Bobcat 963 Skid-Steer Loader Service Manual – S/N 562215001 & Above / S/N 516515001 & Above

Description

Bobcat 963 Service and Repair Coverage

The Bobcat 963 Skid-Steer Loader Service Manual – S/N 562215001 & Above / S/N 516515001 & Above is a detailed mechanic’s reference for servicing, adjustment, troubleshooting, disassembly, inspection, repair, and reassembly of the Bobcat 963 loader and its major systems. The manual is organized as a shop-service document, moving from safety and routine service work through hydraulic, hydrostatic, drive, frame, electrical, engine, HVAC, and specification sections. It is especially useful when a repair requires more than a routine maintenance reference, because the procedures show component access, removal and installation sequences, test points, adjustment methods, inspection criteria, tightening information, and system-specific troubleshooting.

Coverage is tied to the serial-number groups printed on the manual: S/N 562215001 & Above and S/N 516515001 & Above. Serial-number identification matters because the manual itself notes that early or later machines may use different parts or require different procedures. The document also includes wiring and hydraulic/hydrostatic schematic material for the 963, plus service data for the Perkins/1004.40 t Turbo-Charged engine listed in the loader specifications.

File Details

• Manual type: Service Manual
• Brand / model: Bobcat 963 Loader
• Serial-number coverage: S/N 562215001 & Above; S/N 516515001 & Above
• Engine listed: Perkins/1004.40 t Turbo-Charged
• Language: English
• Page count: 640 pages
• File format: PDF
• Manual number: 6900988
• Manual date: (3-06)
• Revision: Revision No: 963-2, Date: 23 March 2006

What This Manual Helps You Service

The Bobcat 963 service manual goes well beyond basic fluid checks. Hydraulic work includes lift and tilt cylinders, control-valve service, the BICS valve, main relief-valve testing and adjustment, hydraulic pumps, filters, the reservoir, the lift-arm by-pass valve, bucket-position valve, and auxiliary-hydraulic components. Procedures are supported by photographs, component identification drawings, pressure checks, disassembly sequences, seal and O-ring replacement steps, and torque values where specified.

The hydrostatic section addresses steering, hydrostatic pumps and motors, charge and replenishing functions, oil cooling, drive-belt related service, pressure checks, neutral adjustments, and troubleshooting for symptoms such as loss of drive, tracking problems, overheating, and warning indications. The drive-system material covers the chaincase, brake, and related drive components. This allows the manual to support diagnosis across the complete power path rather than treating the engine, hydraulics, and final drive as isolated systems.

Electrical service is similarly broad. The manual contains electrical-system information, wiring schematics for applicable serial-number groups and options, diagnostic service codes, controller and BICS-related information, battery and starter service, lighting, sensors, control references, and electrical/hydraulic control identification. For technicians tracing an intermittent control or interlock fault, having the circuit references and component locations in the same service manual can reduce unnecessary disassembly.

Engine coverage includes removal and installation of the engine and mounts, air cleaner and cooling-fan service, engine controls, flywheel and housing work, exhaust and cooling components, engine-component testing, and a substantial engine-reconditioning section. The specifications identify a Perkins/1004.40 t Turbo-Charged diesel engine with four cylinders, while the engine specification pages provide dimensional and service data for internal components, fuel injection equipment, lubrication, cooling, and tightening requirements. HVAC coverage adds air-conditioning service procedures for the compressor, condenser, evaporator/heater unit, expansion valve, receiver/drier, heater components, charging and reclamation, temperature/pressure checks, and troubleshooting.

Chapters Covered

• Safety & Maintenance
  • Bobcat Interlock Control System (BICS)
  • Fuel, engine lubrication and cooling-system service
  • Hydraulic/hydrostatic fluid and filter service
  • Lift arm support, lifting/blocking, towing and transporting
  • Operator cab, seat-bar restraint, Bob-Tach and Power Bob-Tach
  • Service schedule, tire maintenance and loader lubrication
  Complete PDF Bookmark Tree

  Complete Bookmarks

  The complete bookmarks in the “Bobcat 963 Skid-Steer Loader Service Manual – S/N 562215001 & Above / S/N 516515001 & Above” are as follows:

  MAINTENANCE SAFETY

  ALPHABETICAL INDEXp. 5

  +CONTENTSp. 7

  FOREWORDp. 8

  +SAFETY INSTRUCTIONS

  Fire Preventionp. 13

  +SERIAL NUMBER LOCATIONSp. 15

  Loader Serial Numberp. 15

  Engine Serial Numberp. 15

  DELIVERY REPORTp. 15

  BOBCAT LOADER INDENTIFICATIONp. 16

  +SAFETY & MAINTENANCE

  +BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)p. 19

  Inspecting The BICS™ Controller (Engine STOPPED – Key ON)p. 19

  Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)p. 19

  Inspecting The Seat Bar Sensor (Engine RUNNING)p. 19

  Inspecting The Traction Lock (Engine RUNNING)p. 19

  Inspecting The Lift Arm By-Pass Controlp. 19

  Additional Inspection For Loaders With Advanced Hand Controls (AHC)p. 20

  +LIFTING AND BLOCKING THE LOADERp. 21

  Procedurep. 21

  +TRANSPORTING THE LOADERp. 23

  Procedurep. 23

  +TOWING THE LOADERp. 25

  Procedurep. 25

  +LIFT ARM SUPPORT DEVICEp. 27

  Engaging The Lift Arm Support Devicep. 27

  Disengaging The Lift Arm support Devicep. 28

  +HAND-LEVER BOB-TACHp. 29

  Inspection And Maintenancep. 29

  +POWER BOB-TACH (OPTION)p. 31

  Inspection and Maintenancep. 31

  +OPERATOR CABp. 33

  Descriptionp. 33

  Raising The Operator Cabp. 33

  Lowering The Operator Cabp. 34

  Emergency Exitp. 35

  +SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)p. 37

  Descriptionp. 37

  Inspecting The Seat Barp. 37

  Maintaining The Seat Barp. 37

  +SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)p. 39

  Descriptionp. 39

  Inspecting The Seat Barp. 39

  Maintaining The Seat Barp. 39

  +REMOTE STARTp. 41

  Procedure for Loader Without, Attachments Control Harnessp. 41

  Procedure for Loader With Attachments Control Harnessp. 42

  Procedurep. 43

  SERVICE SCHEDULEp. 45

  +FUEL SYSTEMp. 47

  Fuel Specificationsp. 47

  Filling the Fuel Tankp. 47

  Fuel Filtersp. 48

  Removing Air From The Fuel Systemp. 49

  +AIR CLEANER SERVICEp. 51

  Replacing Filter Elementp. 51

  +ENGINE LUBRICATION SYSTEMp. 53

  Checking Engine Oilp. 53

  Replacing OIl and Filterp. 54

  +ENGINE COOLING SYSTEMp. 55

  Cleaning The Cooling Systemp. 55

  Checking The Coolant Levelp. 56

  Replacing The Coolantp. 56

  +HYDRAULIC/HYDROSTATIC SYSTEMp. 59

  Checking And Adding Fluidp. 59

  Replacing The Hydraulic/Hydrostatic Filtersp. 59

  Replacing The Hydraulic Fluidp. 60

  Breather Capp. 61

  +TIRE MAINTENANCEp. 63

  Wheel Nutsp. 63

  Tire Rotationp. 63

  Tire Mountingp. 63

  +LUBRICATING THE BOBCAT LOADERp. 65

  Procedurep. 65

  +HYDRAULIC SYSTEMp. 67

  HYDRAULIC/HYDROSTATIC SCHEMATICS

  +HYDRAULIC SYSTEM INFORMATIONp. 73

  Glossary of Hydraulic/Hydrostatic Symbols for Loadersp. 73

  Troubleshooting Chartp. 77

  Tighten Proceduresp. 78

  +CYLINDER(S)p. 79

  Checking The Lift Cylinder(s)p. 79

  Removal And Installation Of Lift Cylinder(s)p. 79

  Checking The Tilt Cylinder(s)p. 82

  Removal And Installation Of Tilt Cylinder(s)p. 83

  Tilt Cylinder Base End Pivot Pinp. 85

  Lift Cylinder Parts Identificationp. 87

  Tilt Cylinder Parts Identificationp. 88

  Disassemblyp. 89

  Assemblyp. 91

  +MAIN RELIEF VALVEp. 95

  Checking Main Relief Valve At Front Auxiliary Hydraulicsp. 95

  Checking Main Relief Valve At Control Valve.p. 97

  Removal And Installationp. 99

  Adjustmentp. 100

  +MAIN RELIEF VALVE (ADVANCED HAND CONTROL) (AHC)p. 103

  NOT AVAILABLE AT TIME OF PRINTINGp. 103

  +HYDRAULIC CONTROL VALVE (FOOT CONTROL)p. 105

  Removal And Installationp. 105

  BICS™ Valve, Removal And Installationp. 110

  BICS™ Valve, Lift Arm By-Pass Orifice Disassembly And Assemblyp. 111

  BICS™ Valve, Check Valve Disassembly And Assemblyp. 112

  BICS™ Valve, Lock Valve Disassembly And Assemblyp. 113

  BICS™ Valve, Solenoid Disassembly And Assemblyp. 114

  BICS™ Valve, Solenoid Testingp. 115

  Identification Chartp. 115

  Load Check Valvep. 116

  Main Relief Valvep. 117

  Port Relief Valve, Tilt Spool (Linkage End)p. 118

  Port Relief Valve, Lift Spool (Bonnet End)p. 118

  Anti-Cavitation Valve/Port Relief Valve, Tilt Spool (Bonnet End)p. 119

  Anti-Cavitation Valve, Lift Spool (Linkage End)p. 119

  Rubber Bootp. 120

  Lift And Tilt Lock Blockp. 120

  Lift Spool and Detentp. 121

  Tilt Spool Removal And Installationp. 130

  Auxiliary Spool Removal And Installation (Bonnet End)p. 132

  Auxiliary Spool Removal And Installation (Linkage End)p. 133

  Auxiliary Plug Removal And Installationp. 134

  Auxiliary Electric Solenoid Disassemblyp. 134

  Port Relief-Auxiliary Section Disassemblyp. 135

  Cleaning And Inspectionp. 136

  +HYDRAULIC CONTROL VALVE (ADVANCE HAND CONTROL) (AHC)p. 137

  NOT AVAILABLE AT TIME OF PRINTINGp. 137

  +LIFT ARM BY-PASS CONTROL VALVEp. 139

  Removal And Installationp. 139

  Disassembly And Assemblyp. 140

  +HYDRAULIC PUMPp. 141

  Checking the Output of the Pumpp. 141

  Removal And Installationp. 142

  Disassembly and Assemblyp. 144

  +HYDRAULIC PUMPp. 151

  Disassembly And Assemblyp. 151

  Inspectionp. 154

  +HYDRAULIC/HYDROSTATIC FILTERp. 155

  Removal And Installationp. 155

  +COOLING FAN FILTERp. 157

  Removal And Installationp. 157

  +HYDRAULIC FLUID RESERVOIRp. 159

  Removal And Installationp. 159

  +CONTROLSp. 165

  Control Pedal Removal And Installationp. 165

  Control Pedal Adjustmentp. 165

  Control Pedals Mounting Panel Removal And Installationp. 165

  +BUCKET POSITION VALVEp. 169

  Removal And Installationp. 169

  Disassembly And Assemblyp. 170

  +TILT JUNCTION BLOCKp. 173

  Removal And Installationp. 173

  +REAR AUXILIARY DIVERTERp. 175

  Removal And Installationp. 175

  Disassemblyp. 178

  Inspectionp. 179

  Solenoid Testingp. 179

  Assemblyp. 179

  +HYDROSTATIC SYSTEMp. 181

  +HYDROSTATIC SYSTEM INFORMATIONp. 183

  Troubleshooting Chartp. 183

  Replenishing Valve Functionp. 184

  +CONTROL PANELp. 185

  Removal And Installationp. 185

  +STEERINGp. 189

  Lever Removal And Installationp. 189

  Disassembly And Assemblyp. 189

  Neutral Adjustmentp. 200

  +HYDROSTATIC MOTORp. 203

  Removal and Installationp. 203

  Throttle Controlp. 205

  Shuttle Check Valvep. 205

  Flushing Valvep. 206

  Disassemblyp. 207

  Inspectionp. 210

  Assemblyp. 212

  Cover Removal And Installationp. 217

  Neutral Adjustmentp. 217

  +CHARGE PRESSUREp. 219

  Checking The Charge Pressurep. 219

  +HYDROSTATIC PUMPp. 221

  Removal And Installationp. 221

  Replenishing/High Pressure Relief Valvep. 222

  Charge Relief Valvep. 223

  DA Controllerp. 223

  Disassemblyp. 224

  Inspectionp. 232

  Assemblyp. 234

  Hydrostatic Pump Start-Upp. 244

  Neutral Adjustmentp. 245

  Timing Procedurep. 247

  +DRIVE BELTp. 253

  Shield Removal And Installationp. 253

  Replacementp. 254

  Adjustmentp. 254

  Tensioner Pulley Removal And Installationp. 255

  Tensioner Tension Springp. 256

  Tensioner Pulley Disassembly And Assemblyp. 256

  Tensioner Pivot Shaftp. 257

  Idler Pulley Removal And Installationp. 258

  +OIL COOLERp. 259

  Removal And Installationp. 259

  +DRIVE SYSTEMp. 261

  +BRAKEp. 263

  Pedal Removal And Installationp. 263

  Pedal Disassembly And Assemblyp. 264

  Two Speed Block Removal And Installationp. 265

  Two Speed Block Disassembly And Assemblyp. 266

  Parking Brake Removal And Installationp. 271

  Parking Brake Disassembly And Assemblyp. 272

  +DRIVE COMPONENTSp. 277

  Axle Seal Removal And Installationp. 277

  Axle, Bearings And Sprocket Removal And Installationp. 280

  Drive Chains Removal And Installationp. 285

  +CHAINCASEp. 287

  Checking And Adding Oilp. 287

  Front Chaincase Cover Removal And Installationp. 287

  Rear Chaincase Cover Removal and Installationp. 287

  Reduction Gearcase Removal And Installationp. 288

  Reduction Gearcase Disassembly And Assemblyp. 292

  Removing The Oil From The Chaincasep. 300

  +MAIN FRAMEp. 301

  +SEAT BARp. 303

  Removal And Installationp. 303

  Assembling Componentsp. 304

  Compression Spring Disassembly And Assemblyp. 306

  +OPERATOR CABp. 307

  Gas Cylinder Removal And Installationp. 307

  Gas Cylinder Bracket Disassembly And Assemblyp. 308

  Removal And Installationp. 309

  +OPERATOR SEATp. 313

  Removal And Installationp. 313

  Slide Rail Removal And Installationp. 313

  Cushion Removal And Installationp. 314

  Back Removal And Installationp. 315

  Shock Removal And Installationp. 315

  +BOB-TACHp. 317

  Removal And Installationp. 317

  Bob-Tach Lever And Wedgep. 319

  Bob-Tach Stopsp. 320

  +POWER BOB-TACHp. 321

  NOT AVAILABLE AT TIME OF PRINTINGp. 321

  +LIFT ARMSp. 323

  Removal And Installationp. 323

  +REAR GRILLp. 327

  Gas Cylinder Removal And Installationp. 327

  +REAR DOORp. 329

  Removal And Installationp. 329

  Adjusting The Rear Door Latchp. 330

  Door Latch Removal And Installationp. 331

  Door Brace Removal And Installationp. 331

  +FUEL TANKp. 333

  Front Removal And Installationp. 333

  Fuel Level Senderp. 334

  Rear Removal And Installationp. 335

  Pick-up Tube Screenp. 337

  +ELECTRICAL SYSTEM & ANALYSISp. 339

  ELECTRICAL SCHEMATICS

  +ELECTRICAL SYSTEM INFORMATIONp. 353

  Troubleshooting Chartp. 355

  Descriptionp. 356

  Fuse Locationp. 358

  Relay Switch Locationp. 358

  Solenoid Testp. 359

  +BATTERYp. 361

  Removal And Installationp. 361

  Servicing The Electrical Systemp. 363

  Using A Booster Battery (Jump Starting)p. 364

  +ALTERNATORp. 365

  Alternator Output Testp. 365

  Rectifier (Diode) Testp. 365

  Alternator Regulator Testp. 366

  Removal And Installationp. 367

  Adjusting The Alternator Beltp. 369

  Disassemblyp. 370

  Stator Continuity Testp. 370

  Stator Ground Testp. 370

  Rotor Continuity Testp. 371

  Rotor Ground Testp. 371

  Rectifier Continuity (Diode) Testp. 371

  Assemblyp. 372

  +STARTERp. 375

  Removal And Installationp. 375

  Parts Identificationp. 377

  Disassembly And Assemblyp. 378

  External Pinionp. 380

  Inspection And Repairp. 381

  Magnetic Switch Testp. 384

  No Load Testp. 385

  +INSTRUMENT PANELp. 387

  Left Panelp. 387

  Right Panel – Standard Instrument Panel (With Key Switch)p. 388

  Right Panel – (Deluxe) (With Keyless Start)p. 389

  Right Panel Set Up Display Options (Deluxe)p. 391

  Passwordsp. 392

  Option And Field Accessory Panelsp. 394

  Standard Panel Removal And Installation (Right Side)p. 395

  Standard Panel Removal And Installation (Right Side) (Cont'd)p. 396

  Deluxe Panel Removal And Installation (Right Side)p. 396

  Standard And Deluxe Panel Removal And Installation (Left Side)p. 397

  +LIGHTSp. 399

  Front Removal And Installationp. 399

  Rear Removal And Installationp. 400

  +BOBCAT CONTROLLERp. 401

  Identification Chartp. 401

  Removal And Installationp. 402

  +DIAGNOSTICS SERVICE CODESp. 405

  Displayp. 405

  +BICS™ SYSTEMp. 407

  Inspecting The BICS™ Controller (Engine STOPPED – Key ON)p. 407

  Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)p. 407

  Inspecting The Seat Bar Sensor (Engine RUNNING)p. 407

  Inspecting The Traction Lock (Engine RUNNING)p. 407

  Inspecting The Lift Arm By-Pass Controlp. 407

  Additional Inspection For Loaders With Advanced Hand Controls (AHC)p. 408

  Troubleshooting Chartp. 409

  Troubleshooting Guidep. 410

  +SEAT BAR SENSORp. 411

  Troubleshooting Chartp. 411

  Testp. 412

  Removal And Installationp. 413

  BICS™ Circuit Testp. 414

  +TRACTION LOCKp. 417

  Troubleshooting Chartp. 417

  +ADVANCED HAND CONTROL (A.H.C.) SYSTEMp. 419

  Components Identificationp. 419

  Troubleshooting Guidep. 420

  Parts Identificationp. 421

  A.H.C. Controller Removal And Installationp. 422

  Handle Control Unit Connectorp. 423

  Switch Handle Removal and Installationp. 424

  Actuators Disassembly and Assemblyp. 427

  +PROPORTIONAL CONTROL (PWM)p. 429

  Troubleshooting Chartp. 429

  Control Handle Testingp. 430

  Electric Solenoid Coil Testingp. 430

  +ELECTRICAL/HYDRAULIC CONTROLS REFERENCEp. 431

  Controls Identification Chartp. 431

  +ENGINE SERVICEp. 433

  +TROUBLESHOOTINGp. 437

  Chartp. 437

  +ENGINE SPEED CONTROLp. 439

  Removal And Installationp. 439

  Disassembly And Assemblyp. 439

  +MUFFLERp. 441

  Spark Arrestor Cleaning Procedurep. 441

  Removal And Installationp. 442

  Exhaust Extension Pipe.p. 443

  +AIR CLEANERp. 445

  Housing Removal And Installationp. 445

  +RADIATORp. 447

  Coolant Recovery Tank Removal And Installationp. 447

  Removal And Installationp. 447

  +COOLING FANp. 451

  Removal And Installationp. 451

  Disassembly And Assemblyp. 453

  Blower Housing Removal And Installation (Cont'd)p. 457

  +ENGINE COMPONENTS AND TESTINGp. 459

  Fuel Injection Pump Removal And Installationp. 459

  Fuel Injector Removal and Installationp. 461

  Fuel Injector Checkingp. 464

  Checking The Fuel Lift Pumpp. 464

  Removal And Installationp. 465

  +ENGINE AND ENGINE MOUNTSp. 467

  Removal And Installationp. 467

  Mounting Brackets Removal And Installationp. 472

  +FLYWHEEL AND HOUSINGp. 473

  Flywheel Removal And Installationp. 473

  Ring Gear Removalp. 474

  Ring Gear Installationp. 474

  +RECONDITIONING THE ENGINEp. 475

  Intake Manifold Removal and Installationp. 475

  Exhaust Manifold Removal and Installationp. 476

  Cylinder Head Disassemblyp. 476

  Cylinder Head Removalp. 478

  Cylinder Head Inspectionp. 479

  Cylinder Head Installationp. 479

  Rocker Shaft Disassembly And Assemblyp. 482

  Valve Removalp. 483

  Valve Springs Checkingp. 483

  Valve Depth Checkingp. 484

  Valve Guides Checkingp. 484

  Valve Guide Removalp. 485

  Valve Guide Installationp. 485

  Valves Checkingp. 486

  Cutting A Valve Seatp. 486

  Valve Seat Assemblyp. 486

  Changing Valve Springs (With Cylinder Head Installed)p. 487

  Valve Clearance Adjustmentp. 488

  Timing Case And Drive Assembly Descriptionp. 489

  Timing Cover Removalp. 489

  Timing Cover Installationp. 489

  Front Oil Seal Removalp. 490

  Front Oil Seal Installationp. 490

  Timing Case And Gear Removalp. 491

  Timing Case And Gear Installationp. 492

  Camshaft And Tappets Removalp. 493

  Camshaft And Tappets Installationp. 493

  Pistons And Connecting Rods Descriptionp. 495

  Pistons And Connecting Rods Removalp. 495

  Pistons And Connecting Rods Disassemblyp. 496

  Piston Ring End Gapp. 497

  Piston Ring Installationp. 497

  Piston Ring Groove Clearancep. 498

  Connecting Rod Inspectionp. 498

  Connecting Rod Bushing Replacementp. 498

  Piston And Connecting Rod Assemblyp. 498

  Piston And Connecting Rod Installationp. 499

  Checking Piston Heightp. 500

  Crankshaft And Bearings Descriptionp. 500

  Crankshaft And Bearings Removalp. 500

  Inspection Of Crankshaft And Bearingsp. 502

  Crankshaft And Bearings Installationp. 503

  Rear Oil Seal Removalp. 504

  Rear Oil Seal Housing Positioningp. 504

  Rear Oil Seal Installationp. 505

  Checking Crankshaft End Playp. 505

  Cooling System Descriptionp. 506

  Thermostat Removal and Installationp. 507

  Thermostat Testingp. 508

  Water Pump Removalp. 508

  Water Pump Installationp. 509

  Engine Oil Cooler Removal And Installationp. 509

  Engine Oil Cooler Disassembly And Assemblyp. 511

  Engine Lubrication System Descriptionp. 512

  Oil Filter Adapter Removalp. 513

  Oil Filter Adapter Installationp. 513

  Oil Pan Removal And Installationp. 514

  Oil Screen And Pick-up Tubep. 514

  Oil Pump Removalp. 514

  Oil Pump Installationp. 515

  Oil Pump Disassembly And Assemblyp. 516

  Oil Pressure Relief Valve Disassembly And Assemblyp. 517

  Engine Block Descriptionp. 517

  Engine Block Disassembly And Assemblyp. 518

  Piston Cooling Jet Removalp. 518

  Piston Cooling Jet Installationp. 518

  Piston Cooling Jet Alignmentp. 519

  Inspectionp. 519

  Cylinder Liner Inspectionp. 519

  Cylinder Liner Removalp. 520

  Cylinder Liner Installationp. 521

  Turbo Charger Troubleshootingp. 522

  Turbo Charger Descriptionp. 523

  Turbo Charger Removal and Installationp. 523

  +HEATING, VENTILATION, AIR CONDITIONINGp. 525

  +AIR CONDITIONING SYSTEM FLOWp. 528

  Principalsp. 528

  Chartp. 529

  +COMPONENTSp. 531

  Identificationp. 531

  +SAFETYp. 535

  Safety Equipmentp. 535

  +REGULAR MAINTENANCEp. 537

  Filter Elements Removal And Installationp. 537

  Compressor Drive Belt Inspectionp. 538

  Cleaning The Condenserp. 539

  +BASIC TROUBLESHOOTINGp. 541

  Poor A/C Performancep. 541

  Cleaning The A/C Evaporator Coil & Heater Coilp. 541

  Compressor Drive Belt Inspection:p. 544

  Checking The Electrical Systemp. 544

  Engine Coolant By-Passing The Heater Valvep. 552

  Heater Valve Not Opening Or Closingp. 552

  +GENERAL AIR CONDITIONING SERVICE GUIDELINESp. 555

  Compressor Oilp. 555

  Compressor Oil Checkp. 555

  Component Replacement And Refrigeration Leaksp. 556

  +SYSTEM TROUBLESHOOTING CHARTp. 557

  Gauge Pressure Related Troubleshootingp. 558

  +TEMPERATURE/PRESSUREp. 561

  Chartp. 561

  +AIR CONDITIONING SERVICEp. 563

  Chartp. 563

  +SYSTEM CHARGING AND RECLAMATIONp. 565

  Reclamation Procedurep. 565

  Charging Procedure With A Manifold Gauge Setp. 567

  Charging Procedurep. 568

  +COMPRESSORp. 571

  Removal And Installationp. 571

  Compressor Clutch Disassemblyp. 571

  +CONDENSERp. 577

  Removal And Installationp. 577

  +RECEIVER/DRIERp. 579

  Removal And Installationp. 579

  +PRESSURE RELIEF VALVEp. 581

  Removal And Installationp. 581

  +PRESSURE SWITCHp. 583

  Removal And Installationp. 583

  +EVAPORATOR/HEATER UNITp. 585

  Removal And Installationp. 585

  Disassembly And Assemblyp. 586

  +THERMOSTATp. 587

  Removal And Installationp. 587

  +EXPANSION VALVEp. 589

  Removal And Installationp. 589

  +EVAPORATORp. 591

  Removal And Installationp. 591

  +HEATER COILp. 593

  Removal And Installation With A/Cp. 593

  Removal And Installation Without A/Cp. 594

  +HEATER/AC FANp. 597

  Removal And Installationp. 597

  Disassembly And Assemblyp. 598

  Wire Connector Removal and Installationp. 600

  +HEATER VALVEp. 603

  Removal and Installationp. 603

  Disassembly And Assemblyp. 603

  +SPECIFICATIONSp. 607

  +LOADER SPECIFICATIONSp. 609

  Loader Dimensionsp. 609

  Performancep. 610

  Controlsp. 610

  Enginep. 610

  Hydraulic Systemp. 611

  Electricalp. 611

  Drive Systemp. 612

  Capacitiesp. 612

  Tiresp. 612

  +ENGINE SPECIFICATIONSp. 613

  Generalp. 613

  Cylinder Headp. 613

  Valve Guidesp. 613

  Exhaust Valvesp. 613

  Intake Valvesp. 614

  Valve Springsp. 614

  Rocker Shaft, Rockers And Bushingsp. 614

  Pistons And Piston Ringsp. 615

  Connecting Rods And Bearingsp. 615

  Crankshaftp. 616

  Crankshaft Re-Grind Datap. 617

  Main Bearingsp. 618

  Thrust Washersp. 618

  Camshaft And Thrust Washerp. 618

  Cylinder Blockp. 618

  Cylinder Linersp. 618

  Fuel Injection Pumpp. 619

  Fuel Injectorsp. 619

  Fuel Lift Pumpp. 619

  Timing Case And Timing Gearsp. 619

  Oil Pump, Gear And Relief Valvep. 620

  Turbochargerp. 620

  Flywheelp. 620

  Water Pump And Thermostatp. 621

  Engine Torquep. 622

  +LOADER TORQUEp. 623

  Specificationsp. 623

  +TORQUE SPECIFICATIONS FOR BOLTSp. 625

  Torque For General SAE Boltsp. 625

  Torque For General Metric Boltsp. 626

  +HYDRAULIC CONNECTION SPECIFICATIONSp. 627

  O-ring Face Seal Connectionp. 627

  Straight Thread O-ring Fittingp. 627

  Tubelines And Hosesp. 627

  Flare Fittingp. 628

  O-ring Flare Fittingp. 629

  Port Seal Fittingp. 631

  +HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONSp. 633

  Specificationsp. 633

  +CONVERSIONSp. 635

  Decimal And Millimeters Equivalentsp. 635

  U.S. To Metric Conversionp. 635

  +SMR

  Revision No: 963-1p. 637

  Revision No: 963-2

• Hydraulic System
  • Hydraulic system information and troubleshooting
  • Lift and tilt cylinders
  • Hydraulic control valve and BICS valve components
  • Main relief valve and lift-arm by-pass control valve
  • Hydraulic pump, reservoir and hydraulic/hydrostatic filter
  • Bucket-position valve, tilt junction block and rear auxiliary diverter
• Hydrostatic System
  • Hydrostatic system information and troubleshooting
  • Control panel and steering
  • Hydrostatic pump and hydrostatic motor service
  • Charge/replenishing functions and pressure checks
  • Oil cooler and drive-related adjustments
• Drive System
  • Chaincase
  • Brake
  • Drive components
• Main Frame
  • Seat bar and operator-seat related components
  • Bob-Tach and Power Bob-Tach
  • Lift arms
  • Fuel tank
  • Rear grill and rear door
• Electrical System & Analysis
  • Electrical system information and wiring schematics
  • Diagnostic service codes
  • BICS system, Bobcat controller and control references
  • Battery, starter and lights
  • Electrical/hydraulic controls and sensors
• Engine Service
  • Air cleaner and cooling fan
  • Engine and engine mounts
  • Engine speed control
  • Flywheel and housing
  • Muffler and radiator
  • Engine components, testing and engine reconditioning
• Heating, Ventilation, Air Conditioning
  • General air-conditioning service guidelines
  • Compressor and condenser
  • Evaporator/heater unit and expansion valve
  • Receiver/drier
  • Heater coil, heater/AC fan and heater valve
  • System charging/reclamation and troubleshooting
• Specifications
  • Loader dimensions, performance, controls and capacities
  • Engine specifications and service dimensions
  • Hydraulic connection specifications
  • Hydraulic/hydrostatic fluid specifications
  • Bolt torque information and unit conversions

Taken as a whole, these chapters give a technician a connected service path from preliminary safety checks and scheduled maintenance to fault isolation, system testing, component removal, bench repair, reinstallation, adjustment, and final verification. The document repeatedly links related procedures so that, for example, a hydraulic repair can be followed through safe loader support, cab access, pressure release, component removal, torque requirements, fluid replacement, and post-repair checks.

Diagnostic, Schematic and Specification Depth

This 963 loader manual contains practical troubleshooting tables rather than only descriptive theory. Hydraulic troubleshooting addresses conditions such as a hydraulic system that will not operate, slow or uneven action, lift-arm drift, and bucket-position problems. Hydrostatic troubleshooting covers one-sided drive loss, straight-line travel issues, overheating, warning indications, pump or motor concerns, fluid level, filter restriction, and steering-linkage adjustment. Electrical troubleshooting and diagnostic-code information provide another layer for faults involving control circuits, interlocks, sensors, starting, charging, and machine functions.

IMAGES PREVIEW

System schematics and component identification drawings are important parts of the manual. The hydraulic/hydrostatic schematic identifies pumps, motors, cylinders, control valves, BICS-related valves, auxiliary circuits, filters, diagnostic couplers, brake/two-speed components, pressure-control devices, and flow paths. Wiring schematics are provided for the 963 with applicable serial ranges and options. Exploded and parts-identification illustrations appear throughout repair procedures, including detailed lift and tilt cylinder component layouts.

The specification section gives the service data needed to check a repair against the values printed for this machine. Loader performance, hydraulic data, electrical data, capacities, tires, drive-system information, engine dimensions, clearances, pressures, torque values, and hydraulic connection information are consolidated near the end of the manual. Examples of machine-level data shown include rated operating capacity, tipping load, operating weight, travel speeds, hydraulic pump capacity, hydraulic relief settings, fluid capacities, battery and alternator information, and engine performance data. Those values are useful not only during overhaul work but also when confirming whether a system is operating within the manual’s stated limits.

Built for Hands-On Bobcat 963 Repair Work

The Bobcat 963 Skid-Steer Loader Service Manual – S/N 562215001 & Above / S/N 516515001 & Above is suited to owners, workshops, and technicians who need to carry out real service work on the covered 963 loaders: diagnose hydraulic or hydrostatic problems, remove and rebuild components, service the engine and cooling system, trace electrical circuits, work on BICS and machine controls, repair frame and drive components, service HVAC equipment, and verify adjustments against the printed specifications. Using the correct procedure, pressure, clearance, torque, fluid, and serial-number-specific information helps reduce guesswork and supports a more controlled repair process.

After purchase, the manual is supplied as an instant PDF download with no physical shipping. It can be opened on compatible phones, tablets, laptops, and desktop computers and printed when a paper reference is useful at the machine or workbench.