Bobcat 963 skid steer loader service repair manual

Service Manual

EQUIPPED WITH BOBCAT INTERLOCK CONTROL SYSTEM (BICSTM)

6724545 (11–97)

Printed in U.S.A.

© Melroe Company 1997

MAINTENANCE SAFETY WARNING

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow W-2003-0903 instructions can cause injury or death.

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

CORRECT

CORRECT

CORRECT

B-10731a

B-12365

B-7469

Never service the Bobcat SkidSteer Loader without instructions.

Use the correct procedure to lift or lower operator cab.

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

B-11799

B-15231

B-15280

Have good ventilation when welding or grinding painted parts.

Wear dust mask when grinding painted parts. Toxic dust and gas can be produced.

Avoid exhaust fume leaks which can kill without warning. Exhaust system must be tightly sealed.

Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Do not go under lift arms when raised unless supported by an approved lift arm support device.

Replace it if damaged.

Never work on loader with lift arms up unless lift arms are held by an approved lift arm support device. Replace if damaged.

Never modify equipment or add attachments not approved by Bobcat Company.

WRONG

WRONG

WRONG

B-6590

B-6580 B-16102

B-6589 B-16102

Stop, cool and clean engine of flammable materials before checking fluids.

Never service or adjust loader with the engine running unless instructed to do so in the manual.

Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes.

Never fill fuel tank with engine running, while smoking or when near open flame.

Keep body, jewelry and clothing away from moving parts, electrical contact, hot parts and exhaust.

Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used.

Use eye protection approved for type of welding.

Keep rear door closed except for service. Close and latch door before operating the loader.

Lead-acid batteries produce flammable and explosive gases.

Keep arcs, sparks, flames and lighted tobacco away from batteries.

Batteries contain acid which burns eyes or skin on contact.

Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention.

Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/ operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course is available from your Bobcat dealer.

MSW01-0805

ALPHABETICAL INDEX ACTUATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1 ACTUATOR VOLTAGE TEST . . . . . . . . . . . . . . . . . . 10–1 A.H.C. COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 10–1 A.H.C./PWM CONTROLLER . . . . . . . . . . . . . . . . . . 10–1 A.H.C. HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1 A.H.C. STEERING LEVER . . . . . . . . . . . . . . . . . . . . 10–1 AIR CLEANER HOUSING . . . . . . . . . . . . . . . . . . . . . . 7–1 AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . 1–1 ALTERNATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 AXLE SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 AXLE, BEARINGS AND SPROCKET . . . . . . . . . . . . 4–1

ELECTRICAL/HYDRAULIC CONTROL REF. . . . . . .

ELECTRICAL SYSTEM INFORMATION . . . . . . . . . .

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . .

ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . .

ENGINE MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE MOUNTING BRACKET . . . . . . . . . . . . . . . . .

ENGINE OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . .

ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .

EXHAUST MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . .

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 BICS™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1, 10–1 BICS™ SYSTEM CONTROLLER . . . . . . . . . . . . . . . . 8–1 BICS™ VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1, 10–1 BLOWER FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 BOSS DIAGNOSTIC TOOL . . . . . . . . . . . . . . . . . . . . 8–1 BOSS INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . 8–1 BOSS UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 BRAKE/TWO SPEED BLOCK . . . . . . . . . . . . . . . . . . 4–1 BUCKET POSITION VALVE . . . . . . . . . . . . . . . . . . . . 2–1

FAN DRIVE TENSION PULLEY . . . . . . . . . . . . . . . . . . 7–1 FAN GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 & 7–1 FAN GEARBOX/BLOWER HOUSING . . . . . . . . . . . . 7–1 FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . 1–1 FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 FRONT CHAINCASE COVER . . . . . . . . . . . . . . . . . . . 4–1 FRONT FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 FRONT LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 FRONT SIDE PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 FUEL INJECTOR NOZZLE . . . . . . . . . . . . . . . . . . . . . . 7–1 FUEL INJECTION PUMP . . . . . . . . . . . . . . . . . . . . . . . 7–1 FUEL LIFT PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1

CAMSHAFT AND TAPPETS . . . . . . . . . . . . . . . . . . . .

CHAINCASE FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLANT RECOVERY TANK . . . . . . . . . . . . . . . . . .

COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROL PEDALS . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONTROL PEDALS MOUNTING PANEL . . . . . . . .

CRANKSHAFT AND BEARINGS . . . . . . . . . . . . . . . .

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7–1 4–1 7–1 7–1 3–1 2–1 2–1 7–1 7–1

DECIMAL & MILLIMETER EQUIVALENTS . . . . . . .

DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE BELT IDLER PULLEY . . . . . . . . . . . . . . . . . . .

DRIVE BELT SHIELD . . . . . . . . . . . . . . . . . . . . . . . . . .

DRIVE BELT TENSIONER PULLEY . . . . . . . . . . . . .

DRIVE CHAINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9–1 3–1 3–1 3–1 3–1 4–1

HANDLE CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . 10–1 HANDLE CONTROL UNIT TEST . . . . . . . . . . . . . . . . 10–1 HYDRAULIC CONTROL VALVE . . . . . . . . . . . 2–1, 10–1 HYDRAULIC CONNECTION SPECIFICATONS . . . . 9–1 HYDRAULIC CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . 2–1 HYDRAULIC/HYDROSTATIC FILTER . . . . . . . . . . . . . 2–1 HYDRAULIC/HYDROSTATIC FLUID SPEC. . . . . . . . 9–1 HYDRAULIC FLUID RESERVOIR . . . . . . . . . . . . . . . . 2–1 HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . 2–1 HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . 1–1 HYDROSTATIC CONTROLLER . . . . . . . . . . . . . . . . . . 3–1 HYDROSTATIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . 3–1 HYDROSTATIC MOTOR COVER . . . . . . . . . . . . . . . . 3–1 HYDROSTATIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 HYDROSTATIC SYSTEM INFORMATION . . . . . . . . . 3–1 INTAKE MAINIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 LIFT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIFT ARM BY–PASS CONTROL VALVE . . . . . . . . . .

LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . .

LIFT CYLINDER(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIFTING AND BLOCKING THE LOADER . . . . . . . . .

LOADER SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .

LOADER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . .

LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . .

A.H.C.–ADVANCED HAND CONTROL SYSTEM BICS–BOBCAT INTERLOCK CONTROL SYSTEM BOSS–BOBCAT OPERATION SENSING SYSTEM PWM–PULSE WITH MODULATION

5–1 2–1 1–1 2–1 1–1 9–1 9–1 1–1 7–1

MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 MONITOR SERVICE CODES . . . . . . . . . . . . . . . . . . . . 8–1

Cont’d On Next Page Revised Mar. 99

8–1 6–1 7–1 7–1 7–1 1–1 1–1 7–1 7–1 7–1 7–1 9–1 7–1

ALPHABETICAL INDEX (Cont’d) OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 OPERATION SENSING SYSTEM UNIT . . . . . . . . . . 8–1 OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . 1–1 & 5–1 OPERATOR CAB GAS CYLINDER . . . . . . . . . . . . . . 5–1 OPERATOR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PARKING BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . .

PEDAL INTERLOCK LINKAGE . . . . . . . . . . . . . . . . .

PISTONS AND CONNECTING RODS . . . . . . . . . . .

PWM CONTROL HANDLE . . . . . . . . . . . . . . . . . . . . .

PWM ELECTRIC SOLENOID . . . . . . . . . . . . . . . . . . .

PWM MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PWM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . .

4–1 4–1 2–1 7–1 8–1 8–1 8–1 8–1

RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR CHAINCASE COVER . . . . . . . . . . . . . . . . . . . .

REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REDUCTION GEARCASE . . . . . . . . . . . . . . . . . . . . .

RELAY SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . .

REMOTE START SWITCH . . . . . . . . . . . . . . . . . . . . .

ROCKER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RPM SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7–1 4–1 5–1 5–1 5–1 4–1 6–1 1–1 7–1 8–1

SEAT BAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . 1–1 SEAT BAR SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 SEAT SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 SENDER AND SENSOR . . . . . . . . . . . . . . . . . . . . . . . 8–1 SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 STANDARD INSTRUMENT PANEL . . . . . . . . . . . . . . 6–1 STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 STEERING LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 STEERING LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 SWITCH HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1 SYSTEM ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 TILT CYLINDER(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 TILT JUNCTION BLOCK . . . . . . . . . . . . . . . . . . . . . . . 2–1 TIMING CASE AND DRIVE ASSEMBLY . . . . . . . . . 7–1 TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . 1–1 TRACTION LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 TRANSPORTING THE LOADER . . . . . . . . . . . . . . . . 1–1 TROUBLESHOOTING . . . . . . 2–1, 3–1, 6–1, 7–1 & 8–1 TROUBLESHOOTING (A.H.C.) . . . . . . . . . . . . . . . . 10–1 TURBOCHARGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 VALVE, VALVE GUIDE AND SPRINGS . . . . . . . . . . 7–1 U.S. TO METRIC CONVERSION . . . . . . . . . . . . . . . . 9–1

Revised Mar. 99

CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii BOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–1 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3–1 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4–1 MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5–1 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6–1 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7–1 SYSTEM ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8–1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9–1 ADVANCED HAND CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 10–1

CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.

PREVENTIVE MAINTENANCE

HYDRAULIC SYSTEM

HYDROSTATIC SYSTEM

DRIVE SYSTEM

MAIN FRAME

ELECTRICAL SYSTEM

ENGINE SERVICE

SYSTEMS ANALYSIS

SPECIFICATIONS

ADVANCED HAND CONTROL SYSTEM

Revised Mar. 99

i

963 Bobcat Loader Service Manual

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.

A general inspection of the following items must be made after the loader has had service or repair: 9. The parking brake function correctly.

1. Check that the ROPS/FOPS (Including sidescreens) is in good condition and is not modified.

must

2. Check that ROPS mounting hardware is tightened and is Melroe approved.

10. Enclosure door latches must open and close freely.

3. The seat belt must be correctly installed, functional and in good condition.

11. Bob–Tach wedges and linkages must function correctly and be in good condition.

4. The seat bar and pedal interlocks must be correctly adjusted, clean and lubricated.

12. Safety treads must in good condition.

5. Check lift arm support device, replace if damaged.

13. Check for correct function of indicator lamps (Optional on some models).

6. Machine signs must be legible and in the correct location.

14. Check hydraulic fluid level, engine oil level and fuel supply.

WARNING

7. Steering levers and foot pedals must return to neutral.

15. Inspect for fuel, oil or hydraulic fluid leaks.

8. Check for correct function of the work lights.

16. Lubricate the loader.

Revised Mar. 99

ii

963 Bobcat Loader Service Manual

17. Check the condition of the battery and cables.

18. Inspect the air cleaner for damage or leaks. Check the condition of the element.

19. Check the electrical charging system.

20. Check tires for wear and pressure.

21. Inspect for loose or broken parts or connections.

22. Operate the loader and check all functions.

23. Check for any field modification not completed.

24. Check for correct function of the Bobcat Interlock Control System (BICS™) before the machine is returned to the customer.

Recommend to the owner that all necessary corrections be made before the machine is returned to service.

Revised Mar. 99

iii

963 Bobcat Loader Service Manual

SAFETY INSTRUCTIONS

Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death.

W–2003–0299

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 routine 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.

Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death.

This notice identifies procedures which must be followed to avoid damage to the machine.

I–2019–0284

W–2044–1285

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

SI05–0299

v

963 Bobcat Loader Service Manual

FIRE PREVENTION The loader has several components that are at high temperature under normal operating conditions. The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcs or sparks.

Flammable debris (leaves, straw, etc.) must be removed regularly. If flammable debris is allowed to accumulate, it will increase the fire hazard. The loader must be cleaned as often as necessary to avoid this accumulation. Flammable debris in the engine compartment is a fire hazard when the loader is parked with a hot engine.

The exhaust system is designed to control the emission of hot particles from the engine and exhaust system, but the muffler and the exhaust gases are still hot.

• Do not use the Bobcat loader where exhaust, arcs, sparks or hot components can contact flammable material, explosive dust or gases.

• The engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent fire hazard and overheating.

• Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace any damaged part.

• Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel for cleaning parts. Use commercial nonflammable solvents.

• Do not use ether or starting fluids on this engine. It has a glow plug. These starting aids can cause explosion and injure you or bystanders.

• Always clean the loader and disconnect the battery before doing any welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the loader when welding. Have good ventilation when grinding or welding painted parts. Wear dust mask when grinding painted parts. Toxic dust or gas can be produced.

• Stop the engine and let it cool before adding fuel. No smoking!

• Use the procedure in the Operation & Maintenance Manual for connecting the battery.

• Use the procedure in the Operation & Maintenance Manual for cleaning the spark arrestor muffler.

• Know where fire extinguishers and first aid kits are located and how to use them.

A fire extinguisher is available from your local dealer. The fire extinguisher can be installed in the location shown [A].

A

P–10650

SI04–0398

vi

963 Bobcat Loader Service Manual

SERIAL NUMBER LOCATIONS

A

Always use the serial number of the loader when requesting service information or when ordering parts.

Early or later models (identification made by serial number) may use different parts, or it may be necessary to use a different procedure in doing a specific service operation.

LOADER SERIAL NUMBER The loader serial number plate is located on the inside of the left upright, above the grill [A].

Explanation of loader Serial Number: XXXX

P–10242

XXXXX Module 2. – Production Sequence (Series)

B

Module 1. – Model/Engine Combination 1. The four digit Model/Engine Combination Module number identifies the model number and engine combination.

2. The five digit Production Sequence Number identifies the order which the loader is produced.

ENGINE SERIAL NUMBER

P–10501

The serial number is on the engine block just above the fuel injection pump [B].

DELIVERY REPORT

C

The Delivery Report must be filled out by the dealer and signed by the owner or operator when the Bobcat loader is delivered. An explanation of the form must be given to the owner. Make sure it is filled out completely [C].

vii

963 Bobcat Loader Service Manual

963 BOBCAT LOADER IDENTIFICATION 963ServiceManual#6724545–ContentsSection

FRONT LIGHTS OPERATOR SEAT SEAT BAR GRAB HANDLES

SAFETY TREADS

STEERING LEVERS TILT CYLINDERS

BUCKET AUXILIARY HYDRAULIC QUICK COUPLERS

BUCKET STEPS

OPERATOR CAB (ROPS & FOPS)

LIFT ARM

REAR GRILL

LIFT ARM SUPPORT DEVICE

TAIL LIGHTS

LIFT CYLINDER

REAR LIGHTS REAR DOOR TIRES*

B–15004 B–15005

* TIRES – Flotation tires (optional) are shown. The Bobcat loader is factory equipped with standard tires.

BUCKET – Several different buckets and other attachments are available for the Bobcat loader.

ROPS, FOPS – Roll Over Protective Structure, Falling Object Protective Structure, per SAE J1040 and ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level l. Level ll is available. The Bobcat loader is base–equipped with a standard operator cab as shown. Extra insulated cab is available as an option (Reduced noise level).

Revised Mar. 99

viii

963 Bobcat Loader Service Manual

PREVENTIVE MAINTENANCE Page Number

PREVENTIVE MAINTENANCE

AIR CLEANER SERVICE Replacing Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–13 ALTERNATOR BELT Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–20 BOB–TACH Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–28 ENGINE COOLING SYSTEM Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–18 Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–18 Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–19 ENGINE LUBRICATION SYSTEM Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17 Replacing The Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–17 FAN GEAR BOX Checking And Maintaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–25 FINAL DRIVE TRANSMISSION (CHAINCASE) Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–25 FUEL SYSTEM Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–15 1–16 1–15 1–16

HYDRAULIC/HYDROSTATIC SYSTEM Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–21 Hydraulic/Hydrostatic Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 1–21 Replacing The Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–22 LIFT ARM SUPPORT DEVICE Disengaging The Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . 1–8 Engaging The Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–7 LIFTING AND BLOCKING THE LOADER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–4 LUBRICATING THE LOADER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–26 OPERATOR CAB Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1–9 1–11 1–10 1–9

REMOTE START SWITCH Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–29 Continued On Next Page Revised Mar. 99 –1–1–

963 Bobcat Loader Service Manual

PREVENTIVE MAINTENANCE (Cont’d) Page Number SEAT BAR RESTRAINT SYSTEM Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 Inspecting The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 Maintaining The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–12 SERVICE SCHEDULE Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–3 SPARK ARRESTOR MUFFLER Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–23 TIRE MAINTENANCE Tire Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–24 Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–24 Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–24 TOWING THE LOADER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–6 TRANSPORTING THE LOADER Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1–5

–1–2–

963 Bobcat Loader Service Manual

SERVICE SCHEDULE Chart Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The service schedule is a guide for correct maintenance of the Bobcat loader.

Instructions are necessary before operating or servicing machine. Read and understand Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death.

W–2003–0199

ITEM Engine Oil Air Filter Engine Air System Engine Cooling System Primary Fuel Filter Lift Arms, Cylinders, Bob– Tach Pivot Pins & Wedges Seat Belt, Seat Bar and Pedal Interlocks Bobcat Interlock Control System (BICS™) Tires Safety Signs & Safety Tread Operator Cab Hydraulic Fluid, Hoses and Tubelines Final Drive Transmission (Chaincase) Control Pedals & Steering Wheel Nuts Spark Arrestor Muffler Battery Steering Shaft Engine/Hydro. Drive Belt Alternator Belt Fan Drive Gearbox Engine Oil and Filter Fuel Filters Hydraulic Reservoir Breather Cap Hyd./Hydro. Filter Hydraulic Reservoir Final Drive Transmission Bobcat Interlock Control System (BICS™)

*

SERVICE REQUIRED

8–10 50 100 250 500 1000

Check the oil level and add oil as needed. Do not overfill.

Check condition indicator. Service only when required.

Check for leaks and damaged components.

Clean debris from oil cooler, radiator and grill. Check coolant level cold in recovery tank. Add premixed coolant as needed.

Remove trapped water.

Lubricate with multi–purpose lithium based grease (14 places).

Check the condition of seat belt. Check the seat bar and pedal interlocks for correct operation. Clean dirt and debris from moving parts.

Check BICS™ functions. Clean dirt, debris or objects from under or behind seat as required.

Check for damaged tires and correct air pressure.

Check for damaged signs (decals) and safety tread. Replace any signs or safety treads that are damaged or worn.

Check the fastening bolts, washers and nuts. Check the condition of cab. Remove debris from the pedal area through the clean–out holes.

Check fluid level and add as needed. Check for damage and leaks.

Repair and replace as needed.

Check oil level and add as needed.

Check for correct operation. Repair or adjust as needed.

Check for loose wheel nuts and tighten to 320–350 ft.–lbs. (434–475 Nm) torque.

Clean the spark chamber.

Check battery for damage, hold down, cables, connections and electrolyte level. Add distilled water as needed.

Grease two fittings on the steering cross–shaft. * Check belt tension.

Check tension and adjust as needed.

Check gear lubrication level.

Replace oil and filter. Use CD or better grade oil and Melroe filter.

Replace filter elements.

Replace the reservoir breather cap.

Replace the filter element.

Replace the fluid.

Replace the oil in the chaincase.

Check lift arm by–pass control.

Check wheel nut torque every 8 hours for the first 24 hours.

Also replace hydraulic/hydrostatic filter element when the transmission warning light comes ON. Or every 12 months.

Check every 8 hours for the first 40 hours of operation.

First oil and filter change must occur at 50 hours.

–1–3–

963 Bobcat Loader Service Manual

A Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing.

Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death.

W–2003–0299 LIFTING AND BLOCKING THE LOADER Procedure B–07023

Always park the loader on a level surface.

Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death.

W–2017–0286

B

Stop the engine. Put the floor jack under the rear of the loader. Lift the rear of the loader and install jackstands [B].

N–15440

C

Put the floor jack under the front of the loader. Lift the front of the loader and install jackstands under the axle tubes [C].

NOTE: Make sure the jackstands do not touch the tires.

N–15441

Revised Mar. 99

–1–4–

963 Bobcat Loader Service Manual

TRANSPORTING THE LOADER

A

Procedure

Adequately designed ramps of sufficient strength are needed to support the weight of the machine when loading onto a transport vehicle. Wood ramps can break and cause personal injury.

W–2058–0494 P–10421

A loader with an empty bucket or no attachment must be loaded backward onto the transport vehicle [A].

B

Be sure the transport vehicle is of adequate size and capacity.

The rear of the trailer must be blocked or supported [A] when loading or unloading the loader to prevent the front end of the trailer from raising up. Some ramps have a wedge shape (Item 1) [A] to support the trailer.

Use the following procedure to fasten the Bobcat loader to the transport vehicle to prevent the loader from moving during sudden stops or when going up or down slopes [B]: P–10423

Lower the bucket or attachment to the floor.

P–10425

Stop the engine.

Engage the parking brake. Install chains at the front and rear of the loader tie down positions (Inset) [B].

Fasten each end of the chain to the transport vehicle.

P–10424

–1–5–

963 Bobcat Loader Service Manual

TOWING THE LOADER

A

Procedure To prevent damage to the loaders hydrostatic system, the loader must be towed only a short distance at a slow speed. (Example: Moving the loader onto a transport vehicle.)

1

2

The towing chain (or cable) must be rated 1–1/2 times the weight of the loader. (See SPECIFICATIONS, Page 9–1.)

Lift and block the rear of the loader. (See Page 1–4.)

Remove the hydrostatic motor access cover (both sides).

(See Page 3–1.)

P–10536

Remove the plugs (Items 1 & 2) [A] from the motor (both sides).

B

Remove the shuttle valve (Item 1) [B] using a small screwdriver (both sides).

2

NOTE: The plug (Item 2) [B] and relief valve may have to be removed so that the shuttle spool can be removed from the housing bore.

Install and tighten the plugs.

Install the rear wheels. Lower the loader to the ground.

Raise the operator cab. (See Page 1–9.)

1 P–10540

Disengage the parking brake solenoid valve by pushing UP on the red Traction Lock By–Pass Knob (Item 1) [C] and turning it 1/4 TURN counterclockwise. The knob will come down to release the solenoid valve.

C

Unexpected loader movement.

Can cause serious injury or death.

Push up on and turn red Traction Lock By–Pass Knob clockwise to engaged position before operating loader.

Read Operation & Maintenance Manual for more instructions.

6803932

1 P–10537

Connect a Port–a–Power to the coupler (Item 1) [D] at the brake/two speed block.

D

1

Operate the Port–a–Power to approximately 350 PSI (2413 kPa) to release the parking brake.

Lower the operator cab. Move the loader to the desired location.

NOTE: Before using the loader again, disconnect the Port–a–Power, push up and turn the red by–pass knob (Item 1) [C] 1/4 turn to engage the traction lock solenoid. Install the shuttle valve (Item 1) [B] into the hydrostatic motors.

P–10541

Revised Mar. 99

–1–6–

963 Bobcat Loader Service Manual

LIFT ARM SUPPORT DEVICE

A 1

Never work on a machine with the lift arms up unless the lift arms are secured by a lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.

2

P–10201

W–2059–0991 P–10200

Engaging The Lift Arm Support Device

B

Maintenance and service work can be done with the lift arms lowered.

1

If the lift arms must be raised for service, use the following procedure: Disconnect the spring (Item 1) [A] from the lift arm support device retaining pin (Item 2) [A]. Hold the support device and remove the retaining pin.

Lower the lift arm support device on top of the lift cylinder.

Hook the free end of the spring (Item 1) [B] to the lift arm support device so there will be no interference with the support device engagement.

With the operator in the seat, seat belt fastened and seat bar lowered, start the engine.

P–10198

C

Raise the lift arms, until the lift arm support device lowers onto the lift cylinder rod [C].

Lower the lift arms slowly until the support device is held between the lift arm and the lift cylinder. Stop the engine.

Raise the seat bar and move foot pedals until both pedals lock.

P–10196

Install the pin (Item 1) [D] into the rear of the lift arm support device below the cylinder rod.

D

Service lift arm support device if damaged or if parts are missing. Using a damaged lift arm support or with missing parts can cause lift arms to drop causing injury or death.

1

W–2271–1197 P–10191

Revised June 98

–1–7–

963 Bobcat Loader Service Manual

LIFT ARM SUPPORT DEVICE (Cont’d)

A

Disengaging The Lift Arm Support Device Remove the pin from the lift arm support device.

Connect the spring (Item 1) [A] from the lift arm support device to the bracket below the lift arms.

1

With the operator in the seat, seat belt fastened and seat bar lowered, start the engine.

P–10197

Raise the lift arms a small amount and the spring will lift the support device (Item 1) [B] off the lift cylinder rod.

B

Lower the lift arms. Stop the engine.

Raise the seat bar and move foot controls until both controls lock.

Disconnect the spring from the bracket.

1

P–10199

Raise the support device into storage position and insert pin (Item 1) [C] through lift arm support device and bracket.

C

Connect spring (Item 2) [C] to the pin.

1 2

P–10201

P–10200

–1–8–

963 Bobcat Loader Service Manual

OPERATOR CAB

A

Description

1

The Bobcat loader has an operator cab (ROPS and FOPS) as standard equipment to protect the operator from rollover and falling objects. Check with your dealer if the operator cab has been damaged. The seat belt must be worn for roll over protection.

ROPS/FOPS – Roll Over Protective Structure per SAE J104 and ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level l. Level ll is available.

Level l – Protection from falling bricks, small concrete blocks and hand tools encountered in operations such as highway maintenance, landscaping, and other construction site services.

P–10161

B

Level ll – Protection from falling trees, rocks; for machines involved in site clearing, overhead demolition or forestry.

Never modify operator cab by welding, grinding, drilling holes or adding attachments unless instructed to do so by Melroe Company.

Changes to the cab can cause loss of operator protection from rollover and falling objects, and result in injury or death.

P–10162

W–2069–1285

C

Raising The Operator Cab Stop the loader on a level surface. Lower the lift arms.

If the lift arms must be up while raising the operator cab, install the lift arm support device. (See Page 1–7.)

Loosen the nut (Item 1) [A] (both sides) at the front of the operator cab.

Remove the nut and plate (both sides) [B].

Stand on the safety tread. Lift on the grab handles and slowly raise the cab until the latching mechanism engages and the cab is all the way up [C].

P–10271

–1–9–

963 Bobcat Loader Service Manual

OPERATOR CAB (Cont’d)

A

Lowering The Operator Cab NOTE: Make sure the seat bar is fully raised or lowered when lowering the cab.

Pull down on the bottom of the operator cab until it stops at the latching mechanism [A].

Release the latching mechanism (Inset) [A] and pull the cab all the way down.

P–10274

P–10273

Install the plate and nut (both sides) [B].

B

P–10162

Tighten the nuts to 40–50 ft.–lbs. (54–68 Nm) torque [C] (both sides).

C

P–10161

–1–10–

963 Bobcat Loader Service Manual

OPERATOR CAB (Cont’d)

A

Emergency Exit The front opening on the operator cab and rear window provide exits.

Rear Window: Pull on the tag on the top of the rear window to remove the rubber cord [A].

P–10168

Push the rear window out of the rear of the operator cab.

Exit through the rear window opening of the operator cab.

B

P–10502

Front Door:

C

NOTE: When the Operator Cab Enclosure Kit is installed, the window of the front door can be used as an emergency exit.

Pull the plastic loop at the top of the window in the front door to remove the rubber cord [C].

P–09216

D

Push the window out with your foot [D].

Exit through the front door.

P–09217

–1–11–

963 Bobcat Loader Service Manual

SEAT BAR RESTRAINT SYSTEM

A

Description The seat bar restraint system has a spring assist pivoting seat bar with arm rests and has spring loaded interlocks for the lift and tilt control pedals.

The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat.

The interlocks require the operator to lower the seat bar in order to operate the foot pedals.

When the seat bar is up, the lift and tilt pedals are locked when returned to the NEUTRAL POSITION.

Clean

AVOID INJURY OR DEATH The seat bar system must lock the lift and tilt control pedals in neutral when the seat bar is up. Service the system if pedals do not lock correctly.

W–2105–1285

Inspecting The Seat Bar Sit in the seat and fasten the seat belt. Engage the parking brake. Pull the seat bar all the way down. Start the engine. Press the greeen PRESS TO OPERATE Button.

Operate each foot pedal to check both the lift and tilt functions. Raise the lift arms until the bucket is about 2 feet (600 mm) off the ground.

P–09790

B

Raise the seat bar. Try to move each foot pedal. Pedals must be firmly locked in NEUTRAL POSITION. There must be no motion of the lift arms or tilt (bucket) when the pedals ar pushed.

Clean

Pull the seat bar down, press the green PRESS TO OPERATE Button and lower the lift arms. Operate the lift pedal. While the lift arms are going up, raise the seat bar and the lift arms should stop.

Lower the seat bar, press the green PRESS TO OPERATE Button, lower the lift arms and put the bucket flat on the ground. Stop the engine. raise the seat bar and operate the foot pedals to be sure that the pedals are firmly locked in the neutral position. Unbuckle the seat belt.

Maintaining The Seat Bar

Clean

See the SERVICE SCHEDULE Page 1–3 for the correct service interval.

Clean the debris or dirt from the moving parts [A] & [B].

Inspect the linkage bolts and nuts for tightness. The correct torque is 25–28 ft.–lbs. (34–38 Nm).

If the seat bar system does not function correctly, check for free movement of each linkage part. Check for excessive wear. Adjust the pedal control linkages.

Replace parts that are worn or damaged. Use only genuine Melroe replacement parts.

Revised Mar. 99

N–15877

–1–12–

963 Bobcat Loader Service Manual

AIR CLEANER SERVICE

A

Replacing Filter Elements

2

See the SERVICE SCHEDULE Page 1–3 for the interval to service the air cleaner system.

Stop the engine.

1

Open the rear door. Raise the rear grill.

Check the air intake hose and air cleaner housing for damage.

Check all the connections.

P–10289

Replace the large (outer) filter element when the red ring (Item 1) [A] shows in the condition indicator window.

B

NOTE: Before replacing the filter element, push the button (Item 2) [A] on the condition indicator and start the engine. Run at full RPM. If the red ring does not show, do not replace the filter element.

Remove the dust cover wing nut (Item 1) [B].

1

Remove the dust cover.

P–10291

C

Remove the wing nut at the large filter element and remove the filter element (Item 1) [C].

NOTE: Make sure all sealing surfaces are free of dirt and debris.

Install the new filter element and tighten the wing nut.

Install the dust cover and tighten the wing nut.

1 P–10290

–1–13–

963 Bobcat Loader Service Manual

AIR CLEANER SERVICE (Cont’d)

A

Replacing Filter Element (Cont’d) Inner Filter Element: Replace the inner filter element every third time the outer filter is replaced. or.....

1

Press the button to remove the red ring in the condition indicator after the outer element has been replaced. Start the engine and run at full RPM. If the red ring shows again, replace the inner filter element.

P–10287

Remove the inner filter element wing nut (Item 1) [A].

Remove the inner filter element [B].

B

Install a new filter element and tighten the wing nut.

P–10288

–1–14–

963 Bobcat Loader Service Manual

FUEL SYSTEM

A

Fuel Specifications Use only clean, high quality diesel fuel, Grade No. 2 or Grade No. 1.

1

The following is one suggested blending guideline which should prevent fuel gelling problems: Temp. F° (C°)

No. 2

No.1

+15°(9°) Down to –20° (–29°) Below –20° (29°)

100% 50% 0%

0% 50% 100% P–10202

We recommend an operator contact their fuel supplier for local recommendations.

B

Filling The Fuel Tank

WRONG

Stop and cool the engine before adding fuel.

NO SMOKING! Failure to obey warnings can cause an explosion or fire.

W–2063–0887

Remove the fuel fill cap (Item 1) [A].

B–13456

Use a clean, approved safety container to add the correct fuel. Add fuel only in an area that has free movement of air and no open flames or sparks. NO SMOKING! [B].

Install and tighten the fuel fill cap [A].

–1–15–

963 Bobcat Loader Service Manual

FUEL SYSTEM (Cont’d)

A

Fuel Filters

3

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

1

W–2103–1285

See the SERVICE SCHEDULE Page 1–3 for the service interval when to remove the water from the fuel filters and when to replace the fuel filters.

To drain the water from the fuel filters, loosen the drain (Items 1 & 2) [A] to drain the water from the filter.

After water is removed, tighten the filter drains.

4

Replace both filters at the same service interval.

Clean the outside surfaces of the filter assembly (Items 3 & 4) [A].

2

Loosen the drain (Items 1 & 2) [A] to drain the fuel from the filters.

N–16231

Support the filter and turn the clamp ring (Item 1) [B] & [C] to the left. Remove the clamp ring.

B

Remove the sediment bowl (Item 2) [C] from the pre–filter element and clean the bowl.

Check the two O–ring seals on the sediment bowl.

Replace as needed.

1

Install the sediment bowl on the filter. Hand tighten only.

Clean the filter heads. Push the filter into the filter head.

Hold the filter element and install the clamp ring. Turn the clamp ring to the right to fasten the filer to the filter head.

Remove the air from the fuel system. (See Below Removing Air From the Fuel System.)

N–16232

Removing Air From The Fuel System

C

3

After replacing the fuel filter elements or when the fuel tank has run out of fuel, the air must be remove from the fuel system before starting the engine.

Loosen the vent plug (Item 3) [C] on the filter head.

4

Squeeze the priming bulb (Item 4) [C] until fuel flows from the vent with no air bubbles showing.

1

Tighten the vent plug.

2

Set the engine speed control to 1/2 speed position. Start the engine. The fuel system is a self–venting system.

N–16233

–1–16–

963 Bobcat Loader Service Manual

ENGINE LUBRICATION SYSTEM

A

Checking Engine Oil

2

Check the engine oil level every day before starting the engine for the work shift.

1

Open the rear door. Remove the dipstick (Item 1) [A].

Keep the oil level between the marks on the dipstick [B].

Use a good quality motor oil that meets API Service Classification of CD, or better.

RECOMMENDED SAE VISCOSITY NUMBER (LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)

C° –40

–34

–29

–23

–18

–13

–7

–1

+4

+10

+15

+21

+27

+32

+38

+43 +49

N–16234

SAE 40W or 20W–50 SAE 10W–30

B

SAE 15W–40

Keep Oil Level Between These Marks

SAE 30W

* SAE 5W–30 SAE 20W–20 SAE 10W SYNTHETIC OIL Use recommendation from Synthetic Oil Mfgr.

–40 –30

F°

–20

–10

0

+10

+20

+30

+40

+50

+60

+70

+80

+90

+100 +110 +120

P–10302

TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (DIESEL ENGINES MUST USE API CLASSIFICATION CD, CF4, CG4)

C

* Can be used ONLY when available with appropriate diesel rating.

1

Replacing The Oil And Filter See the SERVICE SCHEDULE Page 1–3 for the service interval for replacing the engine oil and filter.

Run the engine until it is at operating temperature. Stop the engine.

Open the rear door. Remove the drain hose (Item 1) [C] from the storage position. Remove the drain plug from the end of the hose. Drain the oil into a container.

2

Remove the oil filter (Item 2) [C].

N–16235

Clean the filter housing surface. Put clean oil on the new oil filter gasket. Install the new filter and hand tighten.

Install and tighten the drain plug.

Remove the filler cap (Item 2) [A].

Fill the engine crankcase with oil of the correct grade and viscosity. (See Oil Chart above.) Capacity is 9 qts. (8,5 L.) Start the engine and let it run for several minutes.

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

Stop the engine.

Check for leaks at the oil filter and check the oil level.

W–2103–1285

Add oil as needed if it is not at the top mark on the dipstick

Revised June 98

–1–17–

963 Bobcat Loader Service Manual

ENGINE COOLING SYSTEM

A

Checking The Coolant Level Check the cooling system every day to prevent over–heating, loss of performance or engine damage.

Open the rear door.

Check the coolant level in the coolant recovery tank (Item 1) [A].

The coolant recovery tank must be 1/3 full.

NOTE: The loader is factory filled with propylene glycol coolant. DO NOT mix propylene glycol with ethylene glycol.

Add premixed coolant; 47% water and 53% propylene glycol to the recovery tank if the coolant level is low.

1

One gallon and one pint of propylene glycol mixed with one gallon of water is the correct mixture of coolant to provide a –34°F (–37°C) freeze protection.

Use a refractometeror to check the condition of propylene glycol in your cooling system.

Cleaning The Cooling System Raise the rear grill.

Use air pressure or water pressure to clean the top of the oil cooler (Item 1) [B].

Raise the oil cooler and clean the top of the radiator (Item 2) [B].

N–16239

Check cooling system for leaks.

B 1

AVOID ENGINE DAMAGE Always use the correct ratio of water to antifreeze.

Too much antifreeze reduces cooling system efficiency and may cause serious premature engine damage.

2 P–10295

Too little antifreeze reduces the additives which protect the internal engine components; reduces the boiling point and freeze protection of the system.

Always add a premixed solution. Adding full strength concentrated coolant can cause serious premature engine damage.

I–2124–0497

–1–18–

963 Bobcat Loader Service Manual

ENGINE COOLING SYSTEM (Cont’d)

A

Replacing The Coolant

1

Do not remove radiator cap when the engine is hot. You can be seriously burned.

W–2070–1285

P–10294

Open the rear door. Open the rear grill.

Remove the radiator cap (Item 1) [A].

B

Connect a hose to the engine block drain valve (Item 1) [B]. Open the drain valve and drain the coolant into a container. Close the drain valve after the coolant is removed.

One gallon and one pint (4,3 L.) of propylene glycol mixed with one gallon (3,8 L.) of water is the correct mixture of coolant to provide a –34° F. (–37° C.) freeze protection.

1

Mix the coolant in a separate container. (See SPECIFICATIONS Page 9–1 for correct capacity.)

Fill the radiator with coolant until full. Open the vent plug (Item 1) [C] to remove the air from the engine block.

Tighten the vent plug. Continue to fill the radiator until full.

N–16236

Install the radiator cap.

C

Add coolant to the coolant recovery tank until it is at the FULL COLD mark on the tank.

Run the engine until it is at operating temperature. Stop the engine.

1

Check the coolant level in the recovery tank when cool.

Add coolant to the recovery tank as needed.

N–16162

AVOID ENGINE DAMAGE Always use the correct ratio of water to antifreeze.

Too much antifreeze reduces cooling system efficiency and may cause serious premature engine damage.

Too little antifreeze reduces the additives which protect the internal engine components; reduces the boiling point and freeze protection of the system.

Always add a premixed solution. Adding full strength concentrated coolant can cause serious premature engine damage.

I–2124–0497

–1–19–

963 Bobcat Loader Service Manual

ALTERNATOR BELT

A

Adjusting The Alternator Belt

2

Stop the engine.

Open the rear door.

Loosen the alternator mounting bolt (Item 1) [A].

1

Loosen the adjustment bolt (Item 2) [A].

N–16237

B

Move the alternator until the belt has 5/16 inch (8,0 mm) movement at the middle of the belt span (Item 1) [B] with 15 lbs. (66 N) of force.

Tighten the adjustment bolt and mounting bolt.

Close the rear door.

1

N–16238

–1–20–

963 Bobcat Loader Service Manual

HYDRAULIC/HYDROSTATIC SYSTEM

A

Checking And Adding Fluid Use only recommended fluid in the hydraulic system.

(See SPECIFICATIONS Section Page 9–1 for the correct fluid.)

1

2

Put the Bobcat loader on a level surface. Lower the lift arms and tilt the Bob–Tach fully back.

Stop the engine.

Remove the dipstick (Item 1) [A].

P–10203

B

The fluid level must be between the marks on the dipstick [B].

If fluid is needed, remove the fill cap (Item 2) [A].

Add the fluid as needed to bring the level to the top mark on the dipstick [B]

P–10303

Hydraulic/Hydrostatic Filter Replacement

C

See the SERVICE SCHEDULE Page 1–3 for the correct service interval.

The filter element is under the operator cab on the right hand side of the loader.

Raise the operator cab. (See Page 1–9.)

Remove the filter element (Item 1) [C].

Clean the surface of the filter housing where the element seal contacts the housing. Put clean oil on the rubber seal of the filter element.

1

Install and hand tighten the new filter element.

N–15486

–1–21–

963 Bobcat Loader Service Manual

HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)

A

Replacing The Hydraulic Fluid See the SERVICE SCHEDULE Page 1–3 for the service interval.

1

The fluid must also be replaced if it becomes contaminated or after major repairs.

Remove the reservoir fill cap (Item 1) [A].

Raise the operator cab.

P–10203

Remove the drain plug (Item 1) [B] at the bottom of the reservoir. Let all the fluid flow into a container.

B

Install and tighten the drain plug when the reservoir is empty.

1

P–10398

C

Remove the screen (Item 1) [C]. Wash the screen in clean solvent and install it in the fill pipe.

Remove the hydraulic/hydrostatic filter element. (See Page 1–21.) Install new filter element.

1

Add fluid to the reservoir until the fluid is at the top mark on the dipstick. (See the SPECIFICATIONS Section Page 9–1 for type of fluid and capacity.) DO NOT fill above the top mark on the dipstick.

Lower the operator cab. Start the engine and operate the loader through the hydraulic and hydrostatic functions.

Stop the engine. Check the fluid level again and add as needed.

P–10426

Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death.

W–2103–1285

–1–22–

963 Bobcat Loader Service Manual

SPARK ARRESTOR MUFFLER

A

Cleaning Procedure See SERVICE SCHEDULE Page 1–3 for service interval for cleaning the spark arrestor muffler.

Do not operate the loader with a defective exhaust system.

1

N–16240

This loader is factory equipped with a U.S.D.A. Forestry Service approved spark arrestor muffler. It is necessary to do maintenance on this spark arrestor muffler to keep it in working condition. The spark arrestor muffler must be serviced by dumping the spark chamber every 100 hours of operation.

If this machine is operated on flammable forest, brush or grass covered land, it must be equipped with a spark arrestor attached to the exhaust system and maintained in working order. Failure to do so will be in violation of California State Law, Section 4442 PRC.

When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust outside.

Exhaust fumes contain odorless, invisible gases which can kill without warning.

Make reference to local laws and regulations for spark arrestor requirements.

W–2050–1285

Stop engine and allow the muffler to cool before cleaning the spark chamber. Wear safety glasses or goggles. Failure to obey can cause serious injury.

I–2022–0595

Stop the engine. Open the rear door.

W–2011–1285

Never use machine in atmosphere with explosive dust or gases or where exhaust can contact flammable material. Failure to obey warnings can cause injury or death.

Remove the plug (Item 1) [A] from the bottom of the muffler .

W–2068–1285

When the engine is running during service, the steering levers must be in neutral and the parking brake engaged. Failure to do so can cause injury or death.

W–2006–0284

Start the engine and run for about 10 seconds while a second person, wearing safety glasses, holds a piece of wood over the outlet of the muffler.

This will force contaminants out through the clean out hole.

Stop the engine. Install and tighten the plug. Close the rear door.

–1–23–

963 Bobcat Loader Service Manual

TIRE MAINTENANCE

A

Wheel Nuts See the SERVICE SCHEDULE Page 1–3 for the service interval to check the wheel nuts. The correct torque is 320–350 ft.–lbs. (434–475 Nm) torque [A].

Tire Rotation Check the tires regularly for wear, damage and pressure.

(See SPECIFICATIONS Page 9–1 for the correct tire pressure.)

Rear tires usually wear faster than front tires. To keep tire wear even, move the front tires to the rear and rear tires to the front [B].

N–16244

B

It is important to keep the same size tires on each side of the loader. If different sizes are used, each tire will be turning at a different rate and cause excessive wear. The tread bars of all the tires must face the same direction.

Recommended tire pressure must be maintained to avoid excessive tire wear and loss of stability and handling capability. Check for the correct pressure before operating the loader.

Tire Mounting Tires are to be repaired only by an authorized person using the correct procedures and safety equipment.

Tires and rims must always be checked for correct size before mounting. Check rim and tire bead for damage.

The rim flange must be cleaned and free of rust. The tire bead and rim flange must be lubricated with a rubber lubricant before mounting the tire.

E–01655

Avoid excessive pressure which can rupture the tire and cause serious injury or death.

During inflation of the tire, check the tire pressure frequently to avoid over inflation.

Do not inflate tires above specified pressure.

Failure to use correct tire mounting procedure can cause an explosion which can result in injury or death.

W–2078–1285

Inflate tires to the MAXIMUM pressure shown on the sidewall of the tire. DO NOT mix brands of tires used on the same loader.

I–2057–0794

–1–24–

963 Bobcat Loader Service Manual

FINAL DRIVE TRANSMISSION (CHAINCASE)

A

963ServiceManual#6724545–PreventiveMaintenanceSectionPart1of2

Checking And Adding Oil The chaincase contains the final drive sprockets and chains and uses the same type of oil as the Hydraulic/Hydrostatic System. (See SPECIFICATIONS Section Page 9–1.)

To check the chaincase oil level, use the following procedure:

1

Drive the loader on a level surface. Stop the engine.

Remove the plug (Item 1) [A] from the front of the chaincase housing N–16243

If oil can be reached with the tip of the your finger through the hole the oil level is correct.

B

If the level is low, add oil through the check plug hole until the oil flows from the hole. Install and tighten the plug.

1

FAN GEARBOX Checking And Maintaining See the SERVICE SCHEDULE Page 1–3 for the correct service interval.

Raise the operator cab. (See Page 1–9.)

Disconnect the breather hose from the fitting (Item 1) [B].

Remove the fitting (Item 1) [B] to check the lubricant level.

N–15731

If the level is low, add SAE 90W gear lube through the check plug hole until the lubricant just below the fitting hole.

When adding the gearbox lube, make sure the level does not go above the top of the shaft in the gearbox.

Install and tighten the fitting. Connect the breather hose.

–1–25–

963 Bobcat Loader Service Manual

LUBRICATING THE LOADER

A

Procedure Lubricate the loader as specified in the SERVICE SCHEDULE Page 1–3 for the best performance of the loader.

1

Always use a good quality lithium based multi–purpose grease when you lubricate the loader. Apply the lubricant until extra grease shows.

Lubricate the following locations on the loader: 1. Rod End Lift Cylinder (Both Sides) [A].

P–10235

2. Base End Lift Cylinder (Both Sides) [B].

B

2

P–10231

3. Lift Arm Pivot Pin (Both Sides) [C].

C

3

P–10243

4. Base End Tilt Cylinder (Both Sides) [D].

D 4

P–10204

–1–26–

963 Bobcat Loader Service Manual

LUBRICATING THE LOADER (Cont’d)

A

Procedure (Cont’d) 5. Rod End Tilt Cylinder (Both sides) [A].

6. Bob–Tach Wedge (Both Sides) [A]

5

6

P–10241

B

7. Bob–Tach Pivot Pin (Both Sides) [B].

7 P–10234

C

Every 250 Hours: Add grease to the fittings (Item 1) [C].

1

N–15868

–1–27–

963 Bobcat Loader Service Manual

BOB–TACH

A

963Operation&MaintenanceManual(S/N562211620&Above)#6900792–PreventiveMaintenanceSection

Inspection And Maintenance Move the Bob–Tach levers to engage the wedges [A].

The levers and wedges must move freely.

1 N–17048

The wedges must extend through the holes in the attachment mounting frame (Item 1) [A].

N–17050

Bob–Tach wedges must extend through the holes in attachment. Levers must be fully down and locked. Failure to secure wedges can allow attachment to come off and cause injury or death.

B

W–2102–0588

The spring loaded wedge (Item 1) [A] must contact the lower edge of the hole in the attachment (Item 1) [B] and [C].

If the wedge does not contact the lower edge of the hole [B] and [C], the attachment will be loose and can come off the Bob–Tach.

1

Inspect the mounting frame on the attachment and the Bob–Tach, linkages and wedges for excessive wear or damage. Replace any parts that are damaged, bent, or missing. Keep all fasteners tight.

N–17046

C

Look for cracked welds.

Bob–Tach Wedge

Lubricate the wedges

Wedge Must Contact Lower Edge Of Hole In The Attachment B–15177

Revised Mar. 99

–1–28–

963 Bobcat Loader Service Manual

REMOTE START SWITCH

A

Procedure The tool listed will be needed to do the following procedure: MEL1429 – Remote Start Switch

1 Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death.

W–2017–0286

1

The remote start switch is required when the operator cab is in the raised position for service and the service technician needs to start the engine. (Example: Checking the hydraulic/hydrostatic system).

Lift and block the loader. (See Page 1–4.)

Raise the lift arms and install an approved lift arm support device. (See Page 1–7.)

N–15866

B Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death.

W–2059–0598

Raise the operator cab. (See Page 1–9) The operator cab wire harness connectors must be separated from the engine wiring harness connector under the cab, connect the remote start switch connectors (Item 1) [A] to the wire harness connectors.

Start the engine using the remote start switch [B].

N–15867

Revised Mar. 99

–1–29–

963 Bobcat Loader Service Manual

REMOTE START SWITCH (Cont’d)

A

Procedure (Cont’d)

1

Put the traction lock override switch (Item 1) [A] in the ON position so the traction function is locked. The wheels are not able to turn.

Turn the key to the right and start the engine.

P–04713

B

Move the traction lock override switch (Item 1) [B] to the OFF position so the traction function is unlocked. The wheels are now able to turn.

1

The auxiliary mode switch (Item 2) [B] is used to turn the front auxiliary quick couplers ON and OFF during relief pressure and flow tests.

2 P–04714

Revised Mar. 99

–1–30–

963 Bobcat Loader Service Manual

HYDRAULIC SYSTEM Page Number BICS™ VALVE BICS™ Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .

BICS™ Valve Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift Arm By–Pass Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lock Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–31 2–30 2–29 2–27 2–28

HYDRAULIC SYSTEM

BUCKET POSITION VALVE Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–53 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–52 CONTROL PEDALS Pedal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–65 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–65 CONTROL PEDALS MOUNTING PANEL Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–68 FRONT SIDE PANEL Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–67 HYDRAULIC CONTROL VALVE Anti–Cavitation Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Anti–Cavitation Valve/Port Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Electric Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

H–Port Auxiliary Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift Spool And Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Port Relief (Tilt Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Port Relief Valve (Lift Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rubber Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spool Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tilt Spool And Centering Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–39 2–38 2–48 2–47 2–35 2–49 2–34 2–49 2–42 2–35 2–36 2–40 2–37 2–32 2–41 2–50 2–46

HYDRAULIC CYLINDER Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lift Cylinder Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tilt Cylinder Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–16 2–14 2–12 2–13

HYDRAULIC PUMP Checking The Output Of The Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–55 2–58 2–61 2–56

Continued On Next Page –2–1–

963 Bobcat Loader Service Manual

HYDRAULIC SYSTEM (Cont’d) Page Number HYDRAULIC FLUID RESERVOIR Draining The Hydraulic Fluid Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . 2–63 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–63 HYDRAULIC SYSTEM INFORMATION Tighten Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–4 HYDRAULIC/HYDROSTATIC FILTER Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–62 LIFT ARM BY–PASS CONTROL VALVE Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–51 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–51 LIFT CYLINDER Checking The Lift Cylinder(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–5 MAIN RELIEF VALVE Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Main Relief Valve At Front Auxiliary Hydraulics . . . . . . . . . . .

Checking Main Relief Valve Control Valve . . . . . . . . . . . . . . . . . . . . . . . .

Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2–25 2–21 2–23 2–25

PEDAL INTERLOCK LINKAGE Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–67 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–66 TILT CYLINDER Tilt Cylinder Base End Pivot Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–11 Checking The Tilt Cylinder(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–8 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–9 TILT JUNCTION BLOCK Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–19 TROUBLESHOOTING Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–3

Revised June 98

–2–2–

963 Bobcat Loader Service Manual

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