DOWNLOAD PDF Bobcat 963 Operation & Maintenance Manual

Operation & Maintenance Manual

EQUIPPED WITH BOBCAT INTERLOCK CONTROL SYSTEM (BICSTM)

6724543 (10–97) Revised (7–98)

Printed in U.S.A.

© Melroe Company 1998

OPERATOR SAFETY WARNINGS CORRECT Operator must have instructions before running the machine.

Untrained operators can cause injury or death.

W–2001–1285 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

B–10731

Never use the loader without instructions. See machine signs (decals), Operation & Maintenance Manual and Handbook.

WRONG

B–7403

B–6582

B–13418

Always use the seat bar and fasten seat belt snugly.

Always keep feet on the foot pedals or footrest swhen operating loader.

Never use loader without operator cab with ROPS and FOPS approval.

Never use loader as man lift or elevating device for personnel.

WRONG

WRONG

WRONG

B–6578

B–6585

B–6595

Keep bystanders away from work area.

Always carry bucket or attachments as low as possible.

Do not travel or turn with lift arms up.

Load, unload and turn on flat level ground.

WRONG

WRONG

WRONG

B–6587

B–6594

B–6591

Never exceed rated operating capacity.

Never leave loader with engine running or with lift arms up.

To park, engage parking brake and put attachment flat on the ground.

Do not use loader in atmosphere with explosive dust or gas or where exhaust can contact flammable material.

Never carry riders.

Never modify equipment.

Use only attachments approved

by Melroe Company for this model loader.

SAFETY EQUIPMENT The Bobcat loader must be equipped with safety items necessary for each job. Ask your dealer for information on the safe use of attachments and accessories.

1. SEAT BELT: Check belt fasteners and check for damaged webbing or buckle.

2. SEAT BAR: When up, it must lock the loader controls.

3. OPERATOR CAB (ROPS and FOPS): It must be on the loader with all fasteners tight.

4. HANDBOOK: Must be in the cab.

5. SAFETY SIGNS (DECALS): Replace if damaged.

6. SAFETY TREADS: Replace if damaged.

7. GRAB HANDLES: Replace if damaged.

8. LIFT ARM SUPPORT DEVICE: Replace if damaged.

9. PARKING BRAKE 10. BOBCAT INTERLOCK CONTROL SYSTEM (BICSTM) OSW03–0698

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540, 543 Loader Service Manual

CONTENTS FOREWORD FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 SYSTEMS ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 MACHINE SIGN TRANSLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

SAFETY

OPERATING INSTRUCTIONS

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

REFERENCE INFORMATION Write the correct information for YOUR Bobcat loader in the spaces below.

Always use these numbers when referring to your Bobcat loader.

SYSTEMS ANALYSIS

Loader Serial Number . . . . . . . .

Engine Serial Number . . . . . . . .

MACHINE SIGN TRANSLATIONS

NOTES:

SPECIFICATIONS

YOUR LOADER DEALER: ADDRESS: PHONE: Melroe Company P.O. Box 128 Gwinner, ND 58040–0128 Melroe Europe J. Huysmanslaan 59 B–1651 LOT BELGIUM

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963 Bobcat Loader Operation & Maintenance Manual

Melroe Company is ISO 9001 certified ISO 9001 is a set of international standards that control the processes and procedures which we use to design, develop, manufacture, distribute, and service Melroe Company products.

British Standards Institute (BSI) is the Certified Registrar Melroe chose to assess the Company’s compliance with the ISO 9001 set of standards. The BSI registration certifies that the two Melroe manufacturing plants and the Melroe corporate offices (Gwinner, Bismarck & Fargo) in North Dakota are in compliance with ISO 9001. Only certified assessors, like BSI, can grant registrations. Since registration requires this third–party auditing, it is irrefutable evidence of conformance.

Continued certification is subject to periodic audits.

ISO 9001 means that as a company we say what we do and do what we say. In other words, we have established procedures and policies, and we provide evidence that the procedures and policies are followed.

What does ISO 9001 mean to Bobcat Customers? It means that Melroe Company produces your Bobcat loader, Excavator or Spra–Coupe, and attachments with strict attention to details, using the latest technology and proven techniques.

REGULAR MAINTENANCE ITEMS 6511766

ENGINE OIL FILTER (6 Pack)

6671649

FUEL FILTER, PRIMARY

6670996

FUEL FILTER, SECONDARY

6672453

AIR CLEANER, OUTER

6671969

AIR CLEANER, INNER

6668819

HYDRAULIC/HYDROSTATIC FILTER

6665427

BATTERY

6724094

PROPYLENE GLYCOL ANTI–FREEZE, Premixed – [–34°F (–37°C)]

6724354

PROPYLENE GLYCOL ANTI–FREEZE, Concentrate

6563328

BLACK GOLD Hydraulic/Hydrostatic Fluid – 5 Gallons

6657299

MOTOR OIL 15W40 CE/SG – 1 Qt.

6657301

MOTOR OIL 10W30 CE/SG – 1 Qt.

6657303

MOTOR OIL 30 CE/SG – 1 Qt.

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963 Bobcat Loader Operation & Maintenance Manual

FOREWORD FOREWORD This Operation & Maintenance Manual was written to give the owner/operator instructions on the safe operation and maintenance of the Bobcat loader. READ AND UNDERSTAND THIS OPERATION & MAINTENANCE MANUAL BEFORE OPERATING YOUR LOADER. If you have any questions, see your Bobcat loader dealer.

SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v BOBCAT LOADER IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi OPTIONS AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

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963 Bobcat Loader Operation & Maintenance 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].

C

DELIVERY REPORT 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].

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963 Bobcat Loader Operation & Maintenance Manual

963 BOBCAT LOADER IDENTIFICATION

FRONT LIGHTS OPERATOR SEAT GRAB HANDLES SAFETY TREAD

STEERING LEVERS TILT CYLINDERS

BUCKET AUXILIARY HYDRAULIC QUICK COUPLERS OPERATOR CAB (ROPS & FOPS) SEAT BAR

STEPS

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).

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963 Bobcat Loader Operation & Maintenance Manual

OPTIONS AND ACCESSORIES All 963 Bobcat loaders are equipped with the following standard items: Bob–Tach Spark Arrestor Exhaust System Lift Arm Support Device Operator Cab (with ROPS & FOPS Approval) Bobcat Interlock Control System (BICS™) Seat Belt Seat Bar Parking Brake Gauges/Warning Lights Two–Speed Transmission Top and Rear Windows Hydraulic Bucket Positioning Front Auxiliary Hydraulics Operating Lights Below is a list of some equipment available as a Factory Installed Option or as a Field Installed Accessory from your Bobcat Loader dealer. See your Bobcat dealer for other available accessories and attachments.

Hydraulics

Tires 8.00–19.5, 8 PR . . . . . . . . . . . . . . . . . . . . . .

14.00–17.5, 10 PR Flotation . . . . . . . . . . . .

38 x 20 x 16.1, 8 PR . . . . . . . . . . . . . . . . . .

9 x 16 Solid . . . . . . . . . . . . . . . . . . . . . . . . . .

Std. Opt. Opt. Opt.

Rear Auxiliary Hydraulics . . . . . . . . . . . . . . Opt. & FA Secondary Auxiliary Hydraulics . . . . . . . . .

FA Hydraulic Bucket Positioning (Includes On/Off Selection) . . . . . . . . . . Opt. & FA

Operator Cab Other Advanced Hand Controls . . . . . . . . . . . . . . . . . Opt. Suspension Seat . . . . . . . . . . . . . . . . . . . . . Opt. & FA Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FA Heated Enclosed Cab . . . . . . . . . . . . . . . . . Opt. & FA Special Applications Kit* . . . . . . . . . . . . . . .

FA Cab Enclosure . . . . . . . . . . . . . . . . . . . . . . .

FA Fresh Air Heater W/Plumbing . . . . . . . . . .

FA Large Operator Seat Bar Kit . . . . . . . . . . . .

FA Side Windows Kit . . . . . . . . . . . . . . . . . . . . .

FA 3” Wide Seat Belt Kit . . . . . . . . . . . . . . . . . .

FA

Engine Heater . . . . . . . . . . . . . . . . . . . . . . . Opt. & FA Attachment Control Kit . . . . . . . . . . . . . . . .

FA Two Point or Four Point Lift . . . . . . . . . . . .

FA Heavy Duty Start Kit . . . . . . . . . . . . . . . . . . Opt. & FA Backup Alarm . . . . . . . . . . . . . . . . . . . . . . . .

FA Catalytic Purifier Muffler . . . . . . . . . . . . . . .

FA

Instrumentation Bobcat Operation Sensing System (BOSS®) . . . . . . . . . . . . . . . . . .

Keyless Start System . . . . . . . . . . . . . . . . .

Opt. FA

Std. = Standard Equipment Opt. = Factory Installed Option FA = Field Accessory * Includes 1/2 inch Lexan Front Door; 1/4 inch Lexan Top and Rear windows.

Specifications subject to change without notice

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SAFETY SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi, xii FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii MACHINE SIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv, xv

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963 Bobcat Loader Operation & Maintenance Manual

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963 Bobcat Loader Operation & Maintenance Manual

SAFETY INSTRUCTIONS SAFETY IS THE OPERATOR’S RESPONSIBILITY The Skid Steer Loader is a highly maneuverable and compact machine. In operation, it is rugged and useful under a wide variety of conditions. This presents an operator with hazards associated with off highway, rough terrain applications. The loader has an internal combustion engine with resultant heat and exhaust. All exhaust gases can kill or cause illness so the loader must be used with adequate ventilation. The loader has a spark arrestor muffler which is required for operation in certain areas.

The dealer explains the capabilities and restrictions of the loader and attachments for each application. The dealer demonstrates the safe operation of the loader according to Melroe’s instructional materials; which are also available to operators. The dealer can also identify unsafe modifications or use of unapproved attachments. The attachments and buckets are designed for rated capacity and secure fastening to the loader. The user must check with the dealer, or Melroe Company literature, to determine safe loads of materials of specified densities for his loader–attachment combination.

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 and 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 can be stored in a container provided inside the cab. Replacement Operation and 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 and 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 Bobcat dealer. This course provides information for safe and efficient operation of the Bobcat loader. The course is available in English and Spanish versions.

• The Bobcat Skid–Steer Loader Safety Video is available from your Bobcat Dealer.

The dealer and owner/operator review the recommended uses of the loader and attachments when the loader is delivered.

If the owner/operator will be using the loader for a different application(s) he must ask the dealer for recommendations on the new use.

Call Before You Dig 1–888–258–0808 When you call, you will be directed to a location in your state/city for information about burried lines (telephone, cable TV, water, sewer, gas,etc.).

SI07–0398

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963 Bobcat Loader Operation & Maintenance Manual

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

Operator must have instructions before running the machine.

Untrained operators can cause injury or death.

W–2001–1285 B–10731

The Bobcat loader must be in good operating condition before use.

Check all of the items on the Service Schedule Decal or as shown in this Operation & Maintenance Manual under Daily Inspection.

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

SAFE OPERATION NEEDS A QUALIFIED OPERATOR* A QUALIFIED OPERATOR MUST DO THE FOLLOWING:

• UNDERSTAND THE WRITTEN INSTRUCTIONS, RULES AND REGULATIONS • The written instructions from Melroe Company include the delivery report, Operation & Maintenance Manual and plastic handbook, EMI Safety Manual and machine signs (decals).

• Check the rules and regulations at your location. The rules may include an employer’s work safety requirements.

Regulations may apply to local driving requirements or use of Slow Moving Vehicle emblem. Regulations may identify a hazard such as a utility line.

• HAVE TRAINING WITH ACTUAL OPERATION • Operator training must consist of a demostration and verbal instruction. This training is given by your dealer before the loader is delivered.

• The new operator must start in an area without bystanders and use all the controls until he can operate the loader safely under all conditions of the work area. Always fasten seat belt and lower seat bar before operating.

• KNOW THE WORK CONDITIONS • For each material to be handled, the operator must know how to avoid exceeding the rated operating capacity of the loader. For example, in handling certain loose material with a given bucket, he must know whether he can safely take a full load, or only part of a bucket load.

• The operator must know any prohibited uses or work areas, for example, he needs to know about excessive slopes.

• Wear tight fitting clothing. Always wear safety glasses when maintaining or servicing loader. Safety glasses, hearing

protection or loader special applications kit are required for some work. See your dealer about Melroe Safety equipment.

* For an operator be qualified, he must not use drugs or alcoholic drinks which impair his alertness or coordination while working. An operator who is taking prescription drugs must get medical advice to determine if he can safely operate a machine.

SI02–0498

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963 Bobcat Loader Operation & Maintenance 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

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963 Bobcat Loader Operation & Maintenance Manual

MACHINE SIGNS (DECALS) Follow the instructions on all the machine signs (decals) that are on the loader. Replace any damaged machine signs (decals) and be sure they are in the correct locations. Machine signs (decals) are available from your Bobcat dealer.

6557565 6579510 Foot Pedal 6715941 Advanced Hand Control Only kg.

lbs.

6804790

6708021 Foot Pedal 6708158 Hand Control

6711840

6578368

6707255

6703723 Foot Pedal 6715940 Advanced Hand Control Only 6717043

Advanced Hand Control Only

6710358

6561383

6702301

6702302

*6579528

* Decal located behind lift arm crossmember. xiv

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963 Bobcat Loader Operation & Maintenance Manual

MACHINE SIGNS (DECALS) (Cont’d)

6700388

6565990

6706558

6595014

6708929

6595547

6579511

6804345

Located inside the engine compartment B–14317

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963 Bobcat Loader Operation & Maintenance Manual

OPERATING INSTRUCTIONS ATTACHMENTS & BUCKETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Installing The Bucket Or Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Removing The Bucket Or Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . . . . . . . . . . . . 6 Lift Arm By–Pass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Seat Sensor Override (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Traction Lock Override . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Daily Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

OPERATING INSTRUCTIONS

ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 GETTING READY FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 HIGH SPEED RANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Advanced Hand Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Lift Arm Float Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Lift Arm Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Tilt Operation (Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Attachment Functions Control (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . 16 Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Auxiliary Hydraulics Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Continuous Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Disengage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Momentary Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Bucket Position Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12, 13 Foot Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Lift Arm Float Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Lift Arm Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Tilt Operation (Bucket) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Front Auxiliary Hydraulics Continuous Operation . . . . . . . . . . . . . . . . . . . . . 15 Front Auxiliary Hydraulics Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Indicator Lights (Advanced Hand Control) . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Rear Auxiliary Hydraulics Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Relieving Hydraulic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Quick Couplers (Flush Face) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 BOSS™ Option Display Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Side Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 With BOSS™ (Front Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Without BOSS™ (Front Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 LIFTING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Continued On Next Page

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963 Bobcat Loader Operation & Maintenance Manual

OPERATING INSTRUCTIONS OPERATING PROCEDURE (ADVANCED HAND CONTROLS) . . . . . . . . . 31 Backfilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Emptying The Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Digging Into The Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Filling The Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Leveling The Ground (Using Lift Arms in Float Position) . . . . . . . . . . . . . . . 32 OPERATING PROCEDURE (FOOT PEDALS) . . . . . . . . . . . . . . . . . . . . . . . . 27 Backfilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Emptying The Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Digging Into The Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Filling The Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Leveling The Ground (Using Lift Arms in Float Position) . . . . . . . . . . . . . . . 29 PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 PARKING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30, 33 SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROL) . . . . . 11 SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS) . . . . . . . . . . . . . . . . . . . 10 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Normal Starting (With BOSS™) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Normal Starting (Without BOSS™) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Cold Start System (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Cold Temperature Starting (With BOSS™) . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Cold Temperature Starting (Without BOSS™) . . . . . . . . . . . . . . . . . . . . . . . . 21 Warming The Hydraulic/Hydrostatic System . . . . . . . . . . . . . . . . . . . . . 21, 23 STEERING LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Forward Travel, Reverse Travel, Normal Turning, Fast Turning . . . . . . . . . . 9 STOPPING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9, 30 STOPPING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21, 23 TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 TRANSPORTING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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963 Bobcat Loader Operation & Maintenance Manual

INSTRUMENT PANEL

A

Without BOSS® (Front Panel) [A]

11

The following items are located on the instrument panel [A]:

6

1. TRACTION LOCK OVERRIDE BUTTON – (Functions Only When The Seat Bar Is Raised) Allows you to use the steering levers to move the loader forward or backward when using the backhoe attachment or for loader service. (See Page 7.)

7

9 5 4

8

10

3 12

2. SEAT SENSOR OVERRIDE BUTTON (If Equipped) (Functions Only When The Seat Bar Is Down) Allows operator, when seated with the seat bar lowered, to use lift, tilt, and traction functions if the seat sensor cannot be activated. (See Page 7.)

1

2

13 P–10488

P–10466

3. KEY SWITCH – For starting & stoppng the engine.

4. TRANSMISSION WARNING LIGHT – Light is ON when transmission charge pressure is low, hydraulic filter needs replacement or fluid temperature is high. Stop the engine if the light comes ON. 5. ENGINE WARNING LIGHT – Light is ON when engine oil pressure is low. Stop the engine if the light comes ON. 6. LIGHT SWITCH – Controls the work and travel lights.

7. TWO–SPEED INDICATOR – Indicator light is ON when Two–Speed switch on the right hand steering lever is ON. 8. BUCKET LEVEL SWITCH – Controls the ON/OFF function of the bucket position valve.

9. HOURMETER – Records the total operating hours of the loader.

10. FUEL GAUGE – Shows the amount of fuel in the fuel tank.

11. VOLTMETER – Shows the condition of the battery and the rate of charge.

12. ENGINE TEMPERATURE GAUGE – Shows the engine coolant temperature.

13. AUXILIARY HYDRAULICS SWITCH – For engaging the auxiliary hydraulics (front or rear).

–3–

963 Bobcat Loader Operation & Maintenance Manual

INSTRUMENT PANEL

A

With BOSS® (Front Panel) [A] 1. TRACTION LOCK OVERRIDE BUTTON – (Functions Only When The Seat Bar Is Raised) Allows you to use the steering levers to move the loader when using the backhoe attachment or for loader service. (See Page 7.)

2. SEAT SENSOR OVERRIDE BUTTON (If Equipped) (Functions Only When The Seat Bar Is Down) Allows operator, when seated with the seat bar lowered, to use lift, tilt, and traction functions if the seat sensor cannot be activated. (See Page 7.)

3. KEY SWITCH – For starting and stopping the engine.

4. BOSS DIAGNOSTIC PORT – Connector for diagnostic tool to make service checks of the system operation unit and other components.

5. LIGHT SWITCH (Opt./FA) – Controls the available work and travel lights.

6. TWO–SPEED INDICATOR – Indicator light is ON when Two–Speed switch on the right hand steering lever is ON. 7. BUCKET LEVEL SWITCH (Opt./FA) – Controls the ON/OFF function of the available bucket Position Valve.

8. BOSS DISPLAY PANEL – Display panel for BOSS system and functions (See Page 5.)

9. AUXILIARY HYDRAULIC SWITCH (Opt./FA) – For engaging the available Auxiliary Hydraulics (front and rear).

With BOSS

5 6 7 4 8

3 1

9

2 N–16962

B

P–10489

Side Console 1

2

3 P–10742

Side Console• [B] 1. REAR WIPER/WASHER (FA) – Controls operation of the available rear window wiper and washer.

2. HAZARD SWITCH / HAZARD INDICATORS (Opt./FA) – Controls the available hazard lights.

(Hazard Lights is a separate available accessory.)

Both panel indicators blink for hazard condition when the hazard switch is ON. A red light indicates fuse out for taillights, headlights, worklights, etc.

3. BEACON OR STROBE SWITCH (Opt./FA) – Controls the available flashing beacon or strobe light.

• Available only with Deluxe Cab or with Cab Enclosure

Kit. Opt. – Factory Installed Option FA – Field Installed Accessory – See your Bobcat loader dealer about available Field Accessories.

–4–

963 Bobcat Loader Operation & Maintenance Manual

INSTRUMENT PANEL

A

BOSS Option Display Panel The following items are located on the BOSS Option Display Panel [A].

1. FUEL LEVEL – Shows the amount of fuel in the tank. Flashing pump symbol indicates low fuel level.

H2O symbol is non–functional. (See WARNING SYMBOL)

1

2. BATTERY VOLTAGE – Shows the condition of the battery and charge rate. It will also indicate a WARNING for high or low voltage (See WARNING SYMBOL).

3. ENGINE OIL PRESSURE – Shows engine oil pressure. Flashing symbol indicates low oil pressure (See WARNING and SHUTDOWN SYMBOL).

4. ENGINE COOLANT TEMPERATURE/LEVEL – Shows engine coolant temperature (See WARNING and SHUTDOWN SYMBOL).

5. SHUTDOWN SYMBOL – This symbol is associated with any SHUTDOWN condition. When this symbol comes ON the SHUTDOWN will occur in 30 seconds. During SHUTDOWN the buzzer will sound continuously and the symbol will flash until the key switch is turned OFF.

5

2

4

3

7

6

8

9

12

13

10

11

NOTE: The engine can be restarted for 30–second periods to move the loader after a SHUTDOWN condition.

6. WARNING SYMBOL – The symbol will be ON when any WARNING or SHUTDOWN is activated.

The warning symbol is also used to indicate a WARNING if there is no related symbol on the display. During a WARNING, the buzzer will beep three times and the symbol will be ON continuously.

7. HOURMETER – Records the total operating hours of the loader. The five character code will display the operating hours to the nearest tenth. When WARNING or SHUTDOWN occurs, an alpha–numeric code will be displayed in the hourmeter area to inform the operator of the problem (See SYSTEM ANALYSIS, Page 69).

During a WARNING or SHUTDOWN the hourmeter symbol is not visible.

8. CHARGE PRESSURE AND FILTER CONDITION – Flashing symbol indicates low fluid charge pressure (See SHUTDOWN SYMBOL). If arrows are ON with gear/drop, it is fluid charge pressure.

This symbol will also indicate a clogged hydraulic fluid filter.

9. AIR FILTER CONDITION – This symbol will indicate a clogged air filter element.

10. GLOW PLUG (Diesel) – The symbol will flash when the glow plugs are energized. The hourmeter will also contain characters GLOXX where XX indicates the remaining time the glow plugs will be ON. Time remaining will count down in 5 second increments.

11. ENGINE SPEED – This symbol will indicate an engine overspeed (See WARNING and SHUTDOWN SYMBOL).

BRAKE INDICATOR LIGHT 12. PARKING (Non–Functional) .

13. HYDRAULIC FLUID TEMPERATURE – This symbol will indicate a high fluid temperature. (See WARNING or SHUTDOWN SYMBOL above).

MC–02320

–5–

963 Bobcat Loader Operation & Maintenance Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)

A

The Bobcat Interlock Control System (BICS™) requires the operator to be seated in the operating position with the seat bar fully lowered before the lift, tilt and traction functions can be operated.

1 2 3 4

The seat belt must be fastened anytime you operate the loader.

5

The lift, tilt and traction drive functions are interlocked with the seat bar. The lift and tilt functions are interlocked with the seat.

The BICS™ System Controller is located inside the cab; behind and to the right of the operator’s seat [A].

P–10157

There are five green lights on the BICS™ System Controller and all must be ON to operate the loader.

B

The light functions are as follows [A]: 1. SEAT – ON when operator is in the seat.

2. SEAT BAR – ON when the seat bar is in down position.

1

3. VALVE – ON when lift and tilt hydraulic functions can be used.

4. TRACTION – ON when loader can be moved forward or backward.

5. POWER – ON when the Controller is operating correctly.

NOTE: If any of the lights are off or blinking, see the BICS Troubleshooting Chart on Page 77 of this manual or see BICS Inspection and Maintenance instructions on Page 47.

P–10158

Lift Arm By–Pass Control The lift arm by–pass control knob (Item 1) [B] is used to lower the lift arms if the lift arms can not be lowered during normal operation.

Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise seat bar.

• (Foot Pedal Controls) Move pedals until both lock.

• (Advanced Hand Controls) Move the hand controls to the NEUTRAL POSITION to make sure that both lift and tilt functions are deactivated.

The seat bar system must deactivate the lift and tilt control functions when the seat bar is up. Service the system if hand controls do not deactivate.

With the operator in the seat, seat belt fastened and the seat bar fully lowered, turn the lift arm by–pass control knob (Item 1) [B] clockwise 1/4 turn. Then, pull up and hold the lift arm by–pass control until the lift arms slowly lower.

AVOID INJURY OR DEATH

W–2327–0798

The Bobcat Interlock Control System (BICS™) must deactivate the lift, tilt and traction drive functions. If it does not, contact your dealer for service. DO NOT modify the system.

W–2151–0394

–6–

963 Bobcat Loader Operation & Maintenance Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) (Cont’d)

A

Traction Lock Override (Functions Only When The Seat Bar Is Down) There is a traction lock override button (Item 1) [A] on the left hand instrument panel which will allow you to use the steering levers to move the loader forward & backward when using the backhoe attachment or for service.

• Press the button once to unlock traction drive (green traction light on BICS™ System controller will be ON).

• Press the button a second time to lock the traction drive (green traction light on BICS™ controller will be OFF).

1 P–10472

B Seat Sensor Override (If Equipped) (Functions Only When The Seat Bar Is Down) Seat Sensor Override button (Item 1) [B] allows operator, when seated with the seat bar lowered, to use lift, tilt, and traction functions if the seat sensor cannot be activated.

If seat indicator light on the BICS Controller does not go on, check for debris, dirt, or objects under or behind seat.

1

N–16884

C ENGINE SPEED CONTROL The lever (Item 1) [C] is at the right side of the operator’s seat. Engine speed is controlled by moving the lever forward to increase the engine RPM and backward to decrease the engine RPM.

1

P–10173

–7–

963 Bobcat Loader Operation & Maintenance Manual

PARKING BRAKE

A

Engage the parking brake by pushing down on the top of the pedal [A]. The traction drive system will be locked.

NOTE: The traction lock override button will unlock the traction drive when the operator is NOT in the seat and the seat bar is raised.

MC–1914

The traction lock override button will function if brake pedal is in the engaged or disengaged position.

P–10169

To release the parking brake, push down on the bottom of the pedal [B].

B

NOTE: If the loader will not move when operator is in the operating position with brake pedal released or when Traction Lock Override button is pushed, move the steering levers either forward or backward a small amount to unlock the traction drive.

MC–1914

P–10174

–8–

963 Bobcat Loader Operation & Maintenance Manual

STEERING LEVERS

A

1

2

AVOID INJURY OR DEATH When operating the machine: • Keep the seat belt fastened snugly.

• The seat bar must be lowered.

• Keep your feet on the pedal controls or footrests.

W–2261–0397 P–10167

The steering levers (Item 1) [A] are on the right and left side in front of the seat.

B

For safe control of the loader always move the levers slowly and smoothly. Only a small movement is necessary to move the loader.

FORWARD

REVERSE

The steering levers control forward and reverse travel of the loader [B].

Forward Travel – Push both levers forward.

Reverse Travel – Pull both levers backward.

Normal Turning – Move one lever farther forward than the other.

Fast Turning – Push one lever forward and pull the other lever backward.

For slow travel speed, push the steering levers forward only a small amount.

LEFT TURN

RIGHT TURN

LEFT FAST TURN

RIGHT FAST TURN

To increase travel speed, push both levers farther forward.

For maximum pushing force, push the levers forward only a small amount with the engine at full RPM. HIGH SPEED RANGE High speed range provides faster ground speed for movement from one location to another.

NOTE: The high speed range should not be used while digging or for other work with an attachment.

Push the switch (Item 2) [A] on the right hand steering lever to engage the high speed range function.

The high speed range indicator light on the left hand instrument panel will be ON. STOPPING THE BOBCAT LOADER When the steering levers are moved to the neutral position, the hydrostatic transmission will act as a service brake to stop the loader.

PI–01849

–9–

963 Bobcat Loader Operation & Maintenance Manual

SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)

A

The seat bar restraint system has a spring assist, pivoting seat bar (Item 1) [A] with arm rests and has spring loaded interlocks for the lift and tilt foot pedals.

1

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 pedal controls.

When the seat bar is up, the lift and tilt foot pedals are locked when returned to the NEUTRAL POSITION. P–10193

AVOID INJURY OR DEATH

When operating the machine: • Keep the seat belt fastened snugly.

• The seat bar must be lowered.

• Keep your feet on the pedal controls.

B

SEAT BAR DOWN

W–2046–0595

2

Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise seat bar, move pedals until both lock.

Seat Bar

W–2045–1086

Pedal Linkage

The spring loaded interlocks (Item 1) [B] control the locking and unlocking functions of the control pedals.

3 1 Interlock

The interlocks (Item 1) [B] require the operator to lower the seat bar (Item 2) [B] which allows the operator to move the foot pedals to control the lift and tilt functions.

When the seat bar is lowered, it pushes the interlock (Item 1) [B] down on both sides, releasing the pedal linkages (Item 3) [B] from the interlocks.

MC–01669

The pedals will pivot in both directions when the interlock is down.

C

SEAT BAR RAISED Seat Bar

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

Interlock

When the seat bar is raised, spring forces raise the interlocks [C].

The foot pedals will not pivot when the interlock is up.

Refer to the PREVENTIVE MAINTENANCE section for SEAT BAR RESTRAINT SYSTEM Inspecting The Seat Bar & Maintaining the Seat Bar Page 45.

MC–01669

–10–

963 Bobcat Loader Operation & Maintenance Manual

SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)

A

The seat bar restraint system has a pivoting seat bar (Item 1) [A] with arm rests.

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

1

When the seat bar is down, the lift, tilt, and traction functions can be operated.

When the seat bar is up, the lift, tilt, and traction functions are deactivated.

P–03563

AVOID INJURY OR DEATH When operating the machine: • Keep the seat belt fastened snugly.

• The seat bar must be lowered.

• Keep your feet on the foot rests.

W–2179–0694

Before you leave the operator’s seat:

• Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise seat bar.

• (Advanced Hand Controls) Move the hand controls to the NEUTRAL POSITION to make sure that both lift and tilt functions are deactivated.

The seat bar system must deactivate the lift and tilt control functions when the seat bar is up. Service the system if hand controls do not deactivate.

W–2321–0698

Refer to the PREVENTIVE MAINTENANCE section for SEAT BAR RESTRAINT SYSTEM, Inspecting And Maintaining The Seat Bar, Page 46.

–11–

963 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC CONTROLS

A

Foot Pedals

3

2 P–10170

1 Keep both feet on pedals while operating machine. Failure to do so can cause serious injury.

W–2002–1285 Put your feet on the pedals and KEEP THEM THERE any time you operate the loader.

Two foot pedals (Item 1) [A] control the hydraulic cylinders for the lift and tilt functions.

Lift Arm Operation B–07440

The left pedal controls the lift arms. Push on the bottom (heel) (Item 2) [A] of the pedal to raise the lift arms.

4

Push on the top (toe) (Item 3) [A] of the pedal to lower the lift arms.

Lift Arm Float Position

5

Push the top (toe) (Item 3) [A] of the pedal all the way forward until it locks into float position.

P–10170

Use the float position of the lift arms to level loose material while driving backward.

1

Push the bottom (heel) of the lift pedal to unlock from the float position.

Tilt Operation (Bucket) The right pedal controls the action of the bucket. Push the top (toe) (Item 4) [A] of the pedal to tilt the bucket forward.

Push the bottom of the pedal (heel) (Item 5) [A] to tilt the bucket backward.

NOTE: Keep the foot pedal area clean of dirt and debris that could interfere with pedal operation. Open the cover (Item 1) [B]. Push the dirt or debris out the front of the loader frame, Install the covers.

B–07441

B

Bucket Position Valve

1

The function of the bucket position valve is to keep the bucket in the same approximate position it is placed in before beginning the upward lift cycle.

Bucket position functions automatically during the upward lift cycle only.

The bucket positioning function can be turned OFF with the bucket level switch. (See Page 3 & 4.)

P–10233

–12–

963 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC CONTROLS (Cont’d)

A

Advanced Hand Controls

1 2 Keep both feet on footrests while operating machine. Failure to do so can cause serious injury.

P–13252

P–13253

W–2152–0594

2

Put your feet on the footrests and KEEP THEM THERE for comfort and safety any time you operate the loader.

1

Two hand levers [A] control the hydraulic cylinders for the lift and tilt functions.

Lift Arm Operation The left hand lever controls the lift arms. Move the left hand lever away (Item 1) [A] from the operator to raise the lift arms.

B–07440

Move the left hand lever toward (Item 2) [A] the operator to lower the lift arms.

Lift Arm Float Position Move the left hand lever all the way toward the operator (Item 2) [A] until it locks into float position.

3

Use the float position of the lift arms to level loose material while driving backward.

4

Move the left hand lever upward to unlock from the float position.

P–13252

P–13253

Tilt Operation (Bucket) The right hand lever controls the action of the bucket.

Move the right hand lever away (Item 3) [A] from the operator to tilt the bucket forward.

Move the right hand lever toward (Item 4) [A] the operator to tilt the bucket backward.

3

4

Bucket Position Valve The function of the bucket positioning valve is to keep the bucket in the same approximate position it is placed in before beginning the upward lift cycle.

B–07441

Bucket positioning functions automatically during the upward lift cycle only.

B

The bucket positioning function (if equipped) can be turned OFF with the bucket level switch. (See Page 3 or 4.).

Indicator Lights (Advaced Hand Control)

1

Two lights (Item 1) [B] on the left handle are always ON when the Advanced Hand Controls is functioning correctly. If lights are blinking or do not come ON, see Advanced Hand Controls Troubleshooting Chart Page 77.

Left Steering Lever

–13–

P–13255

963 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC CONTROLS (Cont’d)

A

Auxiliary Hydraulics

AVOID BURNS Hydraulic fluid, tubes, fittings and quick couplers can get hot when running machine and attachments. Be careful when connecting and disconnecting quick couplers.

W–2220–0396

P–10164

NOTE: The loader has auxiliary proportional control for front auxiliary hydraulics only.

Proportional control allows for slow–to–fast movement of auxiliary functions. EXAMPLE: If you move the auxiliary switch half way, the auxiliary function will move at approximately one–half speed.

B

Locked

1

2

Quick Couplers (Flush Face) To Connect: Remove any dirt or debris from the surface of both the male and female couplers, and from the outside diameter of the male coupler. Visually check the couplers for corroding, cracking, damage, or excessive wear, if any of these conditions exist, the coupler(s) must be replaced [A].

To Release 3 P–10566

Install the male coupler into the female coupler. Full connection is made when the ball release sleeve slides forward on the female coupler and the sleeve is rotated so that the locking pins (Item 1) [B] and the groove (Item 2) [B] do NOT align (Locked Position).

This will prevent accidental disconnection.

AUXILIARY C FRONT HYDRAULICS

REAR AUXILIARY HYDRAULICS

NOTE: If the locking pins and groove (Item 1) [B] are aligned, accidental disconnection is possible.

To Disconnect: Rotate the ball release sleeve so that the grooves are aligned with the pins (Item 3) [B] in the female coupler.

1

Holding the male coupler, retract the sleeve on the female coupler until the couplers disconnect.

NOTE: Caps and plugs are not used with flush face couplers.

P–10164

P–10422

The front auxiliary hydraulics [C] are controlled by a switch on the right steering lever.

Rear auxiliary hydraulics (Item 1) [C], if equipped, are controlled by a switch on the left steering lever.

Relieving Hydraulic Pressure To make connecting and disconnecting attachments easier, the hydraulic pressure can be relieved at the front or rear quick couplers.

With the engine running, turn the key switch quickly to the left (counterclockwise) past the OFF position. Hold key for at least five seconds after the engine comes to a complete stop. This relieves pressure that can be trapped in the auxiliary circuit which would make it difficult to engage quick couplers from an attachment.

–14–

963 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC CONTROLS (Cont’d.)

A

Auxiliary Hydraulics (Cont’d) Auxiliary Hydraulics Switch • Momentary Operation Press the Auxiliary Hydraulics Switch (Item 1) [A] once.

1

2

The light (Item 2) [A] will be ON.

3

• Continuous Operation Press the Auxiliary Hydraulics Switch (Item 1) [A] a second time.

Both lights (Items 2 & 3) [A] will be ON. • Disengage Press the Auxiliary Hydraulics Switch (Item 1) [A] a third time.

P–10467

TWO–SWITCH HANDLES

B

Both lights (Items 2 & 3) [A] will be OFF. NOTE: When the operator is seated and raises the seat bar, the Auxiliary Hydraulic System (Front and Rear) will deactivate. Press the Auxiliary Hydraulics Button (Item 1) [A] to reselect operating mode.

1

3 Left Steering Lever

FRONT Auxiliary Hydraulics Operation (RIGHT Steering Lever)

Right Steering Lever

2

• Set the Auxiliary Hydraulics Switch for Momentary Operation (See above).

• Push the switch (Item 1) [B] & [C] to the right or left to change the fluid flow direction to the front quick couplers. (EXAMPLE: Open and close grapple teeth.)

P–02154

FRONT Auxiliary Hydraulics Continuous Operation (RIGHT Steering Lever)

C

• Set the Auxiliary Hydraulics Switch for Continuous Operation (See above).

P–02152

DELUXE HANDLES 1

3

• Push the front switch (Item 2) [B] or [C] to give the front quick couplers a constant flow of fluid (EXAMPLE: Operate a backhoe.)

• To release from continuous operation, press the front switch (Item 2) [B] & [C] a second time.

2 Right Steering Lever

Left Steering Lever

NOTE: The secondary front auxiliary hydraulics and the rear auxiliary hydraulics operate from the same auxiliary section of the control valve.

P–02130

REAR Auxiliary Hydraulics Operation (LEFT Steering Lever)

D

• Set the Auxiliary Hydraulics Switch for Momentary Operation (See above).

P–02129

REAR AUXILIARY HYDRAULICS

• Push the switch (Item 3) [B] & [C] to the right or left to change the fluid flow direction to the rear auxiliary hydraulics (Item 1) [D]. (EXAMPLE: Raise and lower scarifier.)

1

NOTE: See SYSTEMS ANALYSIS Page 69 for troubleshooting malfunctions with the Auxiliary Hydraulics Operation.

P–10422

–15–

963 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC CONTROLS (Cont’d.)

A

Attachment Functions Control (If Equipped) (Attachment Control Kit Required) (Item 1) [A]

1

When his kit is installed, you can use other switches on the right and left control handles (Deluxe Handles) for functions such as water spray, raise/lower the cutter head or extend/retract the cutter head of the Stump Grinder.

The following are examples only, consult Attachment Operation & Maintenance Manual: Switch (Item 1) [B] . . . Left / Right Turn Signals Switch (Item 2) [B] . . . Extend/Retract Cutter Head Switch (Item 3) [B] . . . Raise/Lower Cutter Head

P–10232

B

1

DELUXE HANDLES 2

Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a piece or cardboard or wood to find leaks. Do not use your bare hand.

Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury.

3

Left Steering Lever

W–2072–0496

P–13255

–16–

P–13254

963 Bobcat Loader Operation & Maintenance Manual

DAILY INSPECTION

A

The loader must be in good operating condition [A].

Check the following items before starting each day: Daily Inspection And Maintenance: • • • • • • • • • • • •

Engine Oil Level Hydraulic/Hydrostatic Fluid Level Engine Air Filter, Air System for Damage or Leaks Engine Coolant Level, System for Damage or Leaks Operator Cab, Seat Belt, Seat Bar, Pedal & Mounting Hardware Grease Pivot Pins (Lift Arms, Bob–Tach, Cylinders, Bob–Tach Wedges Tires for Wear or Damage and Correct Air Pressure Fuel Filter, Remove Trapped Water Loose or Broken Parts Safety Treads and Safety Signs (Decals) Bobcat Interlock Control System (BICS™) Lift Arm Support Device

B–07494

Follow the maintenance requirements on the Service Schedule Decal, located inside the rear door [B].

Instructions are necessary before operating or servicing machine. Read 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. Failure to follow instructions can cause injury or death.

Fluids such as engine oil, hydraulic fluid, coolants, etc. must be disposed of in an environmentally safe manner.

Some regulations require that certain spills and leaks on the ground must be cleaned in a specific manner. See local, state and federal regulations for correct disposal.

W–2003–0797

B

6804345

–17–

963 Bobcat Loader Operation & Maintenance Manual

GETTING READY FOR OPERATION

A

Read the Operation & Maintenance Manual and the Operator’s Handbook before operating the loader [A].

1 Operator must have instructions before running the machine. Untrained operators can cause injury or death.

W–2001–1285 P–10159

The Operation & Maintenance Manual and other manuals can be kept in a box (Item 1) [A] provided at the right hand side of the operator seat.

B

Use the bucket or attachment steps, grab handles and safety treads (on top of the loader lift arms and frame) to get on and off the loader [B].

Safety treads are installed on the Bobcat loader to provide a slip resistant surface for getting on and off the loader.

Keep safety treads clean and replace when damaged.

Replacement treads are available from your dealer.

P–10194

C

Move the seat lever (Item 1) [C] to adjust the seat position for comfortable operation of the loader controls.

1

P–10163

–18–

963 Bobcat Loader Operation & Maintenance Manual

GETTING READY FOR OPERATION (Cont’d)

A

AVOID INJURY OR DEATH When operating the machine:

• Keep the seat belt fastened snugly.

• The seat bar must be lowered.

• Keep your feet on the pedal controls.

P–10190

W–2046–0595

Fasten the seat belt snugly and adjust it so that the buckle is centered between your hips [A].

B

Lower the seat bar [B].

Engage the parking brake if it is not already engaged.

All controls must be in the NEUTRAL POSITION before you start the engine. (See STARTING THE ENGINE, below.)

P–10195

Keep your hands on the steering levers and feet on the pedals or foot rests while seated in the loader [C].

C

STARTING THE ENGINE

P–10193

When an engine is running in an enclosed area [D], 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.

D

WRONG

WRONG

W–2050–1285

AVOID INJURY OR DEATH • Engines can have hot parts and hot exhaust gas. Keep flammable material away.

• Do not use machines in atmosphere containing explosive gas [D].

W–2051–1086 B–03724

–19–

B–06578

963 Bobcat Loader Operation & Maintenance Manual

STARTING THE ENGINE (Cont’d)

A

Normal Starting (Without BOSS™) Adjust the seat position for comfortable operation of the foot pedals and steering levers.

Fasten the seat belt snugly and adjust it so the buckle is centered between your hips.

Lower the seat bar [A].

P–10195

Put the foot pedals or hand controls and steering levers in NEUTRAL POSITION (center) (Item 1) [B].

B

NOTE: Advanced Hand Controls Only: The hand controls must be in neutral before starting the engine. If the hand controls are not in neutral, the engine will start but lift and tilt hydraulic functions will not be able to be activated. Turn the key OFF and put hand controls in neutral position. Restart the engine.

NEUTRAL POSITION

1 1/2 SPEED

Be sure the parking brake is engaged.

Set the engine speed control to the 1/2 SPEED position (Item 2) [B].

Turn the key to the ON POSITION. The engine and transmission warning lights will be ON when the key is on and the engine is stopped (Item 3) [B].

2 ON POSITION

Turn the key to START POSITION (Item 4) [B] and release it when the engine starts. (See Cold Temperature Starting if the engine does not start.)

3 START POSITION Do not engage the starter for longer than 15 seconds at a time. Longer use can damage the starter by overheating. Cool the starter for one minute between uses.

I–2034–0284

4 When the engine starts, release the key and it will return to the RUN POSITION (Item 5) [B].

RUN POSITION

STOP THE ENGINE IF THE WARNING LIGHTS DO NOT GO OFF.

5

–20–

PI–02188 MC–02033

963 Bobcat Loader Operation & Maintenance Manual

STARTING THE ENGINE (Cont’d)

A

Cold Temperature Starting (Without BOSS™)

OFF POSITION

If the temperature is below 32°F (0°C), use the following procedure to make starting the engine easier: • Replace the engine oil with the correct type and viscosity for the anticipated starting temperature. (See Oil Chart Page 54.)

• Make sure the battery is at full charge.

• Install an engine heater. (See your Bobcat dealer.)

• Install a Cold Start System. (See your Bobcat dealer.)

PI–02188

NOTE: Advanced Hand Controls Only: The hand controls must be in neutral before starting the engine. If the hand controls are not in neutral, the engine will start but lift and tilt hydraulic functions will not be able to be activated. Turn the key OFF and put hand controls in neutral position. Restart the engine.

When the temperature is below –20°F (–30°C), hydrostatic oil must be warmed before starting. The hydrostatic system will not get enough oil at low temperatures and will be damaged. Park the machine in an area where the temperature will be above 0°F (–18°C) if possible.

Cold Start System (If Equipped) The cold start system dispenses starting fluid into the engine when needed to aid starting. The system checks engine temperature at the time of starting and functions automatically as needed.

I–2007–1285

The starting fluid is in a pressurized replaceable container.

NOTE: The starting fluid contains ether which is a flammable and explosive gas. Arcs, sparks, flames and lighted tobacco must be kept away from ether to avoid explosions and fire.

Warming The Hydraulic/Hydrostatic System Let the engine run for a few minutes to warm the engine and the hydrostatic fluid before operating the loader.

During very cold temperatures 0°F (23°C) and below, let the engine run for at least five minutes.

NOTE: If the transmission warning light comes on when operating the loader, more warm–up time is needed.

STOPPING THE ENGINE Pull the engine speed control fully backward to decrease the engine speed.

Let the engine run at idle speed for several minutes to let the turbocharger cool before stopping the engine.

Turn the key switch to the OFF POSITION [A].

–21–

963 Bobcat Loader Operation & Maintenance Manual

STARTING THE ENGINE (Cont’d)

A

Normal Starting (With BOSS™) Adjust the seat position for comfortable operation of the foot pedals or hand controls and steering levers.

Fasten the seat belt snugly and adjust it so the buckle is centered between your hips.

Lower the seat bar [A].

P–07639

Put the foot pedals or hand controls and steering levers in NEUTRAL POSITION (center) (Item 1) [B].

B

NOTE: Advanced Hand Controls Only: The hand controls must be in neutral before starting the engine. If the hand controls are not in neutral, the engine will start but lift and tilt hydraulic functions will not be able to be activated. Turn the key OFF and put hand controls in neutral position. Restart the engine.

NEUTRAL POSITION

1 1/2 SPEED

Be sure the parking brake is engaged.

Set the engine speed control to 1/2 SPEED position (Item 2) [B].

2

PI–02188

C

Turn the key switch to the ON POSITION, one beep will sound and the display symbols will be ON (Item 1) [C].

Turn the key switch to START. (See Cold Temperature Starting.) Release the key when the engine starts.

Do not engage the starter for longer than 15 seconds at a time. Longer use can damage the starter by overheating. Cool the starter for one minute between uses.

I–2034–0284

When the key switch is turned ON, watch the alpha numeric display for SERVICE CODES. These codes are from the previous work shift when a WARNING may have occurred. (See SYSTEM ANALYSIS Section, Page 69.)

The codes may be viewed again by turning the key switch OFF and then ON again without starting the engine.

1 After the engine has been started, the BOSS Controller will clear all codes from memory. The codes will not appear again unless the problem reoccurs. The alphanumeric display will again show the operating hours.

MC–02320

–22–

963 Bobcat Loader Operation & Maintenance Manual

STARTING THE ENGINE (Cont’d)

A

Cold Temperature Starting (With BOSS™)

Do not use ether with glow plug (preheat) systems. Explosion can result which can cause injury or death.

W–2071–1285

See Normal Starting. Turn the key switch to the ON POSITION. The glow plug symbol (Preheat) will be ON [A].

NOTE: If the display is showing SERVICE CODES, the timing of the glow plug activation may not be visible on the display. However, the glow plugs will be energized.

Characters on the display will be GLOXX where XX will indicate the remaining time the glow plugs will be energized.

If the starting temperature is below 32°F. (0°C.), perform the following to make starting easier: • Replace the engine oil with the correct type and viscosity for the anticipated starting temperature. (See ENGINE LUBRICATION SYSTEM Page 54.)

MC–02042

B

• Make sure the battery is fully charged.

OFF POSITION

• Install an engine heater (frost plug or tank type), available from your Bobcat loader dealer.

See Cold Start System, Page 21.

NOTE: Advanced Hand Controls Only: The hand controls must be in neutral before starting the engine. If the hand controls are not in neutral, the engine will start but lift and tilt hydraulic functions will not be able to be activated. Turn the key OFF and put hand controls in neutral position. Restart the engine.

N–16961

Warming the Hydraulic/Hydrostatic System Let the engine run for a minimum of 5 minutes to warm the engine and hydrostatic transmission fluid before operating the loader. If the warning light comes ON when operating loader (cold), more warm up time is needed.

STOPPING THE ENGINE

When the temperature is below –20°F. (–30°C.), hydrostatic oil must be warmed before starting. The hydrostatic system will not get enough oil at low temperatures and will be damaged. Park the machine in an area where the temperature will be above 0°F. (–18°C.) if possible.

Pull the engine speed control fully backward to decrease the engine speed. Turn the key switch to the OFF POSITION [B].

I–2007–1285

–23–

963 Bobcat Loader Operation & Maintenance Manual

ATTACHMENTS AND BUCKETS

A

Never use attachments or buckets which are not approved by Melroe Company. Buckets and attachments for safe loads of specified densities are approved for each model.

Unapproved attachments can cause injury or death.

W–2052–1285 B–07495

The dealer can identify, for each model loader, the attachments and buckets approved by Melroe Company.

The buckets and attachments are approved for rated operating capacity and for secure fastening to the Bob–Tach.

The rated operating capacity for this loader is shown on a label in the operator cab. (Also see SPECIFICATIONS Page 85.) The rated operating capacity is determined by using a standard dirt bucket, and material of normal density, such as dirt or dry gravel. If longer buckets are used and load center moves forward and reduces the rated operating capacity. If very dense material is loaded, the volume must be reduced.

AVOID INJURY OR DEATH Do not exceed rated operating capacity.

Excessive load can cause tipping or loss of control.

Exceeding the rated operating capacity [A] can cause the following problems:

W–2053–0887

1. Steering the loader may be difficult.

2. Tires may wear faster.

B

3. There will be a loss of stability.

WEIGHT OF LOADS LBS. (KG)

Use the correct size bucket for the type and density of material being handled. For safe handling of materials and avoiding machine damage, the attachment (or bucket) should handle a full load without going over the rated operating capacity for the loader. Partial loads make steering more difficult.

Maximum load to be carried when using a pallet fork are shown in figure [B]. See your Bobcat dealer for more information about pallet forks and other available attachments.

1890(858)

2136(970)

4. The life of the Bobcat loader will be reduced.

15.75 (400)

24.00 (610)

CENTER OF LOAD LOCATION Inches (mm) 6713662

–24–

963 Bobcat Loader Operation & Maintenance Manual

ATTACHMENTS AND BUCKETS (Cont’d)

A

Installing The Bucket Or Attachment The loader is equipped with the Bob–Tach system. The Bob–Tach is used for fast changing of buckets and attachments. See the Attachment Operation & Maintenance Manual to install other attachments.

1

Bob–Tach levers have spring tension. Hold lever tightly and release slowly. Failure to obey warning can cause injury.

N–17044

W–2054–1285

B

Pull the Bob–Tach levers all the way up (Item 1) [A].

Enter the loader.

Fasten the seat belt, lower the seat bar and start the engine.

Release the parking brake.

Lower the lift arms and tilt the Bob–Tach forward.

Drive the loader forward until the top edge of the Bob–Tach is completely under the top flange of the bucket [A] (or other attachments).

N–17045

Be sure the Bob–Tach levers do not hit the bucket.

Tilt the Bob–Tach backward until the cutting edge of the bucket (or other attachment) is slightly off the ground [B].

C

Stop the engine and exit the loader.

1 N–17051

Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise seat bar.

• (Foot Pedal Controls) Move pedals until both lock.

• (Advanced Hand Controls) Move the hand controls to the NEUTRAL POSITION to make sure that both lift and tilt functions are deactivated.

The seat bar system must deactivate the lift and tilt control functions when the seat bar is up. Service the system if hand controls do not deactivate.

W–2327–0798

N–17050

Push down on the Bob–Tach levers until they are fully engaged in the locked position [C].

The levers will contact the frame as shown (Item 1) [C] when locked.

If the levers do not engage in the locked position, see your Bobcat loader dealer for maintenance.

–25–

963 Bobcat Loader Operation & Maintenance Manual

ATTACHMENTS AND BUCKETS (Cont’d)

A

The wedges (Item 1) [A] must extend through the holes (Item 1) [B] in the mounting frame of the bucket (or attachment), securely fastening the bucket to the Bob–Tach. The wedge is shown extending through the hole in the bucket [A].

1

N–17047

B 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.

W–2102–0588

1

N–17046

Removing The Bucket Or Attachment

C

Put the attachment flat on the ground and lower or close the hydraulic equipment. If the attachment is hydraulically controlled (ie: combination bucket, backhoe, etc.), stop the engine and relieve hydraulic pressure in the auxiliary circuit. (See Relieving Hydraulic Pressure, Page 14.)

Raise the seat bar, unfasten the seat belt, set the parking brake and exit the loader.

Pull the Bob–Tach levers [C] all the way up.

Disconnect the hydraulic hoses, if necessary.

Enter the loader.

N–17049

Fasten the seat belt, lower the seat bar and start the engine

D

Release the parking brake.

Lower the lift arms and tilt the Bob–Tach forward.

Move the loader backward, away from the bucket or attachment [D].

N–17044

–26–

963 Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURE (FOOT PEDALS)

A

When operating on a public road or highway, always follow local regulations. For example: Slow Moving Vehicle Sign or directional signals may be required.

WITH BUCKET FULL

Always warm the engine and hydrostatic system before operating the loader.

Going Up Slope

Machines warmed up with moderate engine speed and light load have longer life.

I–2015–0284

B

B–12878

WITH BUCKET FULL

Operate the loader with the engine at full speed for maximum horsepower. Move the steering levers only a small amount to operate the loader slowly.

New operators must operate the loader in an open area without bystanders. Operate the controls until the loader can be handled at an efficient and safe rate for all conditions of the work area.

With a full bucket, go up or down the slope with the heavy end toward the top of the slope [A] & [B].

With empty bucket, go down or up the slope with the heavy end toward the top of the slope [C] & [D].

Going Down Slope

C

B–12878

WITH BUCKET EMPTY

• Keep the lift arms as low as possible.

• Do not travel or turn with the lift arms up.

• Turn on level ground.

• Go up and down slopes, not across them.

• Keep the heavy end of the machine uphill.

• Do not overload the machine.

Going Down Slope

Failure to obey warnings can cause the machine to tip or roll over and cause injury or death.

W–2018–1187

D

B–12873

WITH BUCKET EMPTY

Raise the bucket only high enough to avoid obstructions on rough ground.

Going Up Slope

–27–

B–13297

963 Bobcat Loader Operation & Maintenance Manual

OPERATING (Cont’d)

PROCEDURES

(FOOT

PEDALS)

A

Filling The Bucket Push down on the top of the lift pedal until the lift arms are all the way down.

B–12830

Push the top of the tilt pedal to put the cutting edge of the bucket on the ground [A].

B–12872

Drive slowly forward into the material. Push the bottom of the tilt pedal to raise the front of the bucket [B].

B B–12830

Load, unload and turn on flat level ground. Do not exceed rated operating capacity shown on sign (decal) in cab. Failure to obey warnings can cause the machine to tip or roll over and cause injury or death.

W–2056–1187

Drive backward away from the material.

Emptying The Bucket B–12871

Push down on the bottom of the lift pedal to raise the bucket over the truck box or bin [C].

C

Drive forward slowly until the bucket is over the top of the truck box or bin.

Push the top of the tilt pedal until the bucket is empty [C].

B–12830

If all the material is near the side of the truck or bin, push it to the other side with the bucket.

Never dump over an obstruction that can enter the operator cab. The machine could tip forward and cause injury or death.

W–2057–1285 B–12869

–28–

963 Bobcat Loader Operation & Maintenance Manual

OPERATING (Cont’d)

PROCEDURES

(FOOT

PEDALS)

A

Digging Into The Ground Put the lift arms all the way down.

B–12830

Push the top of the tilt pedal until the cutting edge of the bucket is on the ground.

Drive forward slowly and continue to tilt the bucket down until it enters the ground [A].

Push the bottom of the tilt pedal a small amount to increase traction and keep an even digging depth.

Continue to drive forward until the bucket is full.

When the ground is hard, raise and lower the cutting edge of the bucket with the tilt pedal while driving forward slowly.

B–12874

B

Push the bottom of the tilt pedal to tilt the bucket backward as far as it will go when the bucket is full [B].

B–12830

Leveling The Ground (Using Lift Arms in Float Position) Push the top (toe) of the lift pedal all the way forward until the pedal is in the locked position to put the lift arms in a float position [C].

B–12876

C

Push the tilt pedal to change the position of the cutting edge on the bucket.

With the bucket tilted farther forward, there is more force on the cutting edge and more loose material can be moved.

B–12830

Never drive forward when the hydraulic control for lift arms is in float position.

I–2005–1285

Drive backward to level loose material. Push the bottom of the lift pedal to unlock from the float position.

B–12875

–29–

963 Bobcat Loader Operation & Maintenance Manual

OPERATING (Cont’d)

PROCEDURES

(FOOT

PEDALS)

A

Backfilling Lower the lift arms and put the cutting edge of the bucket on the ground.

B–12830

Drive forward to the edge of the hole to push the material into the hole [A].

Tilt the bucket forward as soon as it is past the edge of the hole [A].

If necessary, raise the lift arms to empty the bucket.

PARKING THE BOBCAT LOADER Stop the Bobcat loader on level ground.

Lower the lift arms fully and put the attachment flat on the ground.

B–12877

Pull the engine speed control lever all the way backward.

Let the engine idle for 15 to 20 seconds to let the turbocharger cool.

Turn the key switch to the OFF POSITION. Engage the parking brake.

AVOID INJURY OR DEATH

Lift the seat bar and make sure the foot pedals are in the locked position.

Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise seat bar, move pedals until both lock.

Unbuckle the seat belt. Remove the key from the switch to prevent operation of the loader by unauthorized personnel.

W–2045–1086

STOPPING THE BOBCAT LOADER When the steering levers are moved to the NEUTRAL POSITION, the hydrostatic transmission will act as a service brake to stop the loader.

–30–

963 Bobcat Loader Operation & Maintenance Manual

OPERATING CONTROLS)

PROCEDURE

(ADVANCED

HAND

A

Filling The Bucket Move the left hand lever toward the operator until the lift arms are all the way down. Move the right hand away from the operator to put the cutting edge of the bucket on the ground [A].

P–13252

P–13253

B–12872

Drive slowly forward into the material. Move the right hand lever toward the operator to raise the front of the bucket [B].

B

Load, unload and turn on flat level ground. Do not exceed rated operating capacity shown on sign (decal) in cab. Failure to obey warnings can cause the machine to tip or roll over and cause injury or death.

P–13252

P–13253

W–2056–1187

Drive backward away from the material.

B–12871

Emptying The Bucket

C

Move the left hand lever away from the operator to raise the bucket over the truck box or bin [C].

Drive forward slowly until the bucket is over the top of the truck box or bin. Move the right hand lever away from the operator until the bucket is empty [C]. If all the material is near the side of the truck or bin, push it to the other side with the bucket.

P–13252

P–13253

Never dump over an obstruction, such as a post, that can enter the operator cab. The machine could tip forward and cause injury or death.

W–2057–0694 B–12869

–31–

963 Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURE CONTROLS) (Cont’d)

(ADVANCED

HAND

A

Digging Into The Ground Put the lift arms all the way down. Move the right hand lever away from the operator until the cutting edge of the bucket is on the ground. Drive forward slowly and continue to tilt the bucket down until it enters the ground [A].

P–13252

Move the right hand lever toward the operator a small amount to increase traction and keep an even digging depth. Continue to drive forward until the bucket is full.

When the ground is hard, raise and lower the cutting edge of the bucket with the hand lever while driving forward slowly.

P–13253

B–12874

B

Move the right hand lever toward the operator to tilt the bucket backwards as far as it will go when the bucket is full [B].

P–13252

P–13253

B–12876

Leveling The Ground (Using Lift Arms In Float Position)

C

Move the left hand lever all the way down and in until the hand lever is in the locked position to put the lift arms in a float position [C].

Move the right hand lever to change the position of the cutting edge on the bucket. With the bucket tilted farther forward, there is more force on the cutting edge and more loose material can be moved.

P–13252

P–13253

Never drive forward when the hydraulic control for lift arms is in float position.

I–2005–1285

Drive backward to level loose material. Move the left hand lever upward to unlock from the float position.

B–12875

–32–

963 Bobcat Loader Operation & Maintenance Manual

OPERATING PROCEDURE CONTROLS) (Cont’d)

(ADVANCED

HAND

A

Backfilling Lower the lift arms and put the cutting edge of the bucket on the ground. Drive forward to the edge of the hole to push the material into the hole [A].

Tilt the bucket forward as soon as it is past the edge of the hole [A]. If necessary, raise the lift arms to empty the bucket.

P–13252

P–13253

PARKING THE BOBCAT LOADER Stop the Bobcat loader on level ground.

Lower the lift arms fully and put the edge of the bucket on the ground.

Pull the engine speed control all the way backward. Turn the key switch to the OFF POSITION.

B–12877

Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise seat bar.

• (Advanced Hand Controls) Move the hand controls to the NEUTRAL POSITION to make sure that both lift and tilt functions are deactivated.

The seat bar system must deactivate the lift and tilt control functions when the seat bar is up. Service the system if hand controls do not deactivate.

W–2321–0698

Engage the parking brake.

Lift the seat bar and make sure the hand controls are deactivated.

Unbuckle the seat belt. Remove the key from the switch to prevent operation of the loader by unauthorized personnel.

–33–

963 Bobcat Loader Operation & Maintenance Manual

TRANSPORTING THE BOBCAT LOADER

A

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

1 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 and towing vehicles are of adequate size and capacity.

Both Sides

Both Sides

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.

Fasten the Bobcat loader to the transport vehicle to prevent the loader from moving during sudden stops or when going up or down slopes.

• Lower the bucket or attachment to the floor.

P–10423

P–10425

• Stop the engine.

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

• Fasten each end of the chain to the transport vehicle.

Cover the exhaust pipe of the loader before transporting.

Air entering the exhaust pipe can turn the turbocharger and cause damage due to lack of lubrication.

P–10424

–34–

963 Bobcat Loader Operation & Maintenance Manual

TOWING THE LOADERrocedure

A

Tow the loader only a short distance at a slow speed to prevent damage to the loaders hydrostatic system.

(Example: Moving the loader onto a transport vehicle.)

1

The towing chain (or cable) must be rated 1 and 1/2 times the weight of the loader. (See SPECIFICATIONS, Page 85.)

2

Block the front wheels to prevent the loader from moving when the shuttle valve is removed.

Put blocks at the front of the front tires to prevent loader from rolling.

Lift and block the rear of the loader. Remove the rear wheels.

P–10536

Remove the hydrostatic motor access cover (both sides).

B

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

2

Remove the shuttle valve (Item 1) [B] (both sides).

NOTE: The plug (Item 2) [B] and relief valve may need 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.

1

Raise the operator cab. (See Raising The Operator Cab, Page 42.)

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

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

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

Operate the Port–a–Power to approximately 350 PSI (24134 kPa) to release the parking brake.

Lower the operator cab. (See Lowering The Operator Cab, Page 43.)

Remove the blocks from front wheels.

Move the loader to the desired location.

1

Park the loader on level ground.

P–10537

Block the rear wheels for transport.

NOTE: Before using the loader again, disconnect the Port–a–Power, push up and turn the red Traction Lock By–Pass Knob (Item 1) [C] 1/4 turn clockwise to engage the brake solenoid valve. Install the shuttle valve (Item 1) [B] and plugs into the hydrostatic motors.

D

1

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 instructions.

&

Maintenance

Manual

for

more P–10541

6803932

–35–

963 Bobcat Loader Operation & Maintenance Manual

LIFTING THE LOADER

AVOID INJURY OR DEATH • Before lifting, check fasteners at the lifting brackets.

• Never allow riders in the cab or bystanders

within 15 feet (5 meters) while lifting the machine.

Failure to secure fasteners can cause injury or death.

W–2163–1294 The loader can be moved by lifting with the lifting kit which is available from your Bobcat dealer.

The lifting brackets must be attached to the main frame according to the instructions in the kit.

Make sure that the lift bracket fastening bolts are tightened to 220–245 ft.–lbs. (300–330 Nm) torque.

The lifting kit, supplied by Melroe Company is designed to lift and hold the Bobcat loader.

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

W–2069–1285

–36–

963 Bobcat Loader Operation & Maintenance Manual

PREVENTIVE MAINTENANCE AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 ALTERNATOR BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Adjusting The Alternator Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) . . . . . . . . . . . . . . . . . 47 Inspecting The Lift Arm By–Pass Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Inspecting The BICS™ Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Inspecting The Seat And Seat Bar Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Inspecting The Traction Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 BOB–TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Removing And Installing The Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Servicing The Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Fuse Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 FAN GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Checking And Maintaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . . . . . . . . . . . . . . 64 Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Removing Air From The Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Replacing The Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Replacing The Hydraulic/Hydrostatic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 61 LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Disengaging The Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Engaging The Lift Arm Support Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 LUBRICATING THE BOBCAT LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 REAR DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Adjusting The Rear Door Latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 REAR GRILL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS) . . . . 46 Inspecting The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Maintaining The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS) . . . . . . . . . . . . . . . . . . . 45 Inspecting The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Maintaining The Seat Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Tire Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 –37–

PREVENTIVE MAINTENANCE

963 Bobcat Loader Operation & Maintenance Manual

MAINTENANCE SAFETY Instructions are necessary before operating or servicing machine. Read 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. Failure to follow instructions can cause injury or death.

W–2003–0797 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–10731

B–12365

B–7469

Never service the Bobcat® Skid Steer Loader without instructions.

Use the correct procedure to lift or lower operator cab with lift arms down.

Cleaning and maintenance are required daily.

WRONG

WRONG

WRONG

B–11799

B–3724

B–6593

Have good ventilation when welding or grinding painted parts.

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

Vent exhaust to outside when engine must be run for service.

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

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 Melroe Company.

WRONG

WRONG

WRONG

B–6590

B–6580

B–6589

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 contacts, 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.

–38–

MSW01–0698

963 Bobcat Loader Operation & Maintenance Manual

SERVICE SCHEDULE 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 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. Failure to follow instructions can cause injury or death.

W–2003–0797

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 and Safety Tread Operator Cab Hydraulic Fluid, Hoses and Tubelines Final Drive Transmission (Chaincase) Control Pedals and 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 the 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 & 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 & 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 downs, cables, connections and electrolyte level. Add distilled water as needed.

Grease three 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; 250 hours thereafter.

–39–

963 Bobcat Loader Operation & Maintenance Manual

LIFT ARM SUPPORT DEVICE

A

2 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.

W–2059–0991

1

P–10201

P–10200

Engaging The Lift Arm Support Device Maintenance and service work can be done with the lift arms lowered.

B 1

If the lift arms are raised, use the following procedure: Remove any attachment.

Put jackstands under the rear corners of the loader.

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 [B].

P–10198

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

C

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

Raise the lift arms, until the 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 pin (Item 1) [D] 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

–40–

963 Bobcat Loader Operation & Maintenance 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.

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

1

P–10197

B

Raise the lift arms a small amount and the spring will lift the support device off the lift cylinder rod [B]. Lower the lift arms. Stop the engine.

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

Disconnect the spring from the bracket.

P–10199

C

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

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

2

1

–41–

P–10201

P–10200

963 Bobcat Loader Operation & Maintenance Manual

OPERATOR CAB

A

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.

B–07705

ROPS/FOPS Roll Over 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.

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

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

B

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 40.)

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

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

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

P–10271

–42–

963 Bobcat Loader Operation & Maintenance Manual

OPERATOR CAB (Cont’d)

A

Lowering The Operator Cab NOTE: Be sure the seat bar is fully raised or lowered when lowering the cab. Always use the grab handles to lower the cab.

Pull down on the bottom of the operator cab until it stops at the latching mechanism [A]. Release the latching mechanism [A] (Inset) and pull the cab all the way down.

P–10274

P–10273

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

B

Tighten the nuts to 40–50 ft.–lbs. (54–68 Nm) torque.

P–10162

C

P–10161

–43–

963 Bobcat Loader Operation & Maintenance 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

B

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

Exit through the rear of the operator cab [B].

P–10502

Front Door:

C

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

Pull the plastic loop at the top of the window in the front door [C].

P–09216

D

Push the window out with your foot [D].

P–09217

–44–

963 Bobcat Loader Operation & Maintenance Manual

SEAT BAR RESTRAINT SYSTEM (FOOT PEDALS)

A

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.

Clean (Left & Right Sides)

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.

P–10361

B AVOID INJURY OR DEATH

Clean (Left & Right Sides)

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. 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.

N–15458

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 are pushed.

Pull the seat bar down, 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, lower the lift arms and place 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 See the SERVICE SCHEDULE Page 39 for correct service interval.

Clean 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. Have your Bobcat dealer adjust the pedal control linkages.

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

–45–

963 Bobcat Loader Operation & Maintenance Manual

SEAT BAR RESTRAINT SYSTEM (ADVANCED HAND CONTROLS)

A

The seat bar restraint system has a pivoting seat bar (Item 1) [A] with arm rests.

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

1

When the seat bar is down, the lift, tilt, and traction drive functions can be operated.

When the seat bar is up, the lift, tilt, and traction drive functions are deactivated.

P–03563

Inspecting The Seat Bar Sit in the operator’s seat. Turn the key ON and lower the seat bar. Both lights on the left handle should be ON.

B

Move each hand control back and forth. You should hear the zip,zip sound of the lift and tilt actuators moving the control valve spools (under the seat).

Clean (Both Sides)

Raise the seat bar fully. Both lights on the left handle should be OFF. Move each hand control back and forth. There must be no sound of the lift or tilt actuators. If either actuator makes a sound while the seat bar is raised, contact your dealer for service.

Maintaining The Seat Bar P–10361

See the SERVICE SCHEDULE Page 39 for correct service interval.

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

If the seat bar system does not function correctly replace parts that are worn or damaged. Use only genuine Bobcat replacement parts.

AVOID INJURY OR DEATH When operating the machine: • Keep the seat belt fastened snugly.

• The seat bar must be lowered.

• Keep your feet on the foot rests.

W–2179–0694

Before you leave the operator’s seat: • Lower the lift arms, put the attachment flat on the ground.

• Stop the engine.

• Engage the parking brake.

• Raise seat bar.

• (Advanced Hand Controls) Move the hand controls to the NEUTRAL POSITION to make sure that both lift and tilt functions are deactivated.

The seat bar system must deactivate the lift and tilt control functions when the seat bar is up. Service the system if hand controls do not deactivate.

W–2321–0698

–46–

963 Bobcat Loader Operation & Maintenance Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)

A

Inspecting The BICS™ System Controller (Engine STOPPED – Key ON)

1 2

1. Sit in the operator’s seat. Turn key ON, lower the seat bar and disengage the parking brake. All five BICS™ controller lights should be ON (Items 1, 2, 3, 4 & 5) [A].

3 4 5

2. Engage the parking brake, raise the seat bar fully.

Seat bar light (Item 2) [A], valve light (Item 3) [A] and traction light (Item 4) [A] should be OFF. 3. Raise up slightly off the seat. Seat light (Item 1) [A] should be OFF. NOTE: Record what lights are blinking (if any) and number of blinks. Refer to Page 77.

P–10157

4. Exit the loader and press traction lock override button. Traction light (Item 4) [A] should be ON. Press override button again and traction light (Item 4) [A] should be OFF.

Clean Behind And Under Seat

B

Inspecting The Seat And Seat Bar Sensors (Engine RUNNING) 5. Sit in the operator’s seat, lower the seat bar and engage the parking brake. Fasten the seat belt.

6. Start the engine and operate at low idle. While raising the lift arms, raise the seat bar fully. The lift arms should stop. Repeat using the tilt function.

Inspecting The Traction Lock (Engine RUNNING) P–10166

7. Fasten the seat belt, disengage the parking brake, and raise the seat bar fully. Move the steering levers slowly forward and backward. The traction lock should be engaged. Lower the seat bar.

Operator Seat

C

8. Engage the parking brake pedal and move the steering levers slowly forward and backward. The traction lock should be engaged.

Inspecting The Lift Arm By–Pass Control 9. Raise the lift arms six feet (2 m) off the ground. Stop the engine. Turn the lift arm by–pass control knob clockwise 1/4 turn. Then pull up and hold the lift arm by–pass control knob until the lift arms slowly lower.

Seat Sensor

1

Seat Spring

Seat Rail Cover

Maintenance MC–02043

Clean any debris, dirt or objects from under or behind the operator seat [B] & [C]. The rear of the seat must move up and down.

Inspect both seat rail covers [C] for wear or damage.

Replace if necessary.

Clearance is necessary between the seat mount (Item 1) [C] and the seat pan, to allow the seat to move up and down freely. With adequate clearance, the seat sensor will be allowed to function correctly.

AVOID INJURY OR DEATH The Bobcat Interlock Control System (BICS™) must deactivate the lift, tilt and traction drive functions. If it does not, contact your dealer for service. DO NOT modify the system.

Inspect seat bar pivot area for tightness of linkage bolts.

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

W–2151–0394

–47–

963 Bobcat Loader Operation & Maintenance Manual

REAR DOOR

A

AVOID INJURY OR DEATH Stop, cool and clean engine of flammable material. Never service or adjust loader with engine running unless instructed to do so in manual.

W–2061–0887 P–04493

Pull up on the door latch [A] and turn it to open the rear door [B].

B

NOTE: If a rear scarifier attachment is installed, prevent damage to the rear door by making sure the rear door is closed and the latch pin lock is installed before the rear scarifier is raised during loader operation.

Keep the rear door closed when operating the machine. Failure to do so could seriously injure a bystander.

P–04495

W–2020–1285

C

Adjusting The Rear Door Latch Loosen the set screw (Item 1) [C]. Loosen the nut (Item 1) [D].

Turn the bolt (Item 2) [D] in or out until the door contacts both the top and the bottom of the loader frame with the lever in the latched position.

1

NOTE: It takes approximately 50 lbs. (20 kg) of force to push the lever down when the latch is correctly adjusted.

P–10282

With the set screw up, the flanges on the bolt must be to the side so that the set screw aligns with the flat surface at the end of the bolt.

D

1

Tighten the set screw [C]. Tighten the nut (Item 1) [D] to 65–70 ft.–lbs. (88–95 Nm) torque.

2 P–10284

–48–

963 Bobcat Loader Operation & Maintenance Manual

REAR GRILL

A

Open the rear door and raise the rear grill [A].

P–10286

B

Clean debris from the oil cooler (Item 1) [B] and the radiator (Item 2).

1

Close the rear door and lower the rear grill before operating the loader.

AIR CLEANER SERVICE

2

See the SERVICE SCHEDULE Page 39 for the interval to service the air cleaner system.

P–10295

Without BOSS™: Replace the outer filter element only when the red ring shows in the window of the condition indicator (Item 1) [C].

C 2

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

1

Replace the inner filter element every third time the outer filter is replaced or when the red ring shows in the indicator window after the outer filter has been replaced.

Stop the engine.

P–10289

Open the rear door.

Raise the rear grill.

D

Remove the dust cover wing nut (Item 1) [D] and remove the dust cover.

1

P–10291

–49–

963 Bobcat Loader Operation & Maintenance Manual

AIR CLEANER SERVICE (Cont’d)

A

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

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

Check the air intake hose for damage.

Check the air cleaner housing for damage.

P–10290

Check to make sure all connections are tight.

B

Inner Element Replace the inner filter element only under the following conditions: • Replace the inner filter element every third time the outer filter is replaced. or . . .

• Without BOSS™: 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.

1

P–10287

• With BOSS™: When the SERVICE CODES on the instrument panel shows symbol AF.2 (see Page 72) during full engine speed, replace the inner filter element only after the outer filter element has been changed.

C

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

Remove the inner filter [C].

Install a new filter and tighten the wing nut.

Lower the rear grill and close the rear door before operating the loader.

P–10288

–50–

963 Bobcat Loader Operation & Maintenance 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

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

100% 50% 0%

0% 50% 100% P–10202

Contact your fuel supplier for local recommendations.

Filling the Fuel Tank

B

WRONG

Stop and cool the engine before adding fuel.

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

W–2063–0887

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

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]!

B–13456

Install and tighten the fuel fill cap [A].

–51–

963 Bobcat Loader Operation & Maintenance Manual

FUEL SYSTEM (Cont’d)

A

Fuel Filters

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.

5

W–2103–1285 P–10377

See the SERVICE SCHEDULE Page 39 for the service interval when to remove the water from the fuel filters and when to replace the fuel filters.

3

Replace both filters at the same service interval.

Open the rear door.

1

Clean the outside surfaces of the filter assembly (Items 1 and 2) [A].

Loosen the drain (Items 3 and 4) [A] to drain water from the filters.

Support the filter and turn the clamp ring (Items 5 and 6) to the left [A]. Remove the clamp ring.

Remove the filter by pulling straight down. Discard the old filter element(s).

Remove the sediment bowl from the pre–filter and clean the bowl.

2

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

Replace if necessary.

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

Clean the filter head and 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 filter to the filter head.

Remove the air from the fuel system. (See Removing Air From The Fuel System Page 53.)

P–10380

6

4 P–10382

–52–

963 Bobcat Loader Operation & Maintenance Manual

FUEL SYSTEM (Cont’d)

A

Removing Air From The Fuel System After replacing the fuel filter elements or when the fuel tank has run out of fuel, the air must be removed from the fuel system before starting the engine.

1

2 Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a piece or cardboard or wood to find leaks. Do not use your bare hand.

Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury.

N–16233

W–2072–0496

Loosen the vent plug (Item 1) [A] on the filter head.

Squeeze the priming bulb (Item 2) [A] until fuel flows from the vent with no air bubbles showing.

Tighten the vent plug.

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

–53–

963 Bobcat Loader Operation & Maintenance Manual

ENGINE LUBRICATION SYSTEM

A

Checking Engine Oil 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].

3

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. (See Oil Chart below.)

2

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

SAE 40W or 20W–50

N–16234

SAE 10W–30

B

SAE 15W–40 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

Keep Oil Level Between These Marks

+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.

Replacing Oil And Filter See the SERVICE SCHEDULE Page 39 for the service interval for replacing the engine oil and filter.

1

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

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

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

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

N–16235

Install and tighten the drain plug.

Remove the filler cap (Item 3) [A].

Fill the engine crankcase with oil of the correct grade and viscosity. (See Oil Chart above.) Capacity is 8 qts. (7,8 liters).

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.

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

W–2103–1285

Install the filler cap and close the rear door before operating the loader.

–54–

963 Bobcat Loader Operation & Maintenance Manual

COOLING SYSTEM

A

Check the cooling system every day to prevent overheating, loss of performance or engine damage.

1

Wear safety glasses to prevent eye injury when any of the following conditions exist:

• When fluids are under pressure.

• Flying debris or loose material is present.

• Engine is running.

• Tools are being used.

P–10379

W–2019–1285

B 1

Checking The Coolant Level 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.

2

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

P–10295

One gallon and one pint (4,3 L) 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 refractometer to check the condition of propylene glycol in your engine cooling system.

Close the rear door.

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

Cleaning The Cooling System

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

Open the rear door and raise the rear grill.

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

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

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

Check cooling system for leaks.

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

Lower the rear grill and close the rear door before operating the loader.

I–2124–0497

–55–

963 Bobcat Loader Operation & Maintenance Manual

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

Open the rear door and raise the rear grill. Remove the radiator cap (Item 1) [A].

P–10294

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.

B 1

Mix the coolant in a separate container. (See SPECIFICATIONS for correct capacity Page 85.) 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.

Fill the radiator with the premixed coolant. Open the vent plug (Item 1) [C] (near the left end of the valve cover) 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.

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

C

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.

Lower the rear grill and close the rear door.

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

–56–

963 Bobcat Loader Operation & Maintenance Manual

ALTERNATOR BELT

A

Adjusting The Alternator Belt

2

Stop the engine.

Open the rear door.

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

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

1 N–16204

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

FAN GEARBOX

C

See the SERVICE SCHEDULE Page 39 for the correct service interval.

Checking And Maintaining Raise the operator cab. (See Raising the Operator Cab Page 42.)

Remove the hose and fitting (Item 1) [C].

1

Lubricant level is correct if lubricant flows from the check plug hole.

If the level is low, add SAE 90W gear lube through the check plug hole until the lubricant flows from the hole.

N–15731

Install the fitting and hose.

Lower the operator cab. (See Lowering The Operator Cab Page 43.)

–57–

963 Bobcat Loader Operation & Maintenance Manual

ELECTRICAL SYSTEM

A

Description The loader has a 12 volt, negative ground alternator charging system.

The electrical system is protected by fuses located in the engine compartment. The fuses will protect the electrical system when there is an electrical overload. The reason for the overload must be found before starting the engine again.

Servicing The Electrical System The battery cables must be clean and tight.

P–09588

Check the electrolyte level in the battery. Add distilled water as needed.

B

Remove acid or corrosion from the battery and cables with a sodium bicarbonate (baking soda) and water solution [A].

1

Put Battery Saver P/N 6664458 or grease on the battery terminals and cable ends to prevent corrosion.

Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.

P–10299

C

In case of acid contact, wash immediately with water. In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes.

If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.

1

W–2065–1296

4

2

5 7 6

Fuse Location The electrical system for this model loader is protected by fuses (Item 1) [B] located in the engine compartment.

3

P–10300

Remove the fuse block covers to check or replace fuses.

D Ref.

Fuse Capacity

Circuit

1.

2.

3.

4.

5.

6.

7.

15 AMP 10 AMP 15 AMP 10 AMP 25 AMP 25 AMP 25 AMP

ENGINE BICS™ BOSS Proportional Control LIGHTS ACCESSORY ACCESSORY

PWM

The fuse capacity and circuits are listed below [C] & [D]:

15 ACCESSORY BOSS

6803593

6803593

–58–

963 Bobcat Loader Operation & Maintenance Manual

ELECTRICAL SYSTEM (Cont’d)

A

Using A Booster Battery (Jump Starting)

4

If it is necessary to use a booster battery to start the engine, BE CAREFUL! There must be one person in the operator’s seat and one person to connect and disconnect the battery cables.

The key switch must be in the OFF POSITION. The booster battery must be 12 volt.

2 N–16242

Keep arcs, sparks, flames and lighted tobacco away from batteries. When jumping from booster battery make final connection (negative) at engine frame.

Do not jump start or charge a frozen or damaged battery. Warm battery to 60°F. (16°C.) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery.

Never lean over battery while boosting, testing or charging.

1

Battery gas can explode and cause serious injury.

3

W–2066–1296

Connect the end of the first cable (Item 1) [A] to the positive (+) terminal of the booster battery. Connect the other end of the same cable (Item 2) [A] to the positive terminal on the starter.

N–16241

Connect the end of the second cable (Item 3) [A] to the negative (–) terminal of the booster battery. Connect the other end of the same cable (Item 4) [A] to the engine.

Keep cables away from moving parts. Start the engine.

(See Cold Temperature Starting Page 21, 23.)

After the engine has started, remove the ground (–) cable (Item 4) [A] first. Remove the cable from the positive terminal on the starter.

Damage to the alternator can occur if:

• Engine is operated with battery cables disconnected.

• Battery cables are connected when using a

fast charger or when welding on the loader (Remove both cables from the battery).

• Extra battery cables (booster cables) are connected wrong.

I–2023–1285

–59–

963 Bobcat Loader Operation & Maintenance Manual

ELECTRICAL SYSTEM (Cont’d)

A

Removing And Installing The Battery Open the rear door.

Remove the wire harness clamp (Item 1) [A] and move the harnesses to allow clearance to remove the battery.

1 N–16237

Disconnect the negative (–) battery cable (Item 1) [B] from the battery.

B

Remove the battery holddown clamp (Item 2) [B].

2

1

N–16201

C

Disconnect the positive (+) battery cable (Item 1) [C].

Remove the battery from the loader.

1

N–16200

Always clean the terminals and cable ends when installing a new battery [D].

D

When installing the battery in the loader, do not touch any metal parts with the battery terminals.

Connect and tighten the battery cables. Connect the negative (–) cable last to prevent sparks.

Close the rear door before operating the loader.

P–09589

–60–

P–09590

963 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC/HYDROSTATIC SYSTEM

A

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

(See SPECIFICATIONS Page 85.)

2

1

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

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

B

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

Add until fluid is at the top mark on the dipstick [B]

P–10303

Replacing The Hydraulic/Hydrostatic Filter

C

See the SERVICE SCHEDULE Page 39 for the correct service interval.

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

Raise the operator Cab. (See Raising the Operator Cab Page 42.)

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.

Install and hand tighten the new filter element.

Lower the operator cab. (See Lowering The Operator Cab Page 43.)

1

N–15486

–61–

963 Bobcat Loader Operation & Maintenance Manual

HYDRAULIC/HYDROSTATIC SYSTEM (Cont’d)

A

Replacing The Hydraulic Fluid

1

See the SERVICE SCHEDULE Page 39 for the service interval.

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

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

P–10203

B

Raise the operator cab. (See Raising The Operator Cab Page 42.)

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

1

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

Remove the hydraulic filter element. (See Page 61.)

Install a new filter element.

Add fluid to the reservoir until the fluid is at the top mark on the dipstick. (See SPECIFICATIONS Page 85 for fluid type and capacity.) DO NOT fill above the top mark on the dipstick.

P–10398

C

Lower the operator cab. (See Lowering The Operator Cab Page 43.)

1

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

Hydraulic fluid escaping under pressure can have sufficient force to enter a person’s body by penetrating the skin and cause serious injury and possibly death if proper medical treatment by a physician familiar with this injury is not received immediately.

W–2145–0290

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

–62–

963 Bobcat Loader Operation & Maintenance Manual

TIRE MAINTENANCE

A

Wheel Nuts See the SERVICE SCHEDULE Page 39 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 85 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

–63–

963 Bobcat Loader Operation & Maintenance Manual

FINAL DRIVE TRANSMISSION (CHAINCASE)

A

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 Page 85.)

1

Stop 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.

DRIVE BELT

3

Adjustment See the SERVICE SCHEDULE Page 39 for the correct service interval.

Loosen the two stop bracket bolts (Item 1) [B].

1 2

Push the stop (Item 2) tight against the idler arm (Item 3).

Tighten the stop bracket bolts (Item 1).

MC–02363 N–15822

–64–

963 Bobcat Loader Operation & Maintenance Manual

SPARK ARRESTOR MUFFLER

A

See the SERVICE SCHEDULE Page 39 for the service interval for cleaning the spark arrestor muffler.

Do not operate the loader with a defective exhaust system.

1 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.

N–16240

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

Cover the battery with a fire retardant material (such as tin) to direct sparks or hot particles from the muffler away from the battery.

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.

NOTE: Be careful not to touch the battery terminals with any metal material.

W–2068–1285

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

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 goggles, holds a piece of wood over the outlet of the muffler.

Stop the engine.

Remove the material that you used to cover the battery.

Install and tighten the plug.

Close the rear door.

–65–

963 Bobcat Loader Operation & Maintenance Manual

LUBRICATING THE BOBCAT LOADER

A

Lubricate the loader as specified in the SERVICE SCHEDULE Page 39 for the best performance of the loader.

Record the operating hours each time you lubricate the Bobcat loader.

1

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

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

P–10198

B

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

2

P–10231

C

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

3

P–10243

D

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

4

P–10204

–66–

963 Bobcat Loader Operation & Maintenance Manual

LUBRICATING THE BOBCAT LOADER (Cont’d)

A

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].

Every 250 Hours: Add grease to the fittings on the steering shaft under the cab.

7 P–10234

PIVOT PINS

C

All lift arm, Bob–Tach and cylinder pivots have a large pin secured with a bolt (Item 1) [C].

Bolts must be tightened to 18–20 ft.–lbs. (24–27 Nm) torque.

1 P–10235

–67–

963 Bobcat Loader Operation & Maintenance Manual

BOB–TACH

A

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

N–17046

C

Bob–Tach Wedge

Wedge Must Contact Lower Edge Of Hole In The Attachment

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

D

Look for cracked welds. Contact your Bobcat dealer for repair or replacement parts.

Lubricate the wedges (See SERVICE SCHEDULE, Page 39 and LUBRICATION OF THE BOBCAT LOADER, Page 66).

TS–01062

–68–

963 Bobcat Loader Operation & Maintenance Manual

SYSTEMS ANALYSIS ADVANCED HAND CONTROLS Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 AUXILIARY HYDRAULICS OPERATION Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 BOBCAT INTERLOCK CONTROL SYSTEM (BICSTM) Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 MONITOR SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 TROUBLESHOOTING THE DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 75 TROUBLESHOOTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 TROUBLESHOOTING THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . 76 SYSTEMS ANALYSIS

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963 Bobcat Loader Operation & Maintenance Manual

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963 Bobcat Loader Operation & Maintenance Manual

SERVICE CODES The following list contains the BOSS defect codes which can occur. These codes are transmitted to the instrument panel display. Some service procedures for correcting the problems can be found in this manual and other procedures must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL.

Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manuals, 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. Failure to follow instructions can cause injury or death.

W–2003–0797

SUBJECT

DISPLAY READS

CONDITION

Engine Coolant Level

ECL 1

SHUTDOWN, No Coolant

Engine Coolant Temp.

EC–1.1 EC–2.1

SHUTDOWN, Engine Temperature WARNING, Engine Temperature

EC 3 EC 4 EC 5 EC 7

Wiring Not Connected Wiring Shorted High Sensor Voltage Sensor Out Of Range

EP 1 EP 2 EP 3

SHUTDOWN, Pressure WARNING, Pressure Wiring Not Connected

Engine Speed

EP 4 EP 5 EP 7 ES 1

Wiring Shorted High Sensor Voltage Sensor Out Of Range SHUTDOWN, Engine Speed Too High

Air Filter

ES–2.1 ES–6 ES–7 AF 2

WARNING, Engine Speed Slightly High Sensor No Signal Sensor Out Of Range WARNING, Restriction Too High

AF 6 b–2.1 b–2.2 FUEL2

Sensor No Signal WARNING, Bad Battery WARNING, Battery Voltage WARNING, Low Level

FUEL3 FUEL4 FUEL5

Wiring Not Connected Wiring Shorted High Sensor Voltage

FUEL7

Sensor Out Of Range

Engine Oil Pressure

Battery Fuel Level

–72–

963 Bobcat Loader Operation & Maintenance Manual

SUBJECT

DISPLAY READS

CONDITION

Hydrostatic Charge Filter Conditions

HF1–2 HF1–6 HF2–2 HF2–6

WARNING, High Restriction (1st Filter) Sensor No Signal WARNING, High Restriction (2nd Filter) Sensor No Signal

Hydrostatic Fluid

HP 1 HP 2 HP 3 HP 4

SHUTDOWN, Pressure WARNING, Pressure Wiring Not Connected Wiring Shorted

HP 5 HP 7 HC 1

High Sensor Voltage Sensor Out Of Range SHUTDOWN, Temperature

HC 2 HC 3 HC 4 HC 5

WARNING, Temperature Wiring Not Connected Wiring Shorted High Sensor Voltage

HC 7

Sensor Out Of Range

Hydrostatic Fluid Temperature

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963 Bobcat Loader Operation & Maintenance Manual

TROUBLESHOOTING The following information identifies loader problems which can occur most often. Service procedures for correcting loader problems can be found in this manual on the pages indicated. Some procedures are marked D/S (Dealer Service) and must be performed only by qualified Bobcat service personnel.

Instructions are necessary before operating or servicing machine. Read Operation & Maintenance Manuals, 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. Failure to follow instructions can cause injury or death.

W–2003–0797

TROUBLESHOOTING THE ENGINE PROBLEM Engine won’t turn over with starter.

CAUSE

CORRECTION

PAGE

Charge battery and find cause for loss of charge.

–

Clean and tighten the battery cables.

–

Check the starting circuit. Repair as needed.

D/S

Wrong starting procedure.

Use correct starting procedure.

19

Air in the fuel system.

Remove air from the fuel system.

53

Fuel shut–off solenoid.

Check electrical connections.

D/S

No fuel in tank.

Fill fuel tank.

51

Vent in fuel filter cap is plugged.

Clean the vent.

–

Dirt or water in fuel system.

Service as needed.

D/S

Fuel filter is dirty.

Install a new filter.

52

Hole in fuel line.

Service as needed.

–

Weak battery.

Charge or replace battery.

–

Wrong oil in engine.

See Oil Specifications.

54

Engine has lost compression.

Recondition the engine.

D/S

Engine has overheated.

Check cooling system.

–

Poor fuel quality.

Use fresh, good quality fuel.

51

Damaged injectors.

Service as needed.

D/S

Dirt, water or air in fuel system.

Clean and service as needed.

D/S

Engine is hot.

See Engine Overheats.

–

Restricted exhaust.

Check exhaust system.

–

Dirty air cleaner.

Install new element.

49

Cylinder compression is low.

Recondition the engine.

D/S

Battery has low charge.

Cables loose connection.

Damaged wiring.

Engine turns with starter, but is difficult to start.

Engine has little power or runs rough.

or

starter,

dirty

poor

solenoid

or

D/S = Dealer Service Only –74–

963 Bobcat Loader Operation & Maintenance Manual

TROUBLESHOOTING THE ENGINE (Cont’d) PROBLEM

CAUSE

Engine overheats.

CORRECTION

PAGE

Restriction in cooling air flow.

Check for debris on radiator grill.

–

Engine is overheated.

Run at full throttle.

– –

TROUBLESHOOTING THE DRIVE SYSTEM PROBLEM

CAUSE

No drive on both sides.

Drive belt is broken.

Replace drive belt.

D/S

Hydraulic fluid is low.

Check fluid level. Add as needed.

61

Damaged hydraulic pump.

Check condition of pump and replace as needed.

D/S

Hydrostatic system is damaged.

Check hydrostatic system.

D/S

Control linkage is disconnected.

Repair linkage.

D/S

Hydrostatic system is damaged.

Check hydrostatic system and service as needed.

D/S

Wrong tire pressure.

Check all tires for correct pressure.

63

Steering linkage interference.

Check steering linkage and adjust as needed.

D/S

Hydrostatic system is damaged.

Check system. Service as needed.

D/S

Loader moves when levers are in neutral.

Steering linkage out of adjustment.

Adjust steering linkage.

D/S

System is overheating.

Hydraulic fluid level is low.

Check fluid level and add as needed.

61

Clean cooling system. Check for debris on radiator grill.

55

Check by–pass valve.

D/S

Bobcat is overloaded.

Use correct size attachment.

D/S

Hydrostatic transmission damage.

Check system and service as needed.

D/S

No drive on one side.

Machine pulls to one side.

Cooling system restricted.

is

Low charge (transmission light on).

CORRECTION

dirty.

Air

pressure

PAGE

D/S = Dealer Service Only

–75–

963 Bobcat Loader Operation & Maintenance Manual

TROUBLESHOOTING THE HYDRAULIC SYSTEM PROBLEM

CAUSE

No hydraulic action.

Hydraulic action is rough.

Hydraulic action is slow.

Hydraulic cylinders leak fluid.

CORRECTION

PAGE

No hydraulic fluid.

Check fluid level and add as needed.

61

Pedals are disconnected.

Check linkage. Service as needed.

–

Hydraulic pump is damaged.

Check pump. Replace as needed.

D/S

Hydraulic fluid is too thick.

Let machine warm up.

21, 23

Hydraulic fluid level is low.

Check fluid level and add as needed.

61

Air in the hydraulic system.

Run hydraulics through functions.

–

Pedal is hitting floor or debris under pedal.

Check debris.

Remove

–

Cylinders leak internally.

Check condition of cylinders and service as needed.

D/S

Hydraulic pump is damaged.

Check pump. Replace as needed.

D/S

Control valve is damaged.

Check valve needed.

D/S

Hydraulic fluid is too thick.

Let machine warm up.

21, 23

Damage to cylinder rods or seals.

Repair cylinders.

D/S

adjustment.

and

service

as

D/S = Dealer Service Only AUXILIARY HYDRAULICS OPERATION Troubleshooting Chart The Auxiliary Hydraulics Control has a built–in diagnostics function.

The two lights will blink in a specific pattern to indicate a problem (See Below).

1

2

INDICATIONS Blinking Momentary Aux. Hyd. Light (Item 1) Locked Hydraulics Light (Item 2) Problem

Causes

Check

Off

Blinking

X

Off X

X Base Solenoid

X Rod Solenoid

Blinking

Off

Blinking

Off P–10467

X

X

At same time

Alternating

X

X

Diverter Solenoid

Wires Disconnected Wires Shorted Wires Cut Solenoid Failed

Right Handle

Spring in the thumb switch is broken

Check for voltage (1–10 volts) at the solenoid connector.

Check for the thumb switch in centered position. Check for voltage to Dk. Blue & Dk. Blue/White wires.

NOTE: Check all of the above first. Any of the above can also indicate a problem with the Auxiliary Control Module. See your Bobcat dealer for module replacement.

–76–

963 Bobcat Loader Operation & Maintenance Manual

BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) Troubleshooting Chart The following list shows the effects which can happen to the loader, and the probable causes when the BICS Controller lights are off or flashing. Have the service procedure performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL.

Indicator Light

Light ON

Light OFF

Flashing Indicator Means System Problem (See Your Bobcat Dealer for Service) Effect on Operation of Loader When Light Is Number of OFF Flashes Cause

Seat

Operator in Seat.

No Operator in Seat.

Lift and tilt functions will not operate.

Seat Bar

Seat Bar Down.

Seat Bar Up.

Lift, tilt and traction functions will not operate.

3

Lift and tilt functions will not operate.

1 2

Valve

Traction

Control Valve Can Be Used.

Loader can be moved forward & backward.

Control Valve Cannot Be Used.

Loader cannot be Loader cannot be moved forward and moved forward and backward. backward.

2 3 2

3 3 1 2 3 4 5 6

Power

BICS Controller is operating correctly.

BICS Controller is not operating correctly.

Seat sensor circuit shorted to battery voltage*.

Seat sensor circuit shorted to ground.

Seat bar sensor circuit shorted to battery voltage*.

Seat bar sensor circuit shorted to ground.

Valve output circuit is open.

Valve output circuit shorted to battery voltage*.

Valve output circuit shorted to ground.

Valve output circuit is not grounded.

Traction lock hold coil circuit is open.

Traction lock hold coil circuit shorted to battery voltage*.

Traction lock hold coil circuit shorted to ground.

Traction lock pull coil circuit is open.

Traction lock pull coil circuit is shorted to battery voltage*.

Traction lock pull coil circuit is shorted to ground.

Lift, tilt and traction functions will not operate.

* Normal BICS operating voltage is less than the electrical system voltage. If voltage is more, the circuit is shorted to system voltage.

NOTES: (1) If the seat and/or seat bar sensor circuits are open, the corresponding lights will be OFF. If one of the lights stay OFF, check the circuit for continuity. See Inspection & Maintenance Instructions in Preventive Maintenance section.

(2) If all five lights flash repeatedly, the voltage supply is greater than 16 volts or less than 9 volts.

(3) Flashing patterns will repeat every 3.25 seconds.

(4) If seat indicator light does not go ON, check for debris, dirt or objects under or behind the seat. The Seat Sensor Override♦ can be used if the seat sensor cannot be activated. ♦ Only on later loaders, and early loaders which have had BICS Controller and switch replaced.

NOTE: If the Seat Bar is lowered before the seat sensor is activated, a 10 second delay will occur before the valve and traction lights come on. (only loaders with BICS controller S/N’s above 200,000 will have this delay.)

ADVANCED HAND CONTROLS (AHC) Troubleshooting Chart The AHC has a built–in diagnostic function which uses the two lights on the left handle.

Both lights will be ON when the AHC is functioning correctly. The lights will flash in a specific pattern to indicate a problem (See Below). (See your Bobcat dealer for service information.)

Number of Flashes Left Hand Light (Lift Circuit) Right Hand Light (Tilt Circuit)

1 Handle Not Calibrated

FLASHING LIGHT MEANS SYSTEM PROBLEM (See Your Bobcat Dealer for Service) 2 3 4 Actuator Not Calibrated

Wiring Fault (Handle)

Wiring Fault (Actuator)

5 Actuator Fault

NOTE: Flashing patterns will repeat every six seconds. One blink will occur if Right or Left Hand Control is not in neutral position before key is turned ON or engine is started.

–77–

963 Bobcat Loader Operation & Maintenance Manual

–78–

963 Bobcat Loader Operation & Maintenance Manual

MACHINE SIGN TRANSLATIONS WARNING (6577754, 6579528, 6803932) . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 SERVICE SCHEDULE (6804345) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 WARNING (6579511) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 WARNING (6579510) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 DANGER (6702302, 6702301) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

MACHINE SIGN TRANSLATIONS

MACHINE SIGNS (DECALS) Machine signs (decals) are an essential part of the loader (See Page xiv & xv). This section provides French and Spanish translations of the machine signs that are in English. The Operator’s Handbook is also available in a combination English, French, German and Spanish, Dutch and Italian edition.

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963 Bobcat Loader Operation & Maintenance Manual

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963 Bobcat Loader Operation & Maintenance Manual

ADVERTENCIA (SPANISH) EVITE HERIDAS O LA MUERTA

• Mantenga le puerta cerrada excepto para dar servicio.

• Mantenga el motor limpio y que no tenga material inflamable.

• Mantenga el cuerpo. objetos sueltos y la ropa lejos de los conductores eléctricos, piezas móviles, piezas calientes y del escape.

• No use el cargador en lugares donde

hay polvo o gases explosivos o materiales inflamables cerca al escape.

• Todos los gases del escape pueden matar. Ventile siempre el lugar de trabajo.

• No use nunca éter o líquido del arranque en los motores

• Les liquides sous pression peuvent pénétrer au travers de

• Escapes de líquido bajo presión pueden penetrat en la

• L’acide des batteries provoque de graves brûlures, porter

• El ácido de la batería puede causar quemaduras

• Les batteries dégagent des gaz inflammables et

de diesel que tienen tapones encendedores. Use solamente las ayudas para el arranque que sean aprobados por el fabricante del motor. piel y causar heridas graves. Se requiere atención médica inmediata. Use gafas. Use cartón para revisar si hay fugas.

severas, use gafas. Si el ácido hace contacto con los ojos, la piel o la ropa, lávelos bién con agua. Si el contactor fuel en los ojos, lávelo bién y vaya al médico.

• Las baterias producen gas inflammable y explosivo.

la peau et causer de graves blessures. Consulter immédiatement un médecin Porter des lunettes de sécurité. Utiliser du carton pour repérer les fuites. des lunettes de sécurité. S’il entre en contact avec les yeux, la peau ou les vêtements, rincer généreusement à l’eau. Pour les yeux, appeler un médecin. explosifs. Tenir les arcs électriques les étincelles, les flammes et las cigarettes allumées à l’écart.

• En cas de démarrage par pontage, effectuer le dernier

Mantenga lejos, arcos, chispas, llamas y tabaco encendido.

branchement (Câble négatif) au moteur (jamais à la batterie). Pour débrancher, déconnecter d’abord le câble négatif du moteur.

• Para arranque con batería auxiliar, conecte de último el

• Ne jamais utiliser d’éther ou de liquide de démarrage sur

cable negativo al motor del cargador (nunca la batería).

Despues de hacer el arranque con cables, quite peimero la conección negativa del motor.

un moteur diesel avec des bougies de préchauffage.

N’employer que les aides au démarrage approuvées par le fabricant.

AVERTISSEMENT (FRENCH) EVITER LES BLESSURES, VOIRE LA MORT

• Maintenir la porte arrière fermée, sauf pour les entretiens.

• Débarasser le moteur de toute matière inflammable.

• Maintenir le corps, les objets non attachés et les vêtements à l’écart des contacts électriques, des pièces mobiles et brûlantes et de l’échappement.

• Ne pas utiliser la machine dans un endroit chargé de poussières ou de gaz explosifs, et où l’échappement risque de toucher des matériaux inflammables.

• Les gaz d’échappement peuvent être mortels. Toujours aérer.

–81–

963 Bobcat Loader Operation & Maintenance Manual

Translations for Service Schedule are not yet available.

–82–

963 Bobcat Loader Operation & Maintenance Manual

ADVERTENCIA (SPANISH)

ATTENTION (FRENCH)

EVITE HERIDAS O LA MUERTE

EVITER LES BLESSURES OU LA MORT

NO USE NUNCA EL CARGADOR SIN LEER LAS INSTRUCCIONES. LEA EL MANUAL DEL OPERATIO, EL MANUAL DE SERVICIO Y LA GIA DEL OPERARIO.

NE JAMAIS SE SERVIR DE LA CHARGEUSE SANS INSTRUCTIONS. LIRE LE MANUEL DE L’OPERATEUR EL D’ENTRETIEN AINSI QUE LE GUIDE D’UTILISATION.

NO VIAJE O DE LA VUELTA CON LOS BRAZOS DE ELEVACION ARRIBA. CARGUE, DESCARGUE Y DE LA VUELTA ESTANDO EN UN SITIO PLANO Y NIVELADO. NO EXCEDA LA CAPACIDAD NOMINAL DE FUNCIONAMIENTO (VEA EL AVISO EN EL CARGADOR).

NE PAS SE DEPLACER NI VIRER AVEC LE BRAS RELEVES. CHARGER, DECHARGER ET VIRER SUR UN SOL PLAT ET HORIZONTAL. NE PAS DEPASSER LE CAPACITE NOMINALE (CONSULTER L’AUTOCOLLANT APPOSE SUR LA CARGEUSE).

USE LA BARRA DEL ASIENTO. ASEGURESE BIEN EL CINTURON DE SEGURIDAD.

UTILISER L’ARCEAU DE SECURITE. ATTACHER SOIGNEUSEMENT LA CEINTURE DE SECURITE.

NUNCA MODIFIQUE EL EQUIPO NI USE ADITAMENTOS QUE NO ESTEN APROBADOS POR LA COMPAÑIA MELROE.

NE JAMAIS MODIFIER L’EQUIPEMENT NI SE SERVIR D’ACCESSOIRES QUE NE SONT PAS APPROUVES PAR MELROE COMPANY.

MANTENGA LOS PIES EN LOS PEDALES. MAINTENIR LES PIEDS SUR LES PEDALES. EN LA PENDIENTES, MANTENGA EL EXTREMO PESADO DE CARGADOR EN POSICION ASCENDENTE. ANTES DE BAJARSE DEL CARGADOR 1. BAJE LOS BRAZOS DE ELEVACION. COLOQUE EL ADITAMENTO BEIN EN EL SUELO.

DANS LES PENTES, TOUJOURS MAINTENIR LA PARTIE LA PLUS LOURDE DE LA CHARGEUSE VERS LE HAUT. POUR QUITTER LA CHARGEUSE: 1. ABAISSER LES BRAS DE LEVAGE. POSER L’EQUIPEMENT A PLATE SUR LE SOL.

2. PARE EL MOTOR

2. ARRETER LE MOTEUR.

3. PONGA EL FRENO. 4. LEVANTE LA BARRA DEL ASIENTO. MUEVA LOS PEDALES HASTA QUE AMBOS SE TRABEN.

–83–

3. ENCLENCHER LE FREIN DE STATIONNEMENT. 4. RELEVER L’ARCEAU DE SECURITE. DEPLACER LES PEDALES JUSQU’A CE QU’ELLES SOIENTE TOUTES DEUX VERROILLEES. 963 Bobcat Loader Operation & Maintenance Manual

ADVERTENCIA (SPANISH) EVITE HERIDAS O LA MUERTE

PELIGRO (SPANISH)

LLEVE LA CARGA EN POSICION BAJA

EVITE LA MUERTE

EL NO OBEDECER ESTA ADVERTENCIA PUEDE CAUSAR LADEAMIENTO O VUELCOS O PERDIDAD DE LA CARGA Y DE LA VISIBILIDAD.

AVERTISSEMENT (FRENCH) EVITER DES BLESSURES OU LA MORT TENIR LA CHARGE VERS LE BAS. LE NON RESPECT PEUT ENTRAINER UN BASCULEMENT OU UN RENVERSEMENT DE LA MACHINE, UNE PERTE DE LA CHARGE OU DE VISIBILITE.

• MANTENGASE RETIRADO DE ESTA AREA

CUANDO LOS BRAZOS DE ELEVACION ESTAN ELEVADOS, A MENOS QUE ESTEN TRABADOS POW EL TOPE. • EL MOVER EL PIE DEL PEDAL O FALLA DE UNA PIEZA PUEDEN CAUSAR LA CAIDA DE LOS BRAZOS DE ELEVACION.

DANGER (FRENCH) EVITER LA MORT

• EVITER CETTER ZONE LORSQUE LES BRAS

DE LEVAGE RELEVÉS NE SONT PAS ASSURÉS PAR DES ARRETS DE BRAS DE LEVAGE. • UNE PEDALE ACTIONNÉE OU UNE PICE DEFECTUEUSE. PEUT PROVOQUER L’ABAISSEMENT DES BRAS DE LEVAGE.

ADVERTENCIA (SPANISH) EL CILINDRO CONTIENE GAS BAJO ALTA PRESION. EL ABNRIR EL CILINDRO PUEDE SOLTAR LA VARILLA Y CAUSAR HERIDAS O LA MUERTE.

AVERTISSEMENT (FRENCH) LES VERINS RENFERMENT UN GAZ SOUS PRESSION. NE JAMAIS OUVRIR UN VERIN CAR LA TIGE RISQUE DE S’ECHAPPER BRUTALEMENT ET DE CAUSER DES BLESSURES OU MEME LA MORT.

PELIGRO (SPANISH) EVITE LA MUERTE

Unexpected loader movement.

Can cause serious injury or death.

• EL FORZAR EL IMPLEMENTO CONTRA EL

ADVERTÊNCIA (PORTUGUESE)

SUELO HACE QUE LA RUEDDAS DELANTERAS SE ELEVEN. • NUNCA SE META DEBAJO NI ALCANCE NADA DEBAJO DE LOS BRAZOS DE ELEVACION O DEL CILINDRO DE ELEVACION SIN QUE ESTE INSLADO UN TOPE APROBADO EN LOS BRAZOS DE ELEVACION.

MOVIMENTO INESPERADO DA CARREGADEIRA.

DANGER (FRENCH)

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.

SW 97 6803932

PODE CAUSAR FERIMENTOS SÉRIOS OU MORTE. EMPURRE PARA CIMA E GIRE NA DIREÇÃO EMPURRE PARA CIMA E GIRE NA DIREÇÃO HORÁIA A MAÇANETA VERMELHA DE BY–PASS DO TRAVAMENT.

EVITER LA MORT

• L’ACCESSOIRE PEUT ETRE APPUYE CONTRE LE SOL ET SOULEVER LES ROUES AVANT.

• NE JAMAIS ALLER SOUS NI METTRE LES

MAINS SOUS LES BRAS OU LE VERIN DE LEVAGE SANS QU’UN ARRET DE BRAS DE LEVAGE APPROUVE SOIT INSTALLE.

LEIA O MANUAL DE OPERAÇÃO E MANUTENÇÃO PARA OBTER MAIS INSTRUÇÕES. –84–

963 Bobcat Loader Operation & Maintenance Manual

SPECIFICATIONS ADDITIONAL PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 CAPACITIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 MELROE CO. APPROVED ATTACHMENTS & ACCESSORIES . . . . . . . . 89 PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

SPECIFICATIONS

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963 Bobcat Loader Operation & Maintenance Manual

–86–

963 Bobcat Loader Operation & Maintenance Manual

SDimensions are given for loader equipped with standard tires and dirt bucket and may

SKID STEER LOADER SPECIFICATIONS

vary with other bucket types. All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

SWhere applicable, specification conform to SAE or ISO standards and are subject to change without notice.

95°

‘‘C” 166.8 (4235)

40°

28.1 (713) 89.7 (2279)

25°

‘‘A”

STD. TIRES – 78.0” (1981)

‘‘B”

Face of Bob–tach

9.4 (239)

98.7 (2507)

30°

‘‘B” ‘‘A”

128.0 (3252)

51.1 (1297) 122.3 (3105)

STD. TIRES – 62.6” (1590)

‘‘C”

8.6 (219) 6595532

78” BUCKET WIDTH – 79.6” (2022)

Changes of structure or weight distribution of the loader can cause changes in control and steering response and can cause failure of the loader parts.

963

SPECIFICATIONS PERFORMANCE Rated Operating Capacity (SAE) . . . . . .

Tipping Load (SAE Rating) . . . . . . . . . . .

Operating Weight . . . . . . . . . . . . . . . . . . .

SAE Breakout Force – Lift . . . . . . . . . . . .

– Tilt . . . . . . . . . . . .

Axle Torque . . . . . . . . . . . . . . . . . . . . . . . .

Travel Speed (Low) . . . . . . . . . . . . . . . . . .

(High) . . . . . . . . . . . . . . . . . .

3000 lbs. (1361 kg) 6000 lbs. (2722 kg) 9900 lbs. (4491 kg) 6050 lbs. (2744 kg) 6300 lbs. (2858 kg) 9200 lbs. (4173 kg) 5.17 MPH (8.3 km/hr.)

9.00 MPH (14.5 km/hr.)

CONTROLS Vehicle Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction and Speed controlled by two hand levers.

Loader Hydraulics Lift and Tilt . . . . . . . . . . . . . . . . . . . . . . . .

Controlled by separate foot pedals.

Front Auxiliary . . . . . . . . . . . . . . . . . . . . .

Controlled by electrical switch on RH steering lever.

Rear Auxiliary (optional) . . . . . . . . . . . .

Controlled by electrical switch on LH steering lever.

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hand lever throttle: Key–type starter switch and shutdown.

Starting Aid . . . . . . . . . . . . . . . . . . . . . . . . .

Push button ether start system – Optional Service Brake . . . . . . . . . . . . . . . . . . . . .

Two independent hydrostatic systems controlled by two hand operated steering levers.

Parking Brake . . . . . . . . . . . . . . . . . . . . . .

Mechanical Disc, foot operated pedal.

ENGINE Make/Model . . . . . . . . . . . . . . . . . . . . . . . .

Fuel/Cooling . . . . . . . . . . . . . . . . . . . . . . . .

Horsepower (ISO) . . . . . . . . . . . . . . . . . . .

Maximum Governed RPM . . . . . . . . . . . .

Torque @ 1600 RPM (ISO) . . . . . . . . . . .

Number of Cylinders . . . . . . . . . . . . . . . . .

Displacement . . . . . . . . . . . . . . . . . . . . . . .

Bore/Stroke . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . .

Crankcase Ventilation . . . . . . . . . . . . . . . .

Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . .

Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Perkins/1004.40T Diesel/Liquid Gross: 105 (78 kg) 2200 RPM Gross: 308 lbf. ft. (418 Nm) Four 243 cu. in. (3,99 L) 3.94/5.00 (100/127) Pressure System W/Filter Open System Dry replaceable cartridge w/safety element Compression –87–

963 Bobcat Loader Operation & Maintenance Manual

SPECIFICATIONS (Cont’d)

963

HYDRAULIC SYSTEM Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pump Capacity . . . . . . . . . . . . . . . . . . . . .

Tilt Relief Settings . . . . . . . . . . . . . . . . .

Lift Relief Settings . . . . . . . . . . . . . . . . .

System Relief @ Quick Couplers . . . .

Engine Driven, Gear Type 26.2 GPM (99,2 L/min.) @ 3575 RPM 3500 PSI (24133 kPa) 4000 PSI (27580 kPa) First Stage – 3025 PSI (20857 kPa) Second Stage – 3375 PSI (23270 kPa) Replaceable #3 micron element

Filter Hydraulic . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Cylinders . . . . . . . . . . . . . . . . . .

Bore Diameter: Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . .

Tilt Cylinder (2) . . . . . . . . . . . . . . . . . . . .

Rod Diameter: Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . .

Tilt Cylinder (2) . . . . . . . . . . . . . . . . . . . .

Stroke: Lift Cylinder (2) . . . . . . . . . . . . . . . . . . . .

Tilt Cylinder (2) . . . . . . . . . . . . . . . . . . . .

Control Valve . . . . . . . . . . . . . . . . . . . . . . .

Fluid Lines . . . . . . . . . . . . . . . . . . . . . . . . .

Fluid Type . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Function Time Raise Lift Arms . . . . . . . . . . . . . . . . . . . .

Lower Lift Arms . . . . . . . . . . . . . . . . . . . .

Bucket Dump . . . . . . . . . . . . . . . . . . . . . .

Bucket Rollback . . . . . . . . . . . . . . . . . . .

ELECTRICAL Alternator . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Instrumentation . . . . . . . . . . . . . . . . . . . . .

DRIVE SYSTEM Main Drive . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission . . . . . . . . . . . . . . . . . . . . . . .

Final Drive . . . . . . . . . . . . . . . . . . . . . . . . .

Doubleacting; Tilt cylinder has custioning feature on dump & rollback 3.00 (76,2) 3.00 (76,2) 1.75 (44,5) 1.50 (38,1) 31.81 (808,0) 21.11 (536,2) 3–spool, open center type w/float detent on lift and hydraulic bucket positioning. Electronically controlled auxiliary spool.

SAE standard tubes, hoses & fittings Bobcat Fluid (P/N 6563328). If fluid is not available, use 10W–30/10W–40 Class SE motor oil for temperature above 0°F (–18°C) 5W–30 Motor Oil for temperatures below 0°F (–18° C) 4.4 Seconds 3.0 Seconds 2.8 Seconds 2.2 Seconds 50 amp open frame w/integral regulator 12 volt, 1000 cold cranking amps. @ 0°F. (–18°C); 180 minute reserve capacity 12 volt, Gear Reduction Type Gauges: Hourmeter, Voltmeter, Fuel, Engine Temperature.

Warning Lights: Engine Oil Pressure, Hydrostatic Charge Pressure, Hydrostatic Fluid Temperature & Hydrostatic Filter.

Optional BOSS™ System: Monitors Engine and Loader System.

Displays visual warnings and audible alarm. Controls automatic shutdown function and has diagnostic capability.

Hydrostatic 4 wheel drive Infinitely variable tandem hydrostatic piston pumps, driving 2 fully reversing hydrostatic motors. Separate gear type charge pump.

Double gear reduction & #120 HS endless roller chain & sprockets in sealed chaincase with oil lubrication

Total Engine to Wheel Reduction . . . . . . . . . . . . . . . . . . . . . . . . .

Axle Size . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel Bolts . . . . . . . . . . . . . . . . . . . . . . . .

N/A 2.95 (75) (10) 3/4 inch

CAPACITIES Cooling System . . . . . . . . . . . . . . . . . . . . .

Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil W/Filter . . . . . . . . . . . . . . . . . .

Hydraulic Reservoir . . . . . . . . . . . . . . . . . .

Hydraulic/Hydrostatic System . . . . . . . . .

Chaincase Reservoir . . . . . . . . . . . . . . . .

20 qts. (18,9 L) 32.5 gals. (123,0 L) 8 qts. (7,6 L) 28 qts. (26,5 L) N/A 20.5 gals. (77,6 L)

TIRES Standard . . . . . . . . . . . . . . . . . . . . . . . . . . .

Flotation . . . . . . . . . . . . . . . . . . . . . . . . . . .

Super Flotation . . . . . . . . . . . . . . . . . . . . .

Solid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Recommended Pressure . . . . . . . . . . .

8–19.5, 8 ply rating 14–17.5, 10 ply rating 38 x 20–16, 8 ply rating 9.00 – 16 Inflate tires to MAXIMUM pressure shown on the side wall of the tire. DO NOT mix brands of tires used on the same loader.

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963 Bobcat Loader Operation & Maintenance Manual

MELROE COMPANY APPROVED ATTACHMENTS & ACCESSORIES These and other attachments are approved for use on this model Bobcat loader. Do not use unapproved attachments.

Attachments not manufactured by Melroe Company may not be approved.

The versatile Bobcat loader quickly turns into a multi–job machine with a tight–fit attachment hook–up . . . from bucket to grapple to pallet fork to backhoe and a variety or other attachments. See your Bobcat dealer for more details on the attachments and field accessories shown on the following pages.

Increase the versatility of your Bobcat Loader with a variety of bucket styles and sizes. Styles and sizes include: BUCKET DESCRIPTIONS 66 inch Construction & Industrial with and without Teeth 78 inch Construction & Industrial with and without Teeth 87 inch Construction & Industrial with and without Teeth 78 inch Utility Bucket 87 inch Utility Bucket 66 inch Low Profile with and without Teeth 78 inch Low Profile with and without Teeth 72 inch Fertilizer Bucket 100 inch Snow Bucket

Rear Stabilizer/Scarifier

811 Backhoe

78 inch Industrial Fork Grapple

Bobcat backhoe attachments are designed for the pipeliner, municipal worker or contractor, for high production digging.

The Fork Grapple is perfect for handling irregular–shaped metal and other assorted scrap and heavy–duty agricultural applications.

68 Inch Industrial Bucket Grapple

Auger – Model 30

6560 Hydraulic Breaker

Clamp onto heavy and odd–shaped objects, and move them with ease. The Bobcat Industrial Grapple is the ideal attachment for handling scrap, waste or pipe. It’s built strong for tough working conditions.

Dig 6’’ – 36’’ holes with speed and plumbline accuracy. Utilizing Bobcat Loader hydraulics, the heavy–duty hydraulic auger bites in with low speed, high torque power. Because of a unique knuckle–joint design, the auger will dig vertical holes even though the Bobcat Loader is working on uneven terrain.

Up to 750 ft.–lb. impact energy class.

Backhoe or loader mounting. Loader mounting frame for vertical and horizontal breaking. Quick–change tool system – variety of tools. Low recoil operating cycle.

Pallet Fork Frame 42 & 48 inch teeth available

Level II FOPS Top Kit

Sweeper

For protection from falling trees, rocks for machines involved in site clearing, overhead demolition or forestry per ISO 3449. (Level I protection is provided with the standard cab.)

Cleans up construction sites. Cutting edge for scraping mud. Sweeps parking lots, warehouse, docks, etc. Sweeps and collects debris with one attachment.

(Recommended for use with backhoe)

Increase your backhoe performance.

Increase your versatility in a wide range of jobs with a set of frame mounted Bobcat Loader rear stabilizers.

Move bulky or bagged materials in one load. Hook on a pallet fork and move your bagged or bulk material fast. Ideal for all kinds of farm chores and fertilizer handling. In industrial plants and landscaping, handle baled or pallet materials.

*SPECIAL APPLICATIONS KIT WHICH INCLUDES A 1/2 INCH LEXAN FRONT DOOR WITH 1/4 INCH TOP AND REAR WINDOWS MUST BE USED WHEN OPERATING THE BOB–TACH MOUNTED HYDRAULIC BREAKER.

Some attachments may not be available from your local dealer.

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963 Bobcat Loader Operation & Maintenance Manual

MELROE COMPANY APPROVED ATTACHMENTS & ACCESSORIES (Cont’d) Planer Manual Depth Adjust Hydraulic Depth Adjust

Trencher – Model LT405

Cut and remove asphalt or concrete.

Quickly mills asphalt or concrete surfaces.

Ideal for street repair. various sizes of drums available.

Versatile trenching ability. Use these Bobcat trencher attachments for a variety of jobs. The LT405 digs three to five feet deep and 5 to 12 inches wide. Hydraulic sideshift to get close to walls. Optional trench cleaner.

Wheel Saw – Models WS12 & WS18

Stump Grinder – Model SG 50

Precise cuts through concrete, asphalt, rebar or frozen ground. Excellent for a variety of road repair or utility applications.

Two modes for 12 or 18 inch cutting depths. Hydraulic depth and sideshift controlled from the operator’s seat.

Tracks Approved by Melroe Company & Sold through Bobcat Loader Dealers

You’ll get better performance in sand, snow and mud. Float over soft, sandy, or muddy ground and get better traction on slippery surfaces with over–tire metal or rubber tracks.

Remove stumps from hard to access areas. The stump grinding attachment is ideal for landscapers, rental yards and stump removal companies. The Bobcat Loader mounted stump grinder adds versatility and maneuverability, when compared to tow–behind stump cutters.

Vibratory Roller W/Smooth Drum or W/Padded Drum

Pack and level smooth and easy. The Bobcat Loader Vibratory Roller features either a smooth or padded 48–inch wide drum. The roller provides up to 4156 pounds of force at 2153 vibrations per minute and is ideal for flatwork, trenching and asphalt patchwork contractors. A bolt–on smooth outer shell is also available for converting the padded drum to a smooth drum.

84 Inch Angle Broom

Put your Bobcat loader to work and clean up almost everything in sight with the hydraulically driven Angle Broom attachment. Use it to sweep driveways, sidewalks, parking lots, loading docks, warehouses, or countless other applications.

Landscape Rake – Model 6B

Break up lumpy soil, pick up rocks as small a 3/4’’, grade, level and scarify in close quarters with the Bobcat Landscape Rake. Use it for ground preparation, for seeding, sodding and lawn leveling. Pick up rocks or hard–packed clumps of soil and dump them where you need them with the Bobcat Landscape Rake.

Some attachments may not be available from your local dealer.

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963 Bobcat Loader Operation & Maintenance Manual

ADDITIONAL PUBLICATIONS The following publications are also available for your Bobcat Loader. You can order them from your Bobcat dealer.

OPERATOR’S HANDBOOK 6708021 Foot Control 6708158 Hand Control SKID STEER LOADER OPERATOR TRAINING COURSE 6722720 –Introduces operator to step–by–step basics of Skid–Steer loader operation. Also available in Spanish P/N 6724036.

–gives basic operation instruction and safety warnings.

OPERATION & MAINTENANCE MANUAL 6724543 –complete instruction on the correct operation and the routine maintenance of the BOBCAT loader.

SAFETY VIDEO 6724793

–provides basic safety instructions.

Skid–Steer Loader

SAFETY MANUAL 6556500

EQUIPMENTMANUFACTURERS INSTITUTE 10S.RIVERSIDEPLAZACHICAGO,ILLINOIS60606–37100

SERVICE MANUAL 6724545 –complete maintenance and overhaul instructions for your BOBCAT loader.

–provides basic safety procedures and warnings for your BOBCAT loader. Also available in Spanish P/N 6724451.

PARTS MICROFICHE

–Up–to–date PARTS information is also available. See your BOBCAT dealer.

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963 Bobcat Loader Operation & Maintenance Manual

–92–

963 Bobcat Loader Operation & Maintenance Manual

WARRANTY 400–900 Series Bobcat Loaders The Melroe Company warrants to its authorized dealer and authorized dealers of Melroe Equipment, Ltd., who in turn warrants to the original buyer (owner) that each new Bobcat Loader will be free from proven defects in material and workmanship for 12 months after delivery to the owner.

During the warranty period, the authorized selling Melroe dealer shall repair or replace, at his option, without charge for parts and labor, any part of the Melroe product which fails because of defects in material and workmanship. The owner shall provide the authorized dealer with prompt written notice of the defect and allow reasonable time for replacement or repair. Melroe may, at its option, request failed parts to be returned to the factory. Travel time of mechanics and transportation of the Melroe product to the authorized Bobcat Loader dealer for warranty work are the responsibility of the owner.

The warranty does not apply to tires or other trade accessories not manufactured

by Melroe. The owner shall rely solely on the existing warranty, if any, of the respective manufacturers thereof. Warranty does not cover replacement of scheduled service items such as oil, filters, tune–up parts, and other high–wear items. The warranty does not cover damages resulting from abuse, accidents, alterations, air flow obstructions, or failure to maintain or use the Melroe product according to the instructions applicable to it.

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES (EXCEPT THOSE OF TITLE), EXPRESSED OR IMPLIED, AND THERE ARE NO WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL THE AUTHORIZED SELLING DEALER OR MELROE BE LIABLE FOR DOWNTIME EXPENSES, LOSS OF MACHINE USE OR OTHER INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES.

6570162 (1–96)

Printed in U.S.A.