Bobcat 963 Loader Service Manual 6900988 (6-12) – PDF DOWNLOAD

Description

Bobcat 963 Loader Service Manual 6900988 (6-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 963 Loader Service Manual 6900988 (6-12) – PDF DOWNLOAD

Language : English
Pages : 642
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Bobcat 963 Loader Service Manual 6900988 (6-12) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
ALPHABETICAL INDEX 5
CONTENTS 7
FOREWORD 8
SAFETY INSTRUCTIONS 11
Fire Prevention 13
SERIAL NUMBER LOCATIONS 15
Loader Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 15
BOBCAT LOADER INDENTIFICATION 16
SAFETY & MAINTENANCE 17
BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 19
Inspecting The BICS™ Controller (Engine STOPPED – Key ON) 19
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 19
Inspecting The Seat Bar Sensor (Engine RUNNING) 19
Inspecting The Traction Lock (Engine RUNNING) 19
Inspecting The Lift Arm By-Pass Control 19
Additional Inspection For Loaders With Advanced Hand Controls (AHC) 20
LIFTING AND BLOCKING THE LOADER 21
Procedure 21
TRANSPORTING THE LOADER 23
Procedure 23
TOWING THE LOADER 25
Procedure 25
LIFT ARM SUPPORT DEVICE 27
Engaging The Lift Arm Support Device 27
Disengaging The Lift Arm support Device 28
HAND-LEVER BOB-TACH 29
Inspection And Maintenance 29
POWER BOB-TACH (OPTION) 31
Inspection and Maintenance 31
OPERATOR CAB 33
Description 33
Raising The Operator Cab 33
Lowering The Operator Cab 34
Emergency Exit 35
SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS) 37
Description 37
Inspecting The Seat Bar 37
Maintaining The Seat Bar 37
SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS) 39
Description 39
Inspecting The Seat Bar 39
Maintaining The Seat Bar 39
REMOTE START 41
Procedure for Loader Without, Attachments Control Harness 41
Procedure for Loader With Attachments Control Harness 42
Procedure 43
SERVICE SCHEDULE 45
FUEL SYSTEM 47
Fuel Specifications 47
Filling the Fuel Tank 47
Fuel Filters 48
Removing Air From The Fuel System 49
AIR CLEANER SERVICE 51
Replacing Filter Element 51
ENGINE LUBRICATION SYSTEM 53
Checking Engine Oil 53
Replacing OIl and Filter 54
ENGINE COOLING SYSTEM 55
Cleaning The Cooling System 55
Checking The Coolant Level 56
Replacing The Coolant 56
HYDRAULIC/HYDROSTATIC SYSTEM 59
Checking And Adding Fluid 59
Replacing The Hydraulic/Hydrostatic Filters 59
Replacing The Hydraulic Fluid 60
Breather Cap 61
TIRE MAINTENANCE 63
Wheel Nuts 63
Tire Rotation 63
Tire Mounting 63
LUBRICATING THE BOBCAT LOADER 65
Procedure 65
HYDRAULIC SYSTEM 67
HYDRAULIC/HYDROSTATIC SCHEMATICS 71
HYDRAULIC SYSTEM INFORMATION 73
Glossary of Hydraulic/Hydrostatic Symbols for Loaders 73
Troubleshooting Chart 77
Tighten Procedures 78
CYLINDER(S) 79
Checking The Lift Cylinder(s) 79
Removal And Installation Of Lift Cylinder(s) 79
Checking The Tilt Cylinder(s) 82
Removal And Installation Of Tilt Cylinder(s) 83
Tilt Cylinder Base End Pivot Pin 85
Lift Cylinder Parts Identification 87
Tilt Cylinder Parts Identification 88
Disassembly 89
Assembly 91
MAIN RELIEF VALVE 95
Checking Main Relief Valve At Front Auxiliary Hydraulics 95
Checking Main Relief Valve At Control Valve 97
Removal And Installation 99
Adjustment 100
MAIN RELIEF VALVE (ADVANCED HAND CONTROL) (AHC) 103
NOT AVAILABLE AT TIME OF PRINTING 103
HYDRAULIC CONTROL VALVE (FOOT CONTROL) 105
Removal And Installation 105
BICS™ Valve, Removal And Installation 110
BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assembly 111
BICS™ Valve, Check Valve Disassembly And Assembly 112
BICS™ Valve, Lock Valve Disassembly And Assembly 113
BICS™ Valve, Solenoid Disassembly And Assembly 114
BICS™ Valve, Solenoid Testing 115
Identification Chart 115
Load Check Valve 116
Main Relief Valve 117
Port Relief Valve, Tilt Spool (Linkage End) 118
Port Relief Valve, Lift Spool (Bonnet End) 118
Anti-Cavitation Valve/Port Relief Valve, Tilt Spool (Bonnet End) 119
Anti-Cavitation Valve, Lift Spool (Linkage End) 119
Rubber Boot 120
Lift And Tilt Lock Block 120
Lift Spool and Detent 121
Tilt Spool Removal And Installation 130
Auxiliary Spool Removal And Installation (Bonnet End) 132
Auxiliary Spool Removal And Installation (Linkage End) 133
Auxiliary Plug Removal And Installation 134
Auxiliary Electric Solenoid Disassembly 134
Port Relief-Auxiliary Section Disassembly 135
Cleaning And Inspection 136
HYDRAULIC CONTROL VALVE (ADVANCE HAND CONTROL) (AHC) 137
NOT AVAILABLE AT TIME OF PRINTING 137
LIFT ARM BY-PASS CONTROL VALVE 139
Removal And Installation 139
Disassembly And Assembly 140
HYDRAULIC PUMP 141
Checking the Output of the Pump 141
Removal And Installation 142
Disassembly and Assembly 144
HYDRAULIC PUMP 151
Disassembly And Assembly 151
Inspection 154
HYDRAULIC/HYDROSTATIC FILTER 155
Removal And Installation 155
COOLING FAN FILTER 157
Removal And Installation 157
HYDRAULIC FLUID RESERVOIR 159
Removal And Installation 159
CONTROLS 165
Control Pedal Removal And Installation 165
Control Pedal Adjustment 165
Control Pedals Mounting Panel Removal And Installation 165
BUCKET POSITION VALVE 169
Removal And Installation 169
Disassembly And Assembly 170
TILT JUNCTION BLOCK 173
Removal And Installation 173
REAR AUXILIARY DIVERTER 175
Removal And Installation 175
Disassembly 178
Inspection 179
Solenoid Testing 179
Assembly 179
HYDROSTATIC SYSTEM 181
HYDROSTATIC SYSTEM INFORMATION 183
Troubleshooting Chart 183
Replenishing Valve Function 184
CONTROL PANEL 185
Removal And Installation 185
STEERING 189
Lever Removal And Installation 189
Disassembly And Assembly 189
Neutral Adjustment 200
HYDROSTATIC MOTOR 203
Removal and Installation 203
Throttle Control 205
Shuttle Check Valve 205
Flushing Valve 206
Disassembly 207
Inspection 210
Assembly 212
Cover Removal And Installation 217
Neutral Adjustment 217
CHARGE PRESSURE 219
Checking The Charge Pressure 219
HYDROSTATIC PUMP 221
Removal And Installation 221
Replenishing/High Pressure Relief Valve 222
Charge Relief Valve 223
DA Controller 223
Disassembly 224
Inspection 232
Assembly 234
Hydrostatic Pump Start-Up 244
Neutral Adjustment 245
Timing Procedure 247
DRIVE BELT 253
Shield Removal And Installation 253
Replacement 254
Adjustment 254
Tensioner Pulley Removal And Installation 255
Tensioner Tension Spring 256
Tensioner Pulley Disassembly And Assembly 256
Tensioner Pivot Shaft 257
Idler Pulley Removal And Installation 258
OIL COOLER 259
Removal And Installation 259
DRIVE SYSTEM 261
BRAKE 263
Pedal Removal And Installation 263
Pedal Disassembly And Assembly 264
Two Speed Block Removal And Installation 265
Two Speed Block Disassembly And Assembly 266
Parking Brake Removal And Installation 271
Parking Brake Disassembly And Assembly 272
DRIVE COMPONENTS 277
Axle Seal Removal And Installation 277
Axle, Bearings And Sprocket Removal And Installation 280
Drive Chains Removal And Installation 285
CHAINCASE 287
Checking And Adding Oil 287
Front Chaincase Cover Removal And Installation 287
Rear Chaincase Cover Removal and Installation 287
Reduction Gearcase Removal And Installation 288
Reduction Gearcase Disassembly And Assembly 292
Removing The Oil From The Chaincase 300
MAIN FRAME 301
SEAT BAR 303
Removal And Installation 303
Assembling Components 304
Compression Spring Disassembly And Assembly 306
OPERATOR CAB 307
Gas Cylinder Removal And Installation 307
Gas Cylinder Bracket Disassembly And Assembly 308
Removal And Installation 309
OPERATOR SEAT 313
Removal And Installation 313
Slide Rail Removal And Installation 313
Cushion Removal And Installation 314
Back Removal And Installation 315
Shock Removal And Installation 315
BOB-TACH 317
Removal And Installation 317
Bob-Tach Lever And Wedge 319
Bob-Tach Stops 320
POWER BOB-TACH 321
NOT AVAILABLE AT TIME OF PRINTING 321
LIFT ARMS 323
Removal And Installation 323
REAR GRILL 327
Gas Cylinder Removal And Installation 327
REAR DOOR 329
Removal And Installation 329
Adjusting The Rear Door Latch 330
Door Latch Removal And Installation 331
Door Brace Removal And Installation 331
FUEL TANK 333
Front Removal And Installation 333
Fuel Level Sender 334
Rear Removal And Installation 335
Pick-up Tube Screen 337
ELECTRICAL SYSTEM & ANALYSIS 339
ELECTRICAL SCHEMATICS 343
ELECTRICAL SYSTEM INFORMATION 353
Troubleshooting Chart 355
Description 356
Fuse Location 358
Relay Switch Location 358
Solenoid Test 359
BATTERY 361
Removal And Installation 361
Servicing The Electrical System 363
Using A Booster Battery (Jump Starting) 364
ALTERNATOR 365
Alternator Output Test 365
Rectifier (Diode) Test 365
Alternator Regulator Test 366
Removal And Installation 367
Adjusting The Alternator Belt 369
Disassembly 370
Stator Continuity Test 370
Stator Ground Test 370
Rotor Continuity Test 371
Rotor Ground Test 371
Rectifier Continuity (Diode) Test 371
Assembly 372
STARTER 375
Removal And Installation 375
Parts Identification 377
Disassembly And Assembly 378
External Pinion 380
Inspection And Repair 381
Magnetic Switch Test 384
No Load Test 385
INSTRUMENT PANEL 387
Left Panel 387
Right Panel – Standard Instrument Panel (With Key Switch) 388
Right Panel – (Deluxe) (With Keyless Start) 389
Right Panel Set Up Display Options (Deluxe) 391
Passwords 392
Option And Field Accessory Panels 394
Standard Panel Removal And Installation (Right Side) 395
Standard Panel Removal And Installation (Right Side) (Cont’d) 396
Deluxe Panel Removal And Installation (Right Side) 396
Standard And Deluxe Panel Removal And Installation (Left Side) 397
LIGHTS 399
Front Removal And Installation 399
Rear Removal And Installation 400
BOBCAT CONTROLLER 401
Identification Chart 401
Removal And Installation 402
DIAGNOSTICS SERVICE CODES 405
Display 405
BICS™ SYSTEM 407
Inspecting The BICS™ Controller (Engine STOPPED – Key ON) 407
Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON) 407
Inspecting The Seat Bar Sensor (Engine RUNNING) 407
Inspecting The Traction Lock (Engine RUNNING) 407
Inspecting The Lift Arm By-Pass Control 407
Additional Inspection For Loaders With Advanced Hand Controls (AHC) 408
Troubleshooting Chart 409
Troubleshooting Guide 410
SEAT BAR SENSOR 411
Troubleshooting Chart 411
Test 412
Removal And Installation 413
BICS™ Circuit Test 414
TRACTION LOCK 417
Troubleshooting Chart 417
ADVANCED HAND CONTROL (A H C ) SYSTEM 419
Components Identification 419
Troubleshooting Guide 420
Parts Identification 421
A H C Controller Removal And Installation 422
Handle Control Unit Connector 423
Switch Handle Removal and Installation 424
Actuators Disassembly and Assembly 427
PROPORTIONAL CONTROL (PWM) 429
Troubleshooting Chart 429
Control Handle Testing 430
Electric Solenoid Coil Testing 430
ELECTRICAL/HYDRAULIC CONTROLS REFERENCE 431
Controls Identification Chart 431
ENGINE SERVICE 433
TROUBLESHOOTING 437
Chart 437
ENGINE SPEED CONTROL 439
Removal And Installation 439
Disassembly And Assembly 439
MUFFLER 441
Spark Arrestor Cleaning Procedure 441
Removal And Installation 442
Exhaust Extension Pipe 443
AIR CLEANER 445
Housing Removal And Installation 445
RADIATOR 447
Coolant Recovery Tank Removal And Installation 447
Removal And Installation 447
COOLING FAN 451
Removal And Installation 451
Disassembly And Assembly 453
Blower Housing Removal And Installation (Cont’d) 457
ENGINE COMPONENTS AND TESTING 459
Fuel Injection Pump Removal And Installation 459
Fuel Injector Removal and Installation 461
Fuel Injector Checking 464
Checking The Fuel Lift Pump 464
Removal And Installation 465
ENGINE AND ENGINE MOUNTS 467
Removal And Installation 467
Mounting Brackets Removal And Installation 472
FLYWHEEL AND HOUSING 473
Flywheel Removal And Installation 473
Ring Gear Removal 474
Ring Gear Installation 474
RECONDITIONING THE ENGINE 475
Intake Manifold Removal and Installation 475
Exhaust Manifold Removal and Installation 476
Cylinder Head Disassembly 476
Cylinder Head Removal 478
Cylinder Head Inspection 479
Cylinder Head Installation 479
Rocker Shaft Disassembly And Assembly 482
Valve Removal 483
Valve Springs Checking 483
Valve Depth Checking 484
Valve Guides Checking 484
Valve Guide Removal 485
Valve Guide Installation 485
Valves Checking 486
Cutting A Valve Seat 486
Valve Seat Assembly 486
Changing Valve Springs (With Cylinder Head Installed) 487
Valve Clearance Adjustment 488
Timing Case And Drive Assembly Description 489
Timing Cover Removal 489
Timing Cover Installation 489
Front Oil Seal Removal 490
Front Oil Seal Installation 490
Timing Case And Gear Removal 491
Timing Case And Gear Installation 492
Camshaft And Tappets Removal 493
Camshaft And Tappets Installation 493
Pistons And Connecting Rods Description 495
Pistons And Connecting Rods Removal 495
Pistons And Connecting Rods Disassembly 496
Piston Ring End Gap 497
Piston Ring Installation 497
Piston Ring Groove Clearance 498
Connecting Rod Inspection 498
Connecting Rod Bushing Replacement 498
Piston And Connecting Rod Assembly 498
Piston And Connecting Rod Installation 499
Checking Piston Height 500
Crankshaft And Bearings Description 500
Crankshaft And Bearings Removal 500
Inspection Of Crankshaft And Bearings 502
Crankshaft And Bearings Installation 503
Rear Oil Seal Removal 504
Rear Oil Seal Housing Positioning 504
Rear Oil Seal Installation 505
Checking Crankshaft End Play 505
Cooling System Description 506
Thermostat Removal and Installation 507
Thermostat Testing 508
Water Pump Removal 508
Water Pump Installation 509
Engine Oil Cooler Removal And Installation 509
Engine Oil Cooler Disassembly And Assembly 511
Engine Lubrication System Description 512
Oil Filter Adapter Removal 513
Oil Filter Adapter Installation 513
Oil Pan Removal And Installation 514
Oil Screen And Pick-up Tube 514
Oil Pump Removal 514
Oil Pump Installation 515
Oil Pump Disassembly And Assembly 516
Oil Pressure Relief Valve Disassembly And Assembly 517
Engine Block Description 517
Engine Block Disassembly And Assembly 518
Piston Cooling Jet Removal 518
Piston Cooling Jet Installation 518
Piston Cooling Jet Alignment 519
Inspection 519
Cylinder Liner Inspection 519
Cylinder Liner Removal 520
Cylinder Liner Installation 521
Turbo Charger Troubleshooting 522
Turbo Charger Description 523
Turbo Charger Removal and Installation 523
HEATING, VENTILATION, AIR CONDITIONING 525
AIR CONDITIONING SYSTEM FLOW 528
Principals 528
Chart 529
COMPONENTS 531
Identification 531
SAFETY 535
Safety Equipment 535
REGULAR MAINTENANCE 537
Filter Elements Removal And Installation 537
Compressor Drive Belt Inspection 538
Cleaning The Condenser 539
BASIC TROUBLESHOOTING 541
Poor A/C Performance 541
Cleaning The A/C Evaporator Coil & Heater Coil 541
Compressor Drive Belt Inspection: 544
Checking The Electrical System 544
Engine Coolant By-Passing The Heater Valve 552
Heater Valve Not Opening Or Closing 552
GENERAL AIR CONDITIONING SERVICE GUIDELINES 555
Compressor Oil 555
Compressor Oil Check 555
Component Replacement And Refrigeration Leaks 556
SYSTEM TROUBLESHOOTING CHART 557
Gauge Pressure Related Troubleshooting 558
TEMPERATURE/PRESSURE 561
Chart 561
AIR CONDITIONING SERVICE 563
Chart 563
SYSTEM CHARGING AND RECLAMATION 565
Reclamation Procedure 565
Charging Procedure With A Manifold Gauge Set 567
Charging Procedure 568
COMPRESSOR 571
Removal And Installation 571
Compressor Clutch Disassembly 571
CONDENSER 577
Removal And Installation 577
RECEIVER/DRIER 579
Removal And Installation 579
PRESSURE RELIEF VALVE 581
Removal And Installation 581
PRESSURE SWITCH 583
Removal And Installation 583
EVAPORATOR/HEATER UNIT 585
Removal And Installation 585
Disassembly And Assembly 586
THERMOSTAT 587
Removal And Installation 587
EXPANSION VALVE 589
Removal And Installation 589
EVAPORATOR 591
Removal And Installation 591
HEATER COIL 593
Removal And Installation With A/C 593
Removal And Installation Without A/C 594
HEATER/AC FAN 597
Removal And Installation 597
Disassembly And Assembly 598
Wire Connector Removal and Installation 600
HEATER VALVE 603
Removal and Installation 603
Disassembly And Assembly 603
SPECIFICATIONS 607
LOADER SPECIFICATIONS 609
Loader Dimensions 609
Performance 610
Controls 610
Engine 610
Hydraulic System 611
Electrical 611
Drive System 612
Capacities 612
Tires 612
ENGINE SPECIFICATIONS 613
General 613
Cylinder Head 613
Valve Guides 613
Exhaust Valves 613
Intake Valves 614
Valve Springs 614
Rocker Shaft, Rockers And Bushings 614
Pistons And Piston Rings 615
Connecting Rods And Bearings 615
Crankshaft 616
Crankshaft Re-Grind Data 617
Main Bearings 618
Thrust Washers 618
Camshaft And Thrust Washer 618
Cylinder Block 618
Cylinder Liners 618
Fuel Injection Pump 619
Fuel Injectors 619
Fuel Lift Pump 619
Timing Case And Timing Gears 619
Oil Pump, Gear And Relief Valve 620
Turbocharger 620
Flywheel 620
Water Pump And Thermostat 621
Engine Torque 622
LOADER TORQUE 623
Specifications 623
TORQUE SPECIFICATIONS FOR BOLTS 625
Torque For General SAE Bolts 625
Torque For General Metric Bolts 626
HYDRAULIC CONNECTION SPECIFICATIONS 627
O-ring Face Seal Connection 627
Straight Thread O-ring Fitting 627
Tubelines And Hoses 627
Flare Fitting 628
O-ring Flare Fitting 629
Port Seal Fitting 631
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS 633
Specifications 633
CONVERSIONS 635
Decimal And Millimeters Equivalents 635
U S To Metric Conversion 635
SMR 637
Revision No: 963-1 637
Revision No: 963-2 639
Revision No: 963-3 641

DESCRIPTION:

Bobcat 963 Loader Service Manual 6900988 (6-12) – PDF DOWNLOAD

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

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.

The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:

Questions? Email us: [email protected]

IMAGES PREVIEW OF THE MANUAL:

PLEASE NOTE:

• This is the SAME MANUAL used by the dealerships to diagnose your vehicle
• No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
• Your payment is all safe and the delivery of the manual is INSTANT – You will be taken to the DOWNLOAD PAGE.
• So have no hesitations whatsoever and write to us about any queries you may have : heydownloadss @gmail.com

S.V