIVE CHAINS 213
Removal And Installation 213
FRONT CHAINCASE COVER 214
Removal And Installation 214
REAR CHAINCASE COVER 214
Removal and Installation 214
REDUCTION GEARCASE 215
Removal And Installation 215
Disassembly And Assembly 218
CHAINCASE FLUID 227
Removing The Fluid From The Chaincase 227
MAIN FRAME 229
SEAT BAR 231
Removal And Installation 231
Assembling Components 234
Compression Spring Disassembly And Assembly 234
OPERATOR CAB GAS CYLINDER 235
Removal And Installation 235
Gas Cylinder Mounting Bracket 236
OPERATOR CAB 237
Removal And Installation 237
OPERATOR SEAT 239
Removal And Installation 239
BOB–TACH 240
Removal And Installation 240
Bob–Tach Lever And Wedge 242
Bob–Tach Stops 243
LIFT ARMS 244
Removal And Installation 244
REAR GRILL 248
Gas Cylinder Removal And Installation 248
Removal And Installation 248
REAR DOOR 249
Removal And Installation 249
Adjusting The Rear Door Latch 250
FRONT FUEL TANK 251
Removal And Installation 251
Fuel Level Sender 251
REAR FUEL TANK 252
Removal And Installation 252
Pickup Tube Screen 253
ELECTRICAL SYSTEM 255
ELECTRICAL SCHEMATICS 257
TROUBLESHOOTING 277
ELECTRICAL SYSTEM INFORMATION 278
Description 278
Fuse Location 278
RELAY SWITCHES 278
Location 278
BATTERY 279
Removal And Installation 279
Servicing The Electrical System 281
Using A Booster Battery (Jump Starting) 282
ALTERNATOR 283
Alternator Output Test 283
Rectifier (Diode) Test 283
Alternator Regulator Test 284
Removal And Installation 285
Adjusting the Alternator Belt 287
Disassembly 288
Stator Continuity Test 288
Stator Ground Test 288
Rotor Continuity Test 289
Rotor Ground Test 289
Rectifier Continuity (Diode) Test 289
Assembly 290
STARTER 291
Removal And Installation 291
Parts Identification 292
Disassembly And Assembly 293
External Pinion 296
Inspection And Repair 297
Magnetic Switch Test 300
No Load Test 300
STANDARD INSTRUMENT PANEL 301
Removal And Installation 301
FRONT LIGHTS 302
Removal And Installation 302
ENGINE SERVICE 303
TROUBLESHOOTING 307
ENGINE SPEED CONTROL 308
Removal And Installation 308
ENGINE MUFFLER 309
Removal And Installation 309
Exhaust Extension Pipe 310
AIR CLEANER HOUSING 311
Removal And Installation 311
COOLANT RECOVERY TANK 312
Removal And Installation 312
RADIATOR 313
Removal And Installation 313
FAN DRIVE TENSION PULLEY 316
Removal And Installation 316
FAN GEARBOX/BLOWER HOUSING 318
Removal And Installation 318
BLOWER FAN 320
Removal And Installation 320
FAN GEARBOX 321
Disassembly 321
Assembly 327
Checking Backlash 332
FLYWHEEL 334
Removal And Installation 334
Ring Gear Removal 335
Ring Gear Installation 335
ENGINE MOUNTING BRACKET 335
Removal and Installation 335
VALVE CLEARANCE 336
Adjustment 336
FUEL LIFT PUMP 337
Checking 337
Removal And Installation 337
FUEL INJECTION PUMP 338
Removal And Installation 338
FUEL INJECTOR NOZZLES 341
Removal and Installation 341
Checking 343
ENGINE 344
Removal And Installation 344
INTAKE MANIFOLD 349
Removal and Installation 349
EXHAUST MANIFOLD 350
Removal and Installation 350
CYLINDER HEAD 351
Removal 351
Inspection 353
Installation 353
ROCKER SHAFT 356
Disassembly And Assembly 356
VALVES, VALVE GUIDES AND SPRINGS 357
Valve Removal 357
Checking Valve Springs 357
Checking Valve Depth 358
Checking Valve Guides 358
Valve Guide Removal 359
Valve Guide Installation 359
Checking Valves 360
Cutting A Valve Seat 360
Assembly 360
Changing Valve Springs (With Cylinder Head Installed) 361
TIMING CASE AND DRIVE ASSEMBLY 362
Description 362
Timing Cover Removal 362
Timing Cover Installation 363
Front Oil Seal Removal 364
Front Oil Seal Installation 364
Timing Case And Gear Removal 364
Timing Case And Gear Installation 365
CAMSHAFT AND TAPPETS 366
Removal 366
Installation 367
PISTONS AND CONNECTING RODS 368
Description 368
Removal 368
Disassembly 369
Piston Ring End Gap 369
Piston Ring Installation 369
Piston Ring Groove Clearance 370
Connecting Rod Inspection 371
Connecting Rod Bushing Replacement 371
Assembly 371
Installation 371
Checking Piston Height 372
CRANKSHAFT AND BEARINGS 373
Description 373
Removal 373
Inspection Of Crankshaft And Bearings 374
Installation 375
Rear Oil Seal Removal 376
Rear Oil Seal Housing Positioning 376
Rear Oil Seal Installation 376
Checking Crankshaft End Play 377
COOLING SYSTEM 378
Description 378
Thermostat Removal and Installation 379
Thermostat Testing 379
Water Pump Removal 380
Water Pump Installation 380
ENGINE OIL COOLER 381
Removal and Installation 381
Disassembly and Assembly 383
LUBRICATION SYSTEM 384
Description 384
Oil Filter Adapter Removal 385
Oil Filter Adapter Installation 385
Oil Pan Removal And Installation 385
Oil Screen And Pick–up Tube 386
Oil Pump Removal 386
Oil Pump Installation 387
Oil Pump Disassembly And Assembly 388
Oil Pressure Relief Valve Disassembly And Assembly 388
ENGINE BLOCK 389
Description 389
Disassembly And Assembly 389
Piston Cooling Jet Removal 390
Piston Cooling Jet Installation 390
Piston Cooling Jet Alignment 390
Inspection 390
Cylinder Liner Inspection 391
Cylinder Liner Removal 391
Cylinder Liner Installation 392
TURBOCHARGER 393
Troubleshooting 393
Description 394
Removal and Installation 394
SYSTEMS ANALYSIS 397
BICS™ (With Press To Operate Button) 399
Inspecting The BICS™ Controller (Engine STOPPED – Key ON) 399
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 399
Inspecting The Seat Bar Sensor (Engine RUNNING) 399
Inspecting The Traction Lock (Engine RUNNING) 399
Inspecting The Lift Arm By–Pass Control 399
Additional Inspection For Advanced Hand Controls 399
Troubleshooting Chart 400
BICS™ (Without Press To Operate Button) 401
Inspecting The BICS™ Controller (Engine STOPPED – Key ON) 401
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 401
Inspecting The Seat And Seat Bar Sensors (Engine RUNNING) 401
Inspecting The Traction Lock (Engine RUNNING) 401
Inspecting The Lift Arm By–Pass Control 401
Maintenance 401
Troubleshooting Chart 402
SEAT SENSOR OVERRIDE ONLY (If Equipped) 402
BICS™ SYSTEM CONTROLLER 403
Troubleshooting Guide 403
Removal And Installation 404
SEAT BAR SENSOR 405
Troubleshooting Guide 405
Seat Bar Sensor Test 406
Removal And Installation 407
BICS™ Controller Seat Bar Sensor Circuit Test 408
SEAT SENSOR 409
Troubleshooting Guide 409
Seat Sensor Test 410
Removal And Installation 411
BICS™ Controller Seat Sensor Circuit Test 412
TRACTION LOCK 413
Troubleshooting Guide 413
BOSS® DIAGNOSTIC TOOL 414
Procedure 414
SENDER AND SENSOR 414
Service Checks 414
Components 414
Adjustment 414
MONITOR SERVICE CODES 415
TROUBLESHOOTING THE BOSS® & LCD DISPLAY 417
BOSS® UNIT 418
Removal and Installation 418
BOSS® INSTRUMENT PANEL 419
Removal and Installation 419
PWM MODULE 420
Description 420
PWM TROUBLESHOOTING 421
Conditions 421
Chart 422
PWM CONTROL HANDLE 423
Handle Testing 423
PWM ELECTRIC SOLENOID 423
Solenoid Coil Testing 423
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE 424
Controls Identification Chart 424
SPECIFICATIONS 425
LOADER SPECIFICATIONS 427
Performance 427
Controls 427
Engine 427
Hydraulic System 428
Electrical 428
Drive System 428
Capacities 428
Tires 428
ENGINE SPECIFICATIONS 429
General 429
Cylinder Head 429
Valve Guides 429
Exhaust Valves 429
Intake Valves 429
Valve Springs 429
Rocker Shaft, Rockers And Bushings 430
Pistons And Piston Rings 430
Connecting Rods And Bearings 430
Crankshaft 430
Crankshaft Re–Grind Data 431
Main Bearings 432
Thrust Washers 432
Camshaft And Thrust Washer 432
Cylinder Block 432
Cylinder Liners 432
Fuel Injection Pump 432
Fuel Injectors 432
Fuel Lift Pump 432
Timing Case And Timing Gears 433
Oil Pump, Gear And Relief Valve 433
Turbocharger 433
Flywheel 433
Water Pump And Thermostat 434
Engine Torque 435
LOADER TORQUE 436
TORQUE SPECIFICATIONS FOR BOLTS 437
Torque For General SAE Bolts 437
Torque For General Metric Bolts 438
HYDRAULIC CONNECTION SPECIFICATIONS 439
O–ring Face Seal Connection 439
Straight Thread O–ring Fitting 439
Tubelines And Hoses 439
Flare Fitting 439
O–ring Flare Fitting 440
Port Seal Fitting 442
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS 443
DECIMAL AND MILLIMETER EQUIVALENTS 444
U S TO METRIC CONVERSION 444
ADVANCE HAND CONTROL SYSTEM (A H C) 445
A H C COMPONENTS 447
Identification 447
TROUBLESHOOTING (A H C ) 448
ACTUATOR VOLTAGE TEST 450
Procedure 450
HANDLE CONTROL UNIT TEST 453
Procedure 453
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 456
Troubleshooting Chart 456
SEAT SENSOR OVERRIDE ONLY 456
ADVANCED HAND CONTROLS (AHC) 456
A H C /PWM CONTROLLER 457
Removal and Installation 457
Description 458
Conditions 459
Troubleshooting Chart 459
Handle Testing 460
Solenoid Coil Testing 460
HANDLE CONTROL UNIT 461
Removal And Installation 461
Control Unit Connector 464
SWITCH HANDLE 465
Removal and Installation 465
A H C HANDLE 468
Removal and Installation 468
Disassembly and Assembly 469
A H C STEERING LEVER 470
Removal and Installation 470
Steering Lever Boot 470
Disassembly and Assembly 472
BICS™ VALVE 473
Lift Arm By–Pass Orifice 473
Check Valve 474
Lock Valve 474
BICS™ Valve Solenoid 475
Removal and Installation 476
HYDRAULIC CONTROL VALVE 477
Removal And Installation 477
Mounting Plate 479
Identification Chart 480
Disassembly and Assembly 481
Load Check Valve 481
Main Relief Valve 482
Port Relief Valve (Lift) 483
Anti–Cavitation/Port Relief Valve 483
Port Relief Valve (Tilt) 484
Anti–Cavitation Valve 484
Rubber Boot 485
Lift and Tilt Spool 486
Inspection 488
Auxiliary Spool 489
Auxiliary Electrical Solenoid 490
H–Port Auxiliary Section 491
Spool Seal Installation 492
SERVICE MANUAL REVISIONS 493
963–1 493
963–2 495
963–3 497
963–4 499
963-5 501

DESCRIPTION:

Bobcat 963 Loader Service Manual 6724545 (6-12) – PDF DOWNLOAD

FOREWORD:

This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc.

SAFETY INSTRUCTIONS:

The following publications provide information on the safe use and maintenance of the loader and attachments:
• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine
is in safe operating condition.
• The Operation & Maintenance Manual delivered with the loader gives operating information as well as routin e
maintenance and service procedures. It is a part of the loader and must stay with the machine when it is sold. Replacement
Operation & Maintenance Manuals can be ordered from your Bobcat loader dealer.
• The loader has machine signs (decals) which instruct on the safe operation and care. The signs and their locations are
shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat loader dealer.
• The loader has a plastic Operator’s Handbook fastened to the operator cab. Its brief instructions are convenient to the
operator. The Handbook is available from your dealer in an English edition or one of many other languages. See your
Bobcat dealer for more information on translated versions.
• The EMI Safety Manual (available in Spanish) delivered with the loader gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shop–type service and
repair work.
• The Skid–Steer Loader Operator Training Course is available through your local dealer. This course is intended to provide
rules and practices for correct operation of the Bobcat loader. The course is available in English and Spanish version.
• The Service Safety Training Course is available from your Bobcat dealer. This course provides information for safe and
correct service procedures for Bobcat Skid–Steer loaders.
• The Bobcat Skid–Steer Loader Safety Video is available from your Bobcat Dealer.

Need help? Contact: [email protected]

IMAGES PREVIEW OF THE MANUAL:

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

S.V