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Bobcat 963 Loader Service Manual (SN 516511001-516514999)

Format: PDF (Printable Document)

File Language: English

File Pages: 502

File Size: 25.58 MB (Speed Download Link)

Brand: Bobcat

Model: 963 Loader

Book No: 6724545

Serial No: SN 516511001-516514999

Type of Document: Service Manual

Categories: ,

$ 45

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Bobcat 963 Loader Service Manual (SN 516511001-516514999)

A Bobcat 963 is a big-frame skid-steer that spends its life loading trucks, handling pallets, and running high-flow attachments. The person who reaches for this service manual is the one actually turning wrenches: shop mechanic, field tech, or an owner who's past warranty and wants dealer-level info. They're trying to get accurate specs and step-by-step procedures so the machine goes back out clean, safe, and not coming back on a hook.

What this manual helps you do

  • Diagnose hydraulic and hydrostatic issues, then check pressures and flows against factory specs
  • Trace and repair electrical faults using wiring diagrams and connector callouts
  • Follow teardown and reassembly procedures for the engine, drive motors, and major hydraulic components
  • Adjust, set, and verify chain case, drive controls, linkages, and Bob-Tach so the loader runs straight and lifts true
  • Replace seals, hoses, and wear parts with the right sequences, test steps, and torque references

Who this is for

This manual is for anyone maintaining or repairing a Bobcat 963 loader in the serial range 516511001 through 516514999: small contractors, rental fleets, owner-operators, and independent shops. If you only need basic operating tips, safety info, or daily checks, you want the operator's handbook instead, not this service manual.

FAQ

Q: Is this a searchable PDF, and can you read the wiring diagrams clearly?

A: These manuals are usually scanned or native PDFs that you can search, zoom, and print, and the wiring diagrams are laid out for screen or paper use.

Q: How do I know it fits my exact 963?

A: Check your loader's serial number; if it falls between 516511001 and 516514999, this is the correct service manual family for your machine.

Q: Is this what I need for real repairs, or is it just maintenance?

A: This is the workshop service manual, so it's aimed at diagnostics and full repairs, not just basic maintenance schedules.

Bottom line, if you own or service a 963 in that serial range and you're doing your own repairs, this is the right manual. If your serial is outside that range, don't buy this one.

📘 Show Index

Table of Contents:

  • MAINTENANCE SAFETY
  • ALPHABETICAL INDEX
  • CONTENTS
    • FOREWORD
    • SAFETY INSTRUCTIONS
    • FIRE PREVENTION
    • SERIAL NUMBER LOCATIONS
    • LOADER SERIAL NUMBER
    • ENGINE SERIAL NUMBER
    • DELIVERY REPORT
    • 963 BOBCAT LOADER IDENTIFICATION
  • PREVENTIVE MAINTENANCE
    • SERVICE SCHEDULE
    • LIFTING AND BLOCKING THE LOADER
      • Procedure
    • TRANSPORTING THE LOADER
      • Procedure
    • TOWING THE LOADER
      • Procedure
    • LIFT ARM SUPPORT DEVICE
      • Engaging The Lift Arm Support Device
      • Disengaging The Lift Arm Support Device
    • OPERATOR CAB
      • Description
      • Raising The Operator Cab
      • Lowering The Operator Cab
      • Emergency Exit
    • SEAT BAR RESTRAINT SYSTEM
      • Description
      • Inspecting The Seat Bar
      • Maintaining The Seat Bar
    • AIR CLEANER SERVICE
      • Replacing Filter Elements
    • FUEL SYSTEM
      • Fuel Specifications
      • Filling The Fuel Tank
      • Fuel Filters
      • Removing Air From The Fuel System
    • ENGINE LUBRICATION SYSTEM
      • Checking Engine Oil
      • Replacing The Oil And Filter
    • ENGINE COOLING SYSTEM
      • Checking The Coolant Level
      • Cleaning The Cooling System
      • Replacing The Coolant
    • ALTERNATOR BELT
      • Adjusting The Alternator Belt
    • HYDRAULIC/HYDROSTATIC SYSTEM
      • Checking And Adding Fluid
      • Hydraulic/Hydrostatic Filter Replacement
      • Replacing The Hydraulic Fluid
    • SPARK ARRESTOR MUFFLER
      • Cleaning Procedure
    • TIRE MAINTENANCE
      • Wheel Nuts
      • Tire Rotation
      • Tire Mounting
    • FINAL DRIVE TRANSMISSION (CHAINCASE)
      • Checking And Adding Oil
    • FAN GEARBOX
      • Checking And Maintaining
    • LUBRICATING THE LOADER
      • Procedure
    • BOB–TACH
      • Inspection And Maintenance
    • REMOTE START SWITCH
      • Procedure
  • HYDRAULIC SYSTEM
    • HYDRAULIC / HYDROSTATIC SCHEMATICS
    • TROUBLESHOOTING
    • HYDRAULIC SYSTEM INFORMATION
      • Tighten Procedures
    • LIFT CYLINDER
      • Checking the Lift Cylinder(s)
      • Removal and Installation
    • TILT CYLINDER
      • Checking The Tilt Cylinder(s)
      • Removal And Installation
    • HYDRAULIC CYLINDER
      • Lift Cylinder Parts Identification
      • Tilt Cylinder Parts Identification
      • Disassembly
      • Assembly
    • TILT JUNCTION BLOCK
      • Removal And Installation
    • MAIN RELIEF VALVE
      • Checking Main Relief Valve At Front Auxiliary Hydraulics
      • Checking Main Relief Valve At Control Valve
      • Removal And Installation
      • Adjustment
    • BICS™ VALVE
      • Lift Arm By–Pass Orifice
      • Lock Valve
      • Check Valve
      • BICS™ Valve Solenoid
      • BICS Valve Removal And Installation
    • HYDRAULIC CONTROL VALVE
      • Removal And Installation
      • Identification Chart
      • Disassembly And Assembly
      • Load Check Valve
      • Main Relief Valve
      • Port Relief Valve (Lift Section)
      • Anti–Cavitation/Port Relief Valve
      • Anti–Cavitation Valve
      • Port Relief Valve (Tilt Section)
      • Rubber Boot
      • Lift Spool And Detent
      • Tilt Spool And Centering Spring
      • Auxiliary Spool
      • Auxiliary Electric Solenoid
      • H–Port – Auxiliary Section
      • Inspection
      • Spool Seal Installation
    • LIFT ARM BY–PASS CONTROL VALVE
      • Removal And Installation
      • Disassembly And Assembly
    • BUCKET POSITION VALVE
      • Removal And Installation
      • Disassembly And Assembly
    • HYDRAULIC PUMP
      • Checking the Output of the Pump
      • Removal And Installation
      • Disassembly And Assembly
      • Inspection
    • HYDRAULIC/HYDROSTATIC FILTER
      • Removal And Installation
    • HYDRAULIC FLUID RESERVOIR
      • Draining The Hydraulic Fluid Reservoir
      • Removal And Installation
    • CONTROL PEDALS
      • Removal And Installation
      • Pedal Adjustment
    • PEDAL INTERLOCK LINKAGE
      • Removal And Installation
      • Adjustment
    • FRONT SIDE PANEL
      • Removal and Installation
    • CONTROL PEDALS MOUNTING PANEL
      • Removal and Installation
  • HYDROSTATIC SYSTEM
    • TROUBLESHOOTING
    • HYDROSTATIC SYSTEM INFORMATION
      • Replenishing Valve Function
      • Checking The Charge Pressure
    • CONTROL PANEL
      • Removal And Installation
    • STEERING LEVERS
      • Disassembly And Assembly
    • STEERING LINKAGE
      • Neutral Adjustment
    • HYDROSTATIC CONTROLLER
      • Removal and Installation
      • Disassembly and Assembly
      • Adjustment
    • HYDROSTATIC MOTOR
      • Removal and Installation
      • Throttle Control
      • Shuttle Check Valve
      • Flushing Valve
      • Disassembly
      • Inspection
      • Assembly
    • HYDROSTATIC PUMP
      • Removal And Installation
      • Hydraulic Pump Removal And Installation
      • Replenishing/High Pressure Relief Valve
      • Charge Relief Valve
      • DA Controller
      • Disassembly
      • Inspection
      • Assembly
      • Hydrostatic Pump Start–Up
      • Timing Procedure
    • DRIVE BELT BELT SHIELD
      • Removal And Installation
    • DRIVE BELT
      • Replacing The Drive Belt
      • Adjusting The Drive Belt
    • DRIVE BELT TENSIONER PULLEY
      • Removal And Installation
      • Tension Spring
      • Disassembly And Assembly
      • Pivot Shaft
    • DRIVE BELT IDLER PULLEY
      • Removal And Installation
    • HYDROSTATIC MOTOR COVER
      • Removal And Installation
    • OIL COOLER
      • Removal And Installation
  • DRIVE SYSTEM
    • PARKING BRAKE PEDAL
      • Removal And Installation
      • Disassembly And Assembly
    • BRAKE/TWO SPEED BLOCK
      • Removal And Installation
      • Disassembly And Assembly
    • PARKING BRAKE
      • Removal And Installation
      • Disassembly And Assembly
    • AXLE SEAL
      • Removal And Installation
    • AXLE, BEARINGS AND SPROCKET
      • Removal And Installation
    • DRIVE CHAINS
      • Removal And Installation
    • FRONT CHAINCASE COVER
      • Removal And Installation
    • REAR CHAINCASE COVER
      • Removal and Installation
    • REDUCTION GEARCASE
      • Removal And Installation
      • Disassembly And Assembly
    • CHAINCASE FLUID
      • Removing The Fluid From The Chaincase
  • MAIN FRAME
    • SEAT BAR
      • Removal And Installation
      • Assembling Components
      • Compression Spring Disassembly And Assembly
    • OPERATOR CAB GAS CYLINDER
      • Removal And Installation
      • Gas Cylinder Mounting Bracket
    • OPERATOR CAB
      • Removal And Installation
    • OPERATOR SEAT
      • Removal And Installation
    • BOB–TACH
      • Removal And Installation
      • Bob–Tach Lever And Wedge
      • Bob–Tach Stops
    • LIFT ARMS
      • Removal And Installation
    • REAR GRILL
      • Gas Cylinder Removal And Installation
      • Removal And Installation
    • REAR DOOR
      • Removal And Installation
      • Adjusting The Rear Door Latch
    • FRONT FUEL TANK
      • Removal And Installation
      • Fuel Level Sender
    • REAR FUEL TANK
      • Removal And Installation
      • Pickup Tube Screen
  • ELECTRICAL SYSTEM
    • ELECTRICAL SCHEMATICS
    • TROUBLESHOOTING
    • ELECTRICAL SYSTEM INFORMATION
      • Description
      • Fuse Location
    • RELAY SWITCHES
      • Location
    • BATTERY
      • Removal And Installation
      • Servicing The Electrical System
      • Using A Booster Battery (Jump Starting)
    • ALTERNATOR
      • Alternator Output Test
      • Rectifier (Diode) Test
      • Alternator Regulator Test
      • Removal And Installation
      • Adjusting the Alternator Belt
      • Disassembly
      • Stator Continuity Test
      • Stator Ground Test
      • Rotor Continuity Test
      • Rotor Ground Test
      • Rectifier Continuity (Diode) Test
      • Assembly
    • STARTER
      • Removal And Installation
      • Parts Identification
      • Disassembly And Assembly
      • External Pinion
      • Inspection And Repair
      • Magnetic Switch Test
      • No Load Test
    • STANDARD INSTRUMENT PANEL
      • Removal And Installation
    • FRONT LIGHTS
      • Removal And Installation
  • ENGINE SERVICE
    • TROUBLESHOOTING
    • ENGINE SPEED CONTROL
      • Removal And Installation
    • ENGINE MUFFLER
      • Removal And Installation
      • Exhaust Extension Pipe
    • AIR CLEANER HOUSING
      • Removal And Installation
    • COOLANT RECOVERY TANK
      • Removal And Installation
    • RADIATOR
      • Removal And Installation
    • FAN DRIVE TENSION PULLEY
      • Removal And Installation
    • FAN GEARBOX/BLOWER HOUSING
      • Removal And Installation
    • BLOWER FAN
      • Removal And Installation
    • FAN GEARBOX
      • Disassembly
      • Assembly
      • Checking Backlash
    • FLYWHEEL
      • Removal And Installation
      • Ring Gear Removal
      • Ring Gear Installation
    • ENGINE MOUNTING BRACKET
      • Removal and Installation
    • VALVE CLEARANCE
      • Adjustment
    • FUEL LIFT PUMP
      • Checking
      • Removal And Installation
    • FUEL INJECTION PUMP
      • Removal And Installation
    • FUEL INJECTOR NOZZLES
      • Removal and Installation
      • Checking
    • ENGINE
      • Removal And Installation
    • INTAKE MANIFOLD
      • Removal and Installation
    • EXHAUST MANIFOLD
      • Removal and Installation
    • CYLINDER HEAD
      • Removal
      • Inspection
      • Installation
    • ROCKER SHAFT
      • Disassembly And Assembly
    • VALVES, VALVE GUIDES AND SPRINGS
      • Valve Removal
      • Checking Valve Springs
      • Checking Valve Depth
      • Checking Valve Guides
      • Valve Guide Removal
      • Valve Guide Installation
      • Checking Valves
      • Cutting A Valve Seat
      • Assembly
      • Changing Valve Springs (With Cylinder Head Installed)
    • TIMING CASE AND DRIVE ASSEMBLY
      • Description
      • Timing Cover Removal
      • Timing Cover Installation
      • Front Oil Seal Removal
      • Front Oil Seal Installation
      • Timing Case And Gear Removal
      • Timing Case And Gear Installation
    • CAMSHAFT AND TAPPETS
      • Removal
      • Installation
    • PISTONS AND CONNECTING RODS
      • Description
      • Removal
      • Disassembly
      • Piston Ring End Gap
      • Piston Ring Installation
      • Piston Ring Groove Clearance
      • Connecting Rod Inspection
      • Connecting Rod Bushing Replacement
      • Assembly
      • Installation
      • Checking Piston Height
    • CRANKSHAFT AND BEARINGS
      • Description
      • Removal
      • Inspection Of Crankshaft And Bearings
      • Installation
      • Rear Oil Seal Removal
      • Rear Oil Seal Housing Positioning
      • Rear Oil Seal Installation
      • Checking Crankshaft End Play
    • COOLING SYSTEM
      • Description
      • Thermostat Removal and Installation
      • Thermostat Testing
      • Water Pump Removal
      • Water Pump Installation
    • ENGINE OIL COOLER
      • Removal and Installation
      • Disassembly and Assembly
    • LUBRICATION SYSTEM
      • Description
      • Oil Filter Adapter Removal
      • Oil Filter Adapter Installation
      • Oil Pan Removal And Installation
      • Oil Screen And Pick–up Tube
      • Oil Pump Removal
      • Oil Pump Installation
      • Oil Pump Disassembly And Assembly
      • Oil Pressure Relief Valve Disassembly And Assembly
    • ENGINE BLOCK
      • Description
      • Disassembly And Assembly
      • Piston Cooling Jet Removal
      • Piston Cooling Jet Installation
      • Piston Cooling Jet Alignment
      • Inspection
      • Cylinder Liner Inspection
      • Cylinder Liner Removal
      • Cylinder Liner Installation
    • TURBOCHARGER
      • Troubleshooting
      • Description
      • Removal and Installation
  • SYSTEMS ANALYSIS
    • BICS™ (With Press To Operate Button)
      • Inspecting The BICS™ Controller (Engine STOPPED – Key ON)
      • Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)
      • Inspecting The Seat Bar Sensor (Engine RUNNING)
      • Inspecting The Traction Lock (Engine RUNNING)
      • Inspecting The Lift Arm By–Pass Control
      • Additional Inspection For Advanced Hand Controls
      • Troubleshooting Chart
    • BICS™ (Without Press To Operate Button)
      • Inspecting The BICS™ Controller (Engine STOPPED – Key ON)
      • Inspecting Deactivation Of The Auxiliary Hydraulics System (Engine STOPPED – Key ON)
      • Inspecting The Seat And Seat Bar Sensors (Engine RUNNING)
      • Inspecting The Traction Lock (Engine RUNNING)
      • Inspecting The Lift Arm By–Pass Control
      • Maintenance
      • Troubleshooting Chart
    • SEAT SENSOR OVERRIDE ONLY (If Equipped)
    • BICS™ SYSTEM CONTROLLER
      • Troubleshooting Guide
      • Removal And Installation
    • SEAT BAR SENSOR
      • Troubleshooting Guide
      • Seat Bar Sensor Test
      • Removal And Installation
      • BICS™ Controller Seat Bar Sensor Circuit Test
    • SEAT SENSOR
      • Troubleshooting Guide
      • Seat Sensor Test
      • Removal And Installation
      • BICS™ Controller Seat Sensor Circuit Test
    • TRACTION LOCK
      • Troubleshooting Guide
    • BOSS® DIAGNOSTIC TOOL
      • Procedure
    • SENDER AND SENSOR
      • Service Checks
      • Components
      • Adjustment
    • MONITOR SERVICE CODES
    • TROUBLESHOOTING THE BOSS® & LCD DISPLAY
    • BOSS® UNIT
      • Removal and Installation
    • BOSS® INSTRUMENT PANEL
      • Removal and Installation
    • PWM MODULE
      • Description
    • PWM TROUBLESHOOTING
      • Conditions
      • Chart
    • PWM CONTROL HANDLE
      • Handle Testing
    • PWM ELECTRIC SOLENOID
      • Solenoid Coil Testing
    • ELECTRICAL/HYDRAULIC CONTROLS REFERENCE
      • Controls Identification Chart
  • SPECIFICATIONS
    • LOADER SPECIFICATIONS
      • Performance
      • Controls
      • Engine
      • Hydraulic System
      • Electrical
      • Drive System
      • Capacities
      • Tires
    • ENGINE SPECIFICATIONS
      • General
      • Cylinder Head
      • Valve Guides
      • Exhaust Valves
      • Intake Valves
      • Valve Springs
      • Rocker Shaft, Rockers And Bushings
      • Pistons And Piston Rings
      • Connecting Rods And Bearings
      • Crankshaft
      • Crankshaft Re–Grind Data
      • Main Bearings
      • Thrust Washers
      • Camshaft And Thrust Washer
      • Cylinder Block
      • Cylinder Liners
      • Fuel Injection Pump
      • Fuel Injectors
      • Fuel Lift Pump
      • Timing Case And Timing Gears
      • Oil Pump, Gear And Relief Valve
      • Turbocharger
      • Flywheel
      • Water Pump And Thermostat
      • Engine Torque
    • LOADER TORQUE
    • TORQUE SPECIFICATIONS FOR BOLTS
      • Torque For General SAE Bolts
      • Torque For General Metric Bolts
    • HYDRAULIC CONNECTION SPECIFICATIONS
      • O–ring Face Seal Connection
      • Straight Thread O–ring Fitting
      • Tubelines And Hoses
      • Flare Fitting
      • O–ring Flare Fitting
      • Port Seal Fitting
    • HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
    • DECIMAL AND MILLIMETER EQUIVALENTS
    • U.S. TO METRIC CONVERSION
  • ADVANCE HAND CONTROL SYSTEM (A.H.C)
    • A.H.C. COMPONENTS
      • Identification
    • TROUBLESHOOTING (A.H.C.)
    • ACTUATOR VOLTAGE TEST
      • Procedure
    • HANDLE CONTROL UNIT TEST
      • Procedure
    • BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)
      • Troubleshooting Chart
    • SEAT SENSOR OVERRIDE ONLY
    • ADVANCED HAND CONTROLS (AHC)
    • A.H.C./PWM CONTROLLER
      • Removal and Installation
      • Description
      • Conditions
      • Troubleshooting Chart
      • Handle Testing
      • Solenoid Coil Testing
    • HANDLE CONTROL UNIT
      • Removal And Installation
      • Control Unit Connector
    • SWITCH HANDLE
      • Removal and Installation
    • A.H.C. HANDLE
      • Removal and Installation
      • Disassembly and Assembly
    • A.H.C. STEERING LEVER
      • Removal and Installation
      • Steering Lever Boot
      • Disassembly and Assembly
    • BICS™ VALVE
      • Lift Arm By–Pass Orifice
      • Check Valve
      • Lock Valve
      • BICS™ Valve Solenoid
      • Removal and Installation
    • HYDRAULIC CONTROL VALVE
      • Removal And Installation
      • Mounting Plate
      • Identification Chart
      • Disassembly and Assembly
      • Load Check Valve
      • Main Relief Valve
      • Port Relief Valve (Lift)
      • Anti–Cavitation/Port Relief Valve
      • Port Relief Valve (Tilt)
      • Anti–Cavitation Valve
      • Rubber Boot
      • Lift and Tilt Spool
      • Inspection
      • Auxiliary Spool
      • Auxiliary Electrical Solenoid
      • H–Port Auxiliary Section
      • Spool Seal Installation
  • SERVICE MANUAL REVISIONS
    • 963–1
    • 963–2
    • 963–3
    • 963–4
    • 963-5

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