Bobcat 963 BICS SM 04670

Service
Manual
EQUIPPED WITH MELROE
BOBCAT INTERLOCK
INGERSOLL~AND
CONTROL SYSTEM (BICSTM) 6724545(11-97) Printed in U.S.A. © Melroe Company 1997
MAINTENANCE SAFETY
Instructions are necessary before gperating or servicin~ machine. Read
and understand the Op'eration & Maintenance Manuar, Handbook and
signs (decals) on machine. Follow warnings and Instructions in the
manuals when making repairs, adjustmenrs or servicing. Check for
correct function after adiustments, repairs or service. Untrained
operators and failure to folrow instructions can cause injury or death.
W-2003-0199
A Safety Alert Symbol: This symbol with a warning statement, means: "Warning, be alert I Your safety is
involved!" Carefully read the message that follows.
Ir---,-..--~-O-R-R-E-CT--'I I ~RRECTI
Ir---~'\-~-~~~-
\ t-/~-R-R-E-CT--'I ,-/_,-
8-10731 8-12365 8-7469

A Never service the Bobcat® Skid A Use the correct procedure to lift or A Cleaning and maintenance are
Steer Loader without lower operator cab. required dally.
Instructions.
WRONG
8-11799 8-15231 8-15280

A Have good ventilation when
A welding or grinding painted parts.
A Disconnecting or 100senin9. any
hydraulic tubellne, hose, fItting,
A Never work on loader with 11ft
arms up unless lift arms are held
. . Wear dust mask When grinding component or a part failure can by an approved lift arm support
painted parts. Toxic dust and gas cause 11ft arms to drop. Do not go device. Replace if damaged.
A can be produced.
.. Avoid exhaust fume leaks which
under lift arms when raised
unless supported by an approved
A Never modify eqUipment or add
attachments not approved by
can kill without warning. Exhaust 11ft arm support device. Replace If Melroe Company.
system must be tightly sealed. damaged.
v~ 1 WRONG WRONG
.~·~V
\\~.(~
8-6590 8-6589
A Stop, cool and clean engine of A Keep body, Jewelry and clothing A Lead-acld batteries produce
flammable materials before away from moving parts, A flammable and explosive gases.
checking fluids. electrical contacts, hot parts and . . Keep arcs, sparks, flames and
A Never service or adjust loader
with the engine running unless A
exhaust.
Wear eye protection to guard
lighted tobacco away from
batteries.
A Instructed to do so In the manual. from battery acid, compressed A Batteries contain acid which
a. Avoid contact with leaking springs, fluids under pressure burns eyes or skin on contact.
hydraulic fluid or diesel fuel and flying debris when engines Wear protective clothing. If acid
under pressure. It can penetrate are running or tools are used. Use contacts body, flush well with
A the skin or eyes. eye protection approved for type water. For eye contact flush well
a. Never fill fuel tank with engine of welding. and get Immediate medical
running, while smoking or wllen A Keep rear door closed except for attention.
near open flame. service. Close and latch door
before operating the loader.
Maintenance procedures which are !;liven in the Operation & Maintenance Manual can be perlormed by
the owner/operator without any specific technical training. Maintenance procedures which are not in the
Operation & Maintenance Manual must be perlormed ONLY BY QUALIFIED BOBCAT SERVICE
PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course
is available from your Bobcat dealer. MSW01~99
ALPHABETICAL INDEX
ACTUATORS . ............ . ... . .. .. . ....... . . 10-1

ELECTRICAUHYDRAULIC CONTROL REF. ...... 8-1
ACTUATOR VOLTAGE TEST . ..... . . . . .. .... .. 10-1

ELECTRICAL SYSTEM INFORMATION . .. . . . .... 6-1
A.H.C . COMPONENTS . .. .......... . . .. ...... 10-1

ENGINE .. ... .... .. .. ..... . .. .. . . . ... ...... .. . 7-1
A.H .C'/PWM CONTROLLER ... . .. ... . .. ...... 10-1

ENGIt\IE BLOCK .. . . . ..... .... . . . . . .. . .. . ... ... 7-1
ENGINE COOLER . .. . . ... . . ........ . ... .... .. . 7-1
A.H .C. HANDLE .. .. .. .. ...... . . .. .... . . .. ... 10-1

ENGINE COOLING SYSTEM .... . ... .... . .. ..... 1-1
A.H.C . STEERING LEVER .. . . . . . . . .... . . .. . .. 10-1

ENGINE LUBRICATION SYSTEM .. . .. ..... ... ... 1-1
AIR CLEANER HOUSING .. . .. . ... . . . .. . . . ... .. 7-1

ENGINE MUFFLER . ... . . . ... .. . . . .. ....... . .. . 7-1
AIR CLEANER SERVICE . . . . . . .... .. ...... . . . . 1-1

ENGINE MOUNTING BRACKET . ... . .... . .. . ... . 7-1
ALTERNATOR .. ... ...... . . . .. . .. ... . . ........ 6-1

Et\IGINE OIL COOLER ..... . . . ...... . ... . . .. . ... 7-1
ALTERNATOR BELT .. .... ... . . ..... . . . ..... .. 1- 1

ENGINE SPEED CONTROL ..... . .. ... ....... . . . 7-1
AXLE SEAL .. ...... . . .. . . ... .. ....... . . ...... 4-1

ENGINE SPECIFICATIONS . .. ... . . . .. .. .... . . .. 9- 1
EXHAUST MANIFOLD .. ...... . . .............. .. 7-1
AXLE, BEARINGS AND SPROCKET ...... . . . ... 4-1
FAN DRIVE TENSIOt\1 PULLEY .. . . . ....... . ..... 7-1
BATTERY .... .. . . .. . ..... . . .... .. . ...... . ... . 6-1

FAN GEARBOX . . ... ..... ....... ... ... . .. 1-1 & 7-1
BICSTM .. . ...... .. ...... .. . .. ...... . ... .. 8-1 , 10-1

FAN GEARBOX/BLOWER HOUSING . . ..... . . . . . 7-1
BICSTM SYSTEM CONTROLLER .... . .. . . . ..... . 8-1

FINAL DRIVE TRANSMISSION (CHAINCASE) ... . 1-1
BICSTM VALVE .. . . .... . . ... .. .... .. . . .. .. 2-1,10-1

FLYWHEEL .... .. . . . . . . ... . . . . . .... ... .... . ... 7-1
BLOWER FAN ... .... ... .... .... .... .. . .. ... .. 7-1
FRONT CHAINCASE COVER ........... . .. . .... 4-1
FRONT FUEL TANK .. .. . ........ . .. ...... . . .... 5-1
BOB-TACH . ... ........... . . . . . ...... .. . ... .. 5-1

FRONT LIGHTS .... . ... ....... ..... .. .. . . .... . 6-1
BOSS DIAGNOSTIC TOOL ........... . . ... . . .. 8-1

FRONT SIDE PANEL .. .... .... .... ...... .. .. . . . 2-1
BOSS INSTRUMENT PANEL ... . .. ..... ... ..... 8-1

FUEL INJECTOR NOZZLE . .. ............ ... . .. . 7-1
BOSS UNIT .. . . . . . .... ..... . . . ..... . . ... . . . . . 8-1

FUEL INJECTION PUMP ... ...... ... . .. . .. . .. .. 7-1
BRAKEfTWO SPEED BLOCK . . .... . . .. ... .. . . . 4-1

FUEL LIFT PUMP ....... .. . ...... . . . . .. .... . . . . 7-1
BUCKET POSITION VALVE ........ . . .... . . . . . . 2-1

FUEL SYSTEM . . .. ........ ... . . . .. .. . . ........ 1-1
HANDLE CONTROL UNIT . ................ . .. . 10-1
CAMSHAFT AND TAPPETS ... ... . ...... . ...... 7-1
HANDLE CONTROL UNIT TEST . . . . .. .... . . .... 10- 1
CHAINCASE FLUID ... . ...... . . .. ...... . . .. . . . 4-1

HYDRAULIC CONTROL VALVE . . ..... . ... 2-1, 10-1
COOLANT RECOVERY TANK .. ..... . . ... ... .. . 7-1

HYDRAULIC CONNECTION SPECIFICATONS . .. . 9-1
COOLING SYSTEM . . . .. ... ...... .... ..... . . . . 7-1

HYDRAULIC CYLINDER ... . . .... ... . ........ . . . 2-1
CONTROL PANEL . ....... ... .. ... . . . . ...... .. 3-1

HYDRAULIC/HYDROSTATIC FILTER . . . . ... .. .. .. 2-1
CONTROL PEDALS . . ...... .... ...... .. ....... 2-1

HYDRAULIC/HYDROSTATIC FLUID SPEC . . ..... . 9-1
CONTROL PEDALS MOUNTING PANEL . . .. .... 2-1

HYDRAULIC FLUID RESERVOIR .... . .. .. ....... 2-1
CRANKSHAFT AND BEARINGS ... ...... ... . . .. 7-1

HYDRAULIC PUMP .. ... ...... ... ..... . .. . .. .. . 2-1
HYDRAULIC SYSTEM INFORMATION ... . .... . .. 2-1
CYLINDER HEAD . . .. . ... ....... . . . . . .. . ...... 7-1

HYDRAULIC/HYDROSTATIC SySTEM ...... . .... 1-1
HYDROSTATIC CONTROLLER .... ..... . .. . . . . .. 3-1
DECIMAL & MILLIMETER EQUiVALENTS . .. . . . . 9-1

HYDROSTATIC MOTOR .... . .... .... . .. . ....... 3-1
DRIVE BELT .... ... . ... ... .. .... ......... .. .. 3-1

HYDROSTATIC MOTOR COVER ... .... . .... . . . . 3-1
DRIVE BELT IDLER PULLEY . .. .. .... .......... 3-1

HYDROSTATIC PUMP .................. ...... .. 3-1
DRIVE BELT SHIELD .. ....... ...... ...... . .... 3-1

HYDROSTATIC SYSTEM INFORMATION . ... . . ... 3-1
DRIVE BELT TENSIONER PULLEY ...... .. .. . .. 3-1
INTAKE MAINIFOLD .... ...... . . . . ... ... .. ..... 7-1
DRIVE CHAINS ........ . . . ... .. . . . ....... .. ... 4-1
LIFT ARMS . . ... ... ...... . . .. . . .. .... ...... .. .. 5-1
LIFT ARM BY-PASS CONTROL VALVE . .... ... .. 2-1
LIFT ARM SUPPORT DEVICE . ........ .. ..... . . . 1-1
LIFT CYLINDER(S) . ......... ... .. . . . ... . . . ..... 2-1
LIFTING AND BLOCKING THE LOADER .. . ... . . . 1-1
LOADER SPECIFICATIONS ....... ....... . .. .. .. 9-1
LOADER TORQUE ..... . .. ..... . . . ... ... ....... 9-1
LUBRICATING THE LOADER ..... . .. ... ..... . .. 1-1
LUBRICATION SySTEM .... . ... .. .. . ....... . . . . 7-1
MAIN RELIEF VALVE . ....... ... .... ... . . . ..... . 2-1
A.H.C.-ADVANCED HAND CONTROL SYSTEM MONITOR SERVICE CODES . . . .. .... .. . ... .... . 8-1
BICS--BOBCAT INTERLOCK CONTROL SYSTEM

BOSS-BOBCAT OPERATION SENSING SYSTEM
PWM-PULSE WITH MODULATION
Cont'd On Next Page
Revised Mar. 99
ALPHABETICAL INDEX (Cont'd)
OIL COOLER . . .... . .... .. ... .. . ... .... ... ... . 3-1
OPERATION SENSING SYSTEM UNIT ... ..... . . 8-1
OPERATOR CAB ......... . ... .. . ... .. . . 1-1 & 5-1
OPERATOR CAB GAS CyLINDER ... . ... .. . 0 . 0 0 5-1
OPERATOR SEAT . 0 0 0 0 0 0 0 0 0 0 0 0 0 • 0 0 0 •• 0 0 0 0 • 0 0 0 5-1
PARKING BRAKE 0 0 0 0 0 •• 0 0 •• 0 0 0 0 0 0 0 0 • • 0 • 0 0 • 0 0 0 4-1

PARKING BRAKE PEDAL 0 0 0 • 0 0 0 0 0 0 0 0 0 • 0 0 0 0 0 0 0 0 4-1
PEDAL INTERLOCK LINKAGE . . 0 0 0 0 00. 000 0 0 0. 0 2-1
PISTONS AND CONNECTII\lG RODS 000. 0 0 o. o. 0 7-1
PWM CONTROL HANDLE 0 0 0 0 0 0 0 0 • 0 • 0 0 0 0 0 0 • • 0 0 8-1
PWM ELECTRIC SOLENOID o. 0 0 ' 0 0 0 0 o. 0 0 0.00 00 8-1
PWM MODULE 0 00 00000 0 00. 0 •• 0 • 0 • 0 • • 0 0 0 0 • • 0 0 0 8-1
PWM TROUBLESHOOTING 00.0000 •• • 0000 00 000 8-1
RADIATOR 00 00 0 00. 0 0 00. 0 0 0 00 .0 0 000 0 . 0 0 0 • 0 • 0 0 0 7-1

REAR CHAINCASE COVER 0 0 • 0 0 0 • 0 •• 0.00 000 00 0 4-1
REAR DOOR o. 0 0 0 • 0 0 0 •• 0 0 0 0 0 0 0 0 .0 0000 0 0 0 •• 0 0 0 5-1
REAR FUEL TANK 00 00 0. 0 0 0 0 0 000 00 000 0 . 0 0 0 • 0 0 0 5-1
REAR GRILL 00. 0 . 0 0 0 0 • 0 0 0 0 o. 0 0 • 0 0 . 0 0. 0 0 • • 0 0 0 0 5-1
REDUCTION GEARCASE 0 0 • 0 0 0 0 0 • 0 0 0 0 0 0 0 0 0 0 0 0 4-1
RELAY SWITCHES 00 0 0 0 00 0 00 00 000 00 0000 0. 0 0 0 0 6-1
REMOTE START SWITCH 0 0 00 00 0 00 . 0 0 • 0 0 0 0 0 0 0 0 1-1
ROCKER SHAFT 0 00 00 0000 000 00 000 00 0 0 0 0 0000 0 0 7-1
RPM SENSOR 0 0 0 0 0 0 0 0 0 0 0 0 0 0 • 0 0 0 0 0 0 • 0 0 0 0 0 0 0 0 0 0 8-1
SEAT BAR 0 0 0 0 0 0 0 0 • 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 • 0 0 0 0 5-1

SEAT BAR RESTRAINT SYSTEM 0 0 0 00 0 0 00 000 0 00 1-1
SEAT BAR SENSOR 0 0000 0 00 0 .0 . 0 0 000 0000 0000 0 8-1
SEAT SENSOR 00000 0 000000 0 0000 0 000 0 000000000 8-1
SENDER AND SENSOR. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 00000 8-1
SERVICE CODES 0 00000000 0 0 0000 . 0 00 0 00 00 00000 8-1
SERVICE SCHEDULE 0 0 0 0000 0 0000000 00 00000000 1-1
STANDARD INSTRUMENT PANEL 0 0 00000. 0 0 0 0 0 0 6-1
STARTER 00 000 000000 0. 0000 0 00000000000 0 000 0 00 6-1
STEERING LEVERS 00 0 00 0 0 . 0 0 0 0 0 0 0 0000 0 000000 3-1
STEERII\lG LINKAGE 0 0 0 0 • 0 0000000 000 000000 0 000 3-1
SWITCH HANDLE 00000 00 000000 0. 0 0 0 0 0 0 0 0 0 0 0 0 10-1
SYSTEM ANALYSIS 0000000.0000 0 00 0 0 00000 .0 000 8-1
TILT CYLINDER(S) 2-1 0 00000000 • • 0 0 0 0 0 0 0 0 0 0 0 0 00000
TILT JUNCTION BLOCK 2-1 0000 0 00000 0 000.0000 0000
TIMING CASE AND DRIVE ASSEMBLY 7-1 00 00 00000
TIRE MAINTENANCE 1-1 0 0000000000000 0 000000000 0
TOWING THE LOADER 1-1 0 0000 0 0000 0 0000 0 0000000
TRACTION LOCK 08-1 0 0 0 0 0 0 0 0 • 0 0 • 0 0 0 0 0 0 0 0 0 0 0 • 0 0 0 0
TRANSPORTING THE LOADER 1-1 000000000000000 0
TROUBLESHOOTING 2-1,3-1,6-1,7-1 & 8-1 00. 0 0 0
TROUBLESHOOTING (A oHoC o) 10-1 0000 000000000 000
TURBOCHARGER . 7-1 0 0 0 0 0 0 .0 0000 0 0000. 0 00 0 0. 0 0 0
VALVE CLEARANCE 00 0000 0 00 000 . 0000 0. 0 0 0 0000 7-1

VALVE , VALVE GUIDE AND SPRINGS 0 000000000 7-1
UoSo TO METRIC CONVERSION 0 0 0 0 0 0 0 00 000 00 00 9-1
Revised Mar. 99
CONTENTS
PREVENTIVE
MAINTENANCE
FOREWORD .. .. .. ....... . ...... . .... .. ...... . .... ... ........ . . . . . ii
SAFETY INSTRUCTIONS . ........... .. . ........................ . ... v
SERIAL NUMBER LOCATIONS ..... .. . . . . ........ . . . ......... . .. . .. vii
DELIVERY REPORT . . ... . . . ...... . .... . ...... .. .......... ... ..... vii
BOBCAT LOADER IDENTIFICATION .......... ... .. . ........ .. . . .... viii

HYDRAULIC
PREVENTIVE MAINTENANCE . ... ... . ....... . .. . ......... . . . ..... 1-1
SYSTEM
HYDRAULIC SYSTEM ........ ... . . ................ . ..... . ....... . 2-1
HYDROSTATIC SySTEM .... . ...... .. ... . . .. ........ ... .......... 3-1
DRIVE SYSTEM ......... . . .. .......... ... ...................... . 4-1
MAIN FRAME .......... .. . .. . ....... ... . .. ....... ... . . ... . .... . . 5-1
HYDROSTATIC
ELECTRICAL SYSTEM ...... . ......... . ........... . .......... . ... 6-1
SYSTEM
ENGINE SERVICE .. . . . ........ . . . . . ........... .. ............ . ... 7-1
SYSTEM ANALYSIS . . .. .......... .. ................. . ............ 8-1
SPECiFiCATIONS .. . ............. . ...... . ... . . . ..... .. .... . ...... 9-1
ADVANCED HAND CONTROL SYSTEM .. . ..... . ......... . . ...... 10-1

DRIVE
SYSTEM
CALIFORNIA
MAIN
PROPOSITION 65 WARNING
FRAME
Diesel engine exhaust and some of its
constituents are known to the State of California
to cause cancer, birth defects and other
reproductive harm.
ELECTRICAL
SYSTEM
ENGINE
SERVICE
SYSTEMS
ANALYSIS
SPECIFICATIONS
ADVANCED
HAND CONTROL
SYSTEM
Revised Mar. 99 963 Bobcat Loader

Service Manual
FOREWORD
This manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment
procedures for the Bobcat loader and its component parts and systems. Refer to the Operation &
Maintenance Manual for operating instructions, starting procedure, daily checks, etc.
A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS

OJI
9. The parking brake
function correctly.
must
(Including sidescreens) is in • •
good condition and is not .
modified. !
2. Check that ROPS mounting 10. Enclosure door latches must
~ £8
hardware is tightened and is open and close freely.
Melroe approved.
3. The seat belt must be correctly 11 . Bob-Tach wedges and

~.~
ma
installed, functional and in linkages must function

good condition. correctly and be in good
~ condition.
4. The seat bar and pedal

interlocks must be correctly
adjusted, clean and lubricated.
,I"'J1l
~'\ ~I
\oj
12. Safety treads must in good
condition.
.~:;r
...'.~.
./~.~,
A.
-=,f..'
.~
f':
5. Check lift arm support device, 13. Check for correct function of
replace if damaged.
~ indicator lamps (Optional on

some models).
~
~
CD
6. Machine signs must be legible 14. Check hydraulic fluid level,

and in the correct location. engine oil level and fuel supply. ~ ®
jtl-r
•"
-r-
-r
7. Steering levers and foot pedals 15. Inspect for fuel, oil or hydraulic
must return to neutral. fluid leaks.
~~
8. Check for correct function of 16. Lubricate the loade~
~
the work lights.
/III,

963 Bobcat Loader

Revjsed Mar. 99 ii Service Manual
17. Check the condition of the
battery and cables.
IL=J\
l c=J )
18. Inspect the air cleaner for

damage or leaks. Check the
101\
condition of the element. \:iV
,n
I-.,i ~.
~j
~9
19. Check the electrical charging
system. <9
" fJ
- (""\\'
~, !
20. Check tires

pressure.
for wear and
&
(()~
~~...f
~
-- -
. - -
~
21 . Inspect for loose or broken
parts or connections.
22 . Operate the loader and check "U))))J))))III)))))))1I J}...
;
))))))Jl )))l )l ))j}})~
all functions.
;:
23. Check for any field ~

modification not completed . ~vQ~~
«" CJ'?
~~"
~o
24. Check for correct function of

the Bobcat Interlock Control
System (BICSTM ) before the
machine is returned to the
customer.
Recommend to the owner that all

necessary corrections be made
•
t
before the machine is returned to
service.
963 Bobcat Loader

Revised Mar. 99 iii Service Manual
ItmucV\l aOll\Jas I\!
Japeol le:>q o 8 £96
SAFETY INSTRUCTIONS
A WARNING
Instructions are necessary before operating or servicing machine. Read and understand the Operation &
Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the
manuals when making repairs, adjustments or servicing. Check for correct function after adjustments,
repairs or service. Untrained operators and failure to follow instructions can cause injury or death.
W-2003-0299
The following publications provide information on the safe use and maintenance of the loader and attachments:
• The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine
is in safe operating condition .
• The Operation & Maintenance Manual delivered with the loader gives operating information as well as routine
maintenance and service procedures. It is a part of the loader and must stay with the machine when it is sold. Replacement
Operation & Maintenance Manuals can be ordered from your Bobcat loader dealer.
• The loader has machine signs (decals) which instruct on the safe operation and care . The signs and their locations are
shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat loader dealer.
• The loader has a plastic Operator's Handbook fastened to the operator cab. Its brief instructions are convenient to the
operator. The Handbook is available from your dealer in an English edition or one of many other languages. See your
Bobcat dealer for more information on translated versions.
• The EMI Safety Manual (available in Spanish) delivered with the loader gives general safety information.
• The Service Manual and Parts Manual are available from your dealer for use by mechanics to do Shop-type service and
repair work.
• The Skid-Steer Loader Operator Training Course is available through your local dealer. This course is intended to provide
rules and practices for correct operation of the Bobcat loader. The course is available in English and Spanish version.
• The Service Safety Training Course is available from your Bobcat dealer. This course provides information for safe and
correct service procedures for Bobcat Skid-Steer loaders.
• The Bobcat Skid-Steer Loader Safety Video is available from your Bobcat Dealer.
AWARNING
IMPORTANT
Warnings on the machine and in the This notice identifies procedures

manuals are for your safety. Failure to which must be followed to avoid
obey warnings can cause injury or damage to the machine.
death. 1-2019-0284
W-2044-1285
• Safety Alert Symbol: This symbol with a warning statement, means: "Warning, be alert! Your safety is
involved!" Carefully read the message that follows.
S105-{)299
963 Bobcat Loader

v Service Man ual
FI RE 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].
SI04-0398
963 Bobcat Loader

vi Service Manual
SE RIAL NUMBER LOCATIONS
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 xxxxx
L Module 2. - Production
Sequence (Series)
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
The serial number is on the engine block just above the

fuel injection pump [B].
DELIVERY REPORT
The Delivery Report must be filled out by the dealer and

c DELIVERY REPORT
~
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]. ==
963 Bobcat Loader

vii Service Manual
963 BOBCAT LOADER IDENTIFICATION
OPERATOR SEAT
SEAT BAR
GRAB
HANDLES ::: ~.'.'.'~ .:u
STEERING ~ ';; ,. , \ r
LEVERS
TII_T CYLIN DERS
t BUCKET ..."
AUXILIARY HYDRAULIC
BUCKET STEPS QUICK COUPLERS
• OPERATOR CAB
/ (ROPS & FOPS)
n ~ ~-
, -_-
. -
REAR GRILL :~ ~- . / ../ • .
TAIL LIGHTS
REAR DOOR
TIRES* 8-15004
8-15005
* TIRES - Flotation tires (optional) are shown. The Bobcat loader is factory equipped with standard tires.
t 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 J1 040 and ISO 3471 ,
and Falling Object Protective Structure per SAE J1 043 and ISO 3449, Levell. Level II 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).
963 Bobcat Loader

Revised Mar. 99 viii Service Manual
PREVENTIVE MAINTENANCE
PREVENTIVE
Page MAINTENANCE
Number
AIR CLEANER SERVICE
Replacing Filter Elements 1-13
ALTERNATOR BELT
Adjusting The Alternator Belt ................................... 1-20
BOB-TACH
Inspection And Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-28
ENGINE COOLING SYSTEM
Cleaning The Cooling System .................................. 1-18
Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-18
Replacing The Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-19
ENGINE LUBRICATION SYSTEM
Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-17
Replacing The Oil and Filter .................................... 1-17
FAN GEAR BOX
Checking And Maintaining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-25
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-25
FUEL SYSTEM
Filling The Fuel Tank .......................................... 1-15
Fuel Filters ................................................... 1-16
Fuel Specifications ............................................ 1-15
Removing Air From The Fuel System ............................ 1-16
HYDRAULIC/HYDROSTATIC SYSTEM
Checking And Adding Fluid ..................................... 1-21
Hydraulic/Hydrostatic Filter Replacement. . . . . . . . . . . . . . . . . . . . . . . .. 1-21
Replacing The Hydraulic Fluid .................................. 1-22
LIFT ARM SUPPORT DEVICE
Disengaging The Lift Arm Support Device ........................ 1-8
Engaging The Lift Arm Support Device ........................... 1-7
LIFTING AND BLOCKING THE LOADER
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-4
LUBRICATING THE LOADER
Procedure .................................................... 1-26
OPERATOR CAB
Description ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-9
Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-11
Lowering The Operator Cab .................................... 1-10
Raising The Operator Cab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-9
REMOTE START SWITCH
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1-29
Continued On Next Page

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

-1-2- Service Manual
SERVICE SCHEDULE
Chart
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat loader.
Instructions are necessary before operating or servicing machine. Read

and understand Operation & Maintenance Manual, Handbook and signs
(decals) on machine. Follow warnings and instructions in the manuals
when making repairs, adjustments or servicing. Check for correct
function after adjustments, repairs or service. Untrained operators and
failure to follow instructions can cause injury or death.
W-2003--Q199
SERVICE SCHEDULE
ITEM SERVICE REQUIRED
level
Lift Arms, Cylinders, Bob

Lubricate with mUlti- purpose lithium based grease (14 places) .
Tach Pivot Pins & Wed
Seat Belt, Seat Bar and

heck the condition of seat belt. Check the seat bar and pedal
Pedal Interlocks
interlocks for correct operation. Clean dirt and debris from moving
Bobcat Interlock Control
nut torque every 8 hours for the first 24 hours.

• Also replace hydrauliclhydrostatic filter element when the transmission warning light comes ON.
• Or every 12 months.
* Check every 8 hours for the first 40 hours of operation.
t First oil and filter change must occur at 50 hours.
963 Bobcat Loader

A
A WARNING
Instructions are necessary before operating or

servicing machine. Read and understand the
Operation & Maintenance Manual, Handbook
and signs (decals) on machine. Follow
warnings and instructions in the manuals when
making repairs, adjustments or servicing.
Check for correct function after adjustments,
repairs or service. Untrained operators and
failure to follow instructions can cause injury
or death. W-2003-0299
LIFTING AND BLOCKING THE LOADER
Procedure
8--07023
Always park the loader on a level surface.
A WARNING
Put jackstands under the front axles and rear

corners of the frame before running the engine
for service. Failure to use jackstands can allow
the machine to fall or move and cause injury or
death.
W-2017"'()286
Stop the engine. Put the floor jack under the rear of the
loader. Lift the rear of the loader and install jackstands
[B].
N-15440
Put the floor jack under the front of the loader. Lift the front
-
of the loader and install jackstands under the axle tubes
[C].
NOTE: Make sure the jackstands do not touch the
tires.
"
963 Bobcat Loader
Revised Mar. 99 -1-4 Service Manual
TRANSPORTING THE LOADER
Procedure
A WARNING
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-{)494
A loader with an empty bucket or no attachment must be

loaded backward onto the transport vehicle [A].
Be sure the transport vehicle is of adequate size and

capacity.
The rear of the trailer must be blocked or supported [A]

when loading or unloading the loader to prevent the front
end of the trailer from raiSing up. Some ramps have a
wedge shape (Item 1) [A] to support the trailer.
Use the following procedure to fasten the Bobcat loader

to the transport vehicle to prevent the loader from moving
during sudden stops or when going up or down slopes [8]:
Lower the bucket or attachment to the floor.
Stop the engine .
Engage the parking brake. Install chains at the front

and rear of the loader tie down positions (Inset) [8].
Fasten each end of the chain to the transport vehicle .
963 Bobcat Loader

TOWING THE LOADER
Procedure
To prevent damage to the loaders hydrostatic system, the

loader must be towed only a short distance at a slow
speed. (Example: Moving the loader onto a transport
vehicle .)
The towing chain (or cable) must be rated 1-1/2 times the
weight of the loader. (See SPECIFICA TlONS, Page 9-1 .)
Lift and block the rear of the loader. (See Page 1-4.)
Remove the hydrostatic motor access cover (both sides).

(See Page 3-1.)
Remove the plugs (Items 1 & 2) [A] from the motor (both
sides).
Remove the shuttle valve (Item 1) [B] using a small

screwdriver (both sides).
NOTE: The plug (Item 2) [B] and relief valve may have
to be removed so that the shuttle spool can
be removed from the housing bore.
Install and tighten the plugs.
Install the rear wheels. Lower the loader to the ground.
Raise the operator cab . (See Page 1-9.)
Disengage the parking brake solenoid valve by pushing

UP on the red Traction Lock By-Pass Knob (Item 1) [C]
and turning it 114 TURN counterclockwise. The knob will
come down to release the solenoid valve.
Connect a Port-a-Power to the coupler (Item 1) [0] at the

brake/two speed block.
Operate the Port-a-Power to approximately 350 PSI

(2413 kPa) to release the parking brake.
Lower the operator cab. Move the loader to the desired

location.
NOTE: Before using the loader again, disconnect

the Port-a-Power, push up and turn the red
by-pass knob (Item 1) [C] 114 turn to engage
the traction lock solenoid. Install the shuttle
valve (Item 1) [8] into the hydrostatic motors.
963 Bobcat Loader

Revised Mar. 99 -1-6- Service Manua\
LIFT ARM SUPPORT DEVICE
A WARNING
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-20S9-{)991
Engaging The Lift Arm Support Device
Maintenance and service work can be done with the lift

arms lowered.
If the lift arms must be raised for service, use the following
procedure:
Disconnect the spring (Item 1) [A] from the lift arm

support device retaining pin (Item 2) [A]. Hold the support
device and remove the retaining pin .
Lower the lift arm support device on top of the lift cylinder.
Hook the free end of the spring (Item 1) [B] to the lift arm
support device so there will be no interference with the
support device engagement.
With the operator in the seat, seat belt fastened and seat
bar lowered, start the engine.
Raise the lift arms, until the lift arm support device lowers
onto the lift cylinder rod [C].
Lower the lift arms slowly until the support device is held
between the lift arm and the lift cylinder. Stop the engine.
Raise the seat bar and move foot pedals until both pedals
lock.
Install the pin (Item 1) [0] into the rear of the lift arm
support device below the cylinder rod.
A WARNING
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 t o drop causing injury or death.
W-2271-1197
963 Bobcat Loader

Revised June 98 -1-7- Service Man ual
LIFT ARM SUPPORT DEVICE (Cont'd)
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.
Raise the lift arms a small amount and the spring will lift
the support device (Item 1) [B] off the lift cylinder rod.
Lower the lift arms. Stop the engine.
Raise the seat bar and move foot controls until both
controls lock.
Disconnect the spring from the bracket.
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 the pin.
963 Bobcat Loader

OPERATOR CAB
Description
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 rollover protection.
ROPS/FOPS - RollOver Protective Structure per SAE

J104 and ISO 3471, and Falling Object Protective
Structure per SAE J1 043 and ISO 3449, Levell. Level II .,.,
is available.
Level I - Protection from falling bricks, small concrete

blocks and hand tools encountered in operations such as -10161
highway maintenance, landscaping, and other
construction site services.
Levell/- Protection from falling trees, rocks; for machines

involved in site clearing, overhead demolition or forestry.
A WARNING
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
Raising The Operator Cab
Stop the loader on a level surface. Lower the lift arms.
If the lift arms must be up while raising the operator cab,

install the lift arm support device. (See Page 1-7.)
Loosen the nut (Item 1) [A] (both sides) at the front of the
operator cab.
Remove the nut and plate (both sides) [B].
Stand on the safety tread. Lift on the grab handles and

slowly raise the cab until the latching mechanism
engages and the cab is all the way up [C].
963 Bobcat Loader

OPERATOR CAB (Cont'd)
Lowering The Operator Cab

NOTE: Make sure the seat bar is fully raised or
lowered when lowering the cab.
Pull down on the bottom of the operator cab until it stops
at the latching mechanism [A].
Release the latching mechanism (Inset) [A] and pull the

cab all the way down.
Install the plate and nut (both sides) [B].
.\ -= ~,
-
\
-10162
Tighten the nuts to 40-50 ft .-Ibs. (54--68 Nm) torque [C]

(both sides) .
963 Bobcat Loader

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].
Push the rear window out of the rear of the operator cab.
Exit through the rear window opening of the operator cab .
Front Door:
NOTE: When the Operator Cab Enclosure Kit is
installed, the window of the front door can be
used as an emergency exit.
Pull the plastic loop at the top of the window in the front
door to remove the rubber cord [C].
Push the window out with your foot [OJ.
Exit through the front door.
963 Bobcat Loader

SEAT BAR RESTRAINT SYSTEM
Description
The seat bar restraint system has a spring assist pivoting

seat bar with arm rests and has spring loaded interlocks
for the lift and tilt control pedals.
The operator controls the use of the seat bar. The seat bar
in the down position helps to keep the operator in the seat.
The interlocks require the operator to lower the seat bar

in order to operate the foot pedals.
When the seat bar is up, the lift and tilt pedals are locked
when returned to the NEUTRAL POSITION .
A WARNING
AVOID INJURY OR DEATH

The seat bar system must lock the lift and tilt
control I?edals in neutral when the seat bar is
up. Service the system if pedals do not lock
correctly.
W-21 05-1285
Inspecting The Seat B ar
Sit in the seat and fasten the seat belt. Engage the
parking brake. Pull the seat bar all the way down . Start the P-{)9790
engine . Press the greeen PRESS TO OPERATE Button.
Operate each foot pedal to check both the lift and tilt
functions . Raise the lift arms until the bucket is about 2
feet (600 mm) off the ground .
Raise the seat bar. Try to move each foot pedal. Pedals
must be firmly locked in NEUTRAL POSITION . There
must be no motion of the lift arms or tilt (bucket) when the
pedals ar pushed . .
Pull the seat bar down, press the green PRESS TO

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

OPERA TE Button, lower the lift arms and put the bucket
flat on the ground. Stop the engine. raise the seat bar and
operate the foot pedals to be sure that the pedals are
firmly locked in the neutral position. Unbuckle the seat
belt.
Maintaining The Seat Bar
See the SERVICE SCHEDULE Page 1-3 for the correct

service interval.
Clean the debris or dirt from the moving parts [A] & [B].
Inspect the linkage bolts and nuts for tightness . The
correct torque is 25-28 ft.-Ibs. (34-38 Nm).
If the seat bar system does not function correctly, check

for free movement of each linkage part. Check for
excessive wear. Adjust the pedal control linkages.
Replace parts that are worn or damaged. Use only

genuine Melroe replacement parts.
963 Bobcat Loader

Rp\I;spd Mar. 99 -1-12 Service Manual
AIR CLEANER SERVICE
Replacing Filter Elements
See the SERVICE SCHEDULE Page 1-3 for the interval
to service the air cleaner system.
Stop the engine .
Open the rear door. Raise the rear grill.
Check the air intake hose and air cleaner housing for
damage.
Check all the connections.
Replace the large (outer) filter element when the red ring
(Item 1) [A] shows in the condition indicator window.
NOTE: Before replacing the filter element, push the

button (Item 2) [A] on the condition indicator
and start the engine. Run at full RPM. If the
red ring does not show, do not replace the
filter element.
Remove the dust cover wing nut (Item 1) [B].
Remove the dust cover.
Remove the wing nut at the large filter element and

remove the filter element (Item 1) [C].
NOTE: Make sure all sealing surfaces are free of dirt

and debris.
Install the new filter element and tighten the wing nut.
Install the dust cover and tighten the wing nut.
963 Bobcat Loader

AIR CLEANER SERVICE (ConI' d)
Replacing Filter Element (ConI' d)
Inner Filter Element:
Replace the inner filter element every third time the outer
filter is replaced .
or... ..
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.
Remove the inner filter element wing nut (Item 1) [A].
Remove the inner filter element [B].
Install a new filter element and tighten the wing nut.
963 Bobcat Loader

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

Grade No.1.
The following is one suggested blending guideline which

should prevent fuel gelling problems:
Temp. P (CO) No.2 No.1
+15°(9°) 100% 0%
Down to -20° (-29°) 50% 50%
Below -20° (29°) 0% 100%
We recommend an operator contact their fuel supplier for

local recommendations .
Filling The Fuel Tank B WRONG
A WARNING
Stop and cool the engine before adding fuel.

NO SMOKING! Failure to obey warnings can
cause an explosion or fire.
W-2063-0887
Remove the fuel fill cap (Item 1) [A].

8-1 3456
Use a clean, approved safety container to add the correct
fuel. Add fuel only in an area that has free movement of
air and no open flames or sparks. NO SMOKING! [B].
Install and tighten the fuel fill cap [A].
963 Bobcat Loader

FUEL SYSTEM (Cont'd)
Fuel Filters
. A WARNING
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
See the SERVICE SCHEDULE Page 1-3 for the service

interval when to remove the water from the fuel filters and
when to replace the fuel filters.
To drain the water from the fuel filters, loosen the drain
(Items 1 & 2) [A] to drain the water from the filter.
After water is removed, tighten the filter drains.
Replace both filters at the same service interval.
Clean the outside surfaces of the filter assembly (Items

3 & 4) [Al
Loosen the drain (Items 1 & 2) [A] to drain the fuel from
the filters .
Support the filter and turn the clamp ring (Item 1) [B] & [C]
to the left. Remove the clamp ring.
Remove the sediment bowl (Item 2) [C] from the pre-filter

element and clean the bowl.
Check the two O-ring seals on the sediment bowl.
Replace as needed.
Install the sediment bowl on the filter. Hand tighten only.
Clean the filter heads. Push the filter into the filter head.
Hold the filter element and install the clamp ring. Turn the
clamp ring to the right to fasten the filer to the filter head.
Remove the air from the fuel system . (See Below

Removing Air From the Fuel System.)
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 remove from the
fuel system before starting the engine.
Loosen the vent plug (Item 3) [C] on the filter head.
Squeeze the priming bulb (Item 4) [C] 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.
963 Bobcat Loader

-1-16 Service Manual
ENGINE LUBRICATION SYSTEM
Checking Engine Oil
Check the engine oil level every day before starting the
engine for the work shift.
Open the rear door. Remove the dipstick (Item 1) [A).
Keep the oil level between the marks on the dipstick [B].
Use a good quality motor oil that meets API Service

Classification of CD, or better.
RECOMMENDED SAE VISCOSITY NUMBER
co (LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)
-40 - 34 -2 9 - 23 - 18 - 13 -7 -1 +4 + 10 +1 5 +2 1 .,.27 +32 +38 +4 3 +49
I I I I I
IIII -
SAE 40W or 20W-50
I-- SA E10W-30
~
I I
SAE 15W-40
~
B
- ' SAE30W Keep Oil
- ~
Level Between
- * SAE5W-30
-- These Marks
I ~ SAE20W-20
-I- t
"'(
r-
_ SAE 1~W
.,
-r I I I I
~NTHETIC OIL Use recommendation from Synthetic Oil Mf~r.
-40 -30
l
- 20 - 10
i
+1 0 +20 +30 +40 + 50 +60 +70 +80 +90
r
+1 00 + 110 +1 20
P P-10302
TEMPERATURE RANGE ANTICIPATED
BEFORE NEXT OIL CHANGE (DIESEL ENGINES MUST USE API
CLASSIFICATION CD, CF4, CG4)
* Can be used ONLY when available with appropriate diesel rating.

Replacing The Oil And Filter
interval for replacing the engine oil and filter.
Run the engine until it is at operating temperature. Stop

the engine.
Open the rear door. Remove the drain hose (Item 1) [C]
from the storage position. Remove the drain plug from the
end of the hose. Drain the oil into a container.
Remove the oil filter (Item 2) [C).
Clean the filter housing surface. Put clean oil on the new
oil filter gasket. Install the new filter and hand tighten .
Install and tighten the drain plug .
Remove the filler cap (Item 2) [A].
Fill the engine crankcase with oil of the correct grade and
viscosity. (See Oil Chart above .) Capacity is 9 qts. (8,5 L.)
A WARNING
Start the engine and let it run for several minutes. Always clean up spilled fuel or oil. Keep heat,
Stop the engine . fuel and oil. Failure to use care aro un d
Check for leaks at the oil filter and check the oil level. which can result in injury or death.
W-2103-1285
Add oil as needed if it is not at the top mark on the dipstick
963 Bobcat Loader

Revised June 98 -1-17- Service Manual
ENGINE COOLING SYSTEM
Checking The Coolant Level
Check the cooling system every day to prevent

over-heating, loss of performance or engine damage.
Open the rear door.
Check the coolant level in the coolant recovery tank (Item

1) [A].
The coolant recovery tank must be 1/3 full.

NOTE: The loader is factory filled with propylene
glycol coolant. DO NOT mix propylene glycol
with ethylene glycol.
Add premixed coolant; 47% water and 53% propylene
glycol to the recovery tank if the coolant level is low.
One gallon and one pint of propylene glycol mixed with

one gallon of water is the correct mixture of coolant to
provide a -34°F (-3rC) freeze protection.
Use a refractometeror to check the condition of propylene

glycol in your cooling system.
Cleaning The Cooling System
Raise the rear grill.
Use air pressure or water pressure to clean the top of the

oil cooler (Item 1) [B].
Raise the oil cooler and clean the top of the radiator (Item
2) [B].
Check cooling system for leaks.
IMPORTANT
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.
1-2124-0497
963 Bobcat Loader

-1-18- Service Manua\
ENGINE COOLING SYSTEM (Cont'd)
Replacing The Coolant
A WARNING
Do not remove radiator cap when the engine is

hot. You can be seriously burned.
W-207o-1285
Open the rear door. Open the rear grill.
Remove the radiator cap (Item 1) [A].
Connect a hose to the engine block drain valve (Item 1)

[B]. Open the drain valve and drain the coolant into a
container. Close the drain valve after the coolant is
removed .
One gallon and one pint (4,3 L.) of propylene glycol mixed
with one gallon (3,8 L.) of water is the correct mixture of
coolant to provide a-34° F. (-37° C.) freeze protection.
Mix the coolant in a separate container. (See

SPECIFICA TlONS Page 9-1 for correct capacity.)
Fill the radiator with coolant until full. Open the vent plug
(Item 1) [C] to remove the air from the engine block.
Tighten the vent plug. Continue to fill the radiator until full.
Install the radiator cap.
Add coolant to the coolant recovery tank until it is at the

FULL COLD mark on the tank.
Run the engine until it is at operating temperature. Stop

the engine .
Check the coolant level in the recovery tank when cool.

Add coolant to the recovery tank as needed.
IMPORTANT
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.
1-2124--0497
963 Bobcat Loader

ALTERNATOR BELT
A
Adjusting The Alternator Belt
Stop the engine.
Open the rear door.
Loosen the alternator mounting bolt (Item 1) [AJ.
Loosen the adjustment bolt (Item 2) [AJ.
Move the alternator until the belt has 5/16 inch (8 ,0 mm)
movement at the middle of the belt span (Item 1) [8] with
15 Ibs. (66 N) of force .
Tighten the adjustment bolt and mounting bolt.
Close the rear door.
963 Bobcat Loader

HYDRAULIC/HYDROSTATIC SYSTEM
Checking And Adding Fluid
Use only recommended fluid in the hydraulic system.

(See SPECIFICA TlONS Section Page 9-1 for the correct
fluid .)
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].
The fluid level must be between the marks on the dipstick I B

[B].
If fluid is needed, remove the fill cap (Item 2) [A].
Add the flu id as needed to bring the level to the top mark
on the dipstick [B)
P-10303
Hydraulic/Hydrostatic Filter Replacement
service interval.
The filter element is under the operator cab on the right
hand side of the loader.
Raise the operator cab. (See Page 1-9.)
Remove the filter element (Item 1) [C).
Clean the surface of the filter housing where the element
seal contacts the housing . Put clean oil on the rubber seal
of the filter element.
Install and hand tighten the new filter element.
963 Bobcat Loader

HYDRAULIC/HYDROSTATIC SYSTEM (Cont'd)
Replacing The Hydraulic Fluid

interval.
The fluid must also be replaced if it becomes

contaminated or after major repairs.
Remove the reservoir fill cap (Item 1) [A).
Raise the operator cab.
Remove the drain plug (Item 1) [B] at the bottom of the

reservoir. Let all the fluid flow into a container.
Install and tighten the drain plug when the reservoir is

empty.
Remove the screen (Item 1) [C]. Wash the screen in clean

solvent and install it in the fill pipe.
Remove the hydraulic/hydrostatic filter element. (See

Page 1-21.) Install new filter element.
Add fluid to the reservoir until the fluid is at the top mark
on the dipstick. (See the SPECIFICA TlONS Section
Page 9-1 for type of fluid and capacity.) DO NOT fill
above the top mark on the dipstick.
Lower the operator cab. Start the engine and operate the
loader through the hydraulic and hydrostatic functions .
Stop the engine. Check the fluid level again and add as
. 'I~. ?~ ;;
needed . . ".
A WARNING

combustib les can cause explosion or fire
W-2103-1285
963 Bobcat Loader

SPARK ARRESTOR MUFFLER
A
Cleaning Procedure
See SERVICE SCHEDULE Page 1-3 for service interval

for cleaning the spark arrestor muffler.
Do not operate the loader with a defective exhaust

system.
IMPORTANT
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.
A WARNING
If this machine is operated on flammable forest, When an engine is running in an enclosed

brush or grass covered land, it must be area, fresh air must be added to avoid
equipped with a spark arrestor attached to the concentration of exhaust fumes. If the engine
exhaust system and maintained in working is stationary, vent the exhaust outside.
order. Failure to do so will be in violation of Exhaust fumes contain odorless, invisible
California State Law, Section 4442 PRC. gases which can kill without warning.
Make reference to local laws and regulations for W-205Q-1285
spark arrestor requirements. Stop engine and allow the muffler to cool
1-2022-0595 before cleaning the spark chamber. Wear
safety glasses or goggles. Failure to obey
can cause serious injury.
Stop the engine. Open the rear door. W-2011-1285
Remove the plug (Item 1) [A] from the bottom of the Never use machine in atmosphere with
muffler . explosive dust or gases or where exhaust can
contact flammable material. Failure to obey
warnings can cause injury or death.
W-2068-1285
A WARNING
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-{)284
Start the engine and run for about 10 seconds while a

second person, wearing safety glasses, holds a piece of
wood over the outlet of the muffler.
This will force contaminants out through the clean out

hole.
Stop the engine. Install and tighten the plug. Close the
rear door.
963 Bobcat Loader

TIRE MAINTENANCE
Wheel Nuts

interval to check the wheel nuts. The correct torque is
320-350 ft.-Ibs. (434-475 Nm) torque [A].
Tire Rotation
Check the tires regularly for wear, damage and pressure.

(See SPECIFICATIONS Page 9-1 for the correct tire
pressure.)
Rear tires usually wear faster than front tires. To keep tire
wear even , move the front tires to the rear and rear tires
to the front [B].
It is important to keep the same size tires on each side of

the loader. If different sizes are used, each tire will be
B
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 E--Q1655
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.
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.
A WARNING
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
IMPORTANT
Inflate tires to the MAXIMUM pressure shown

on the sidewall of the tire. DO NOT mix brands
of tires used on the same loader.
1-2057-{)794
963 Bobcat Loader

-1 - 24 Service Manual
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Oil
The chaincase contains the final drive sprockets and

chains and uses the same type of oil as the
Hydraulic/Hydrostatic System. (See SPECIFICATIONS
Section Page 9-1.)
To check the chaincase oil level , use the following

procedure:
Drive the loader on a level suriace. Stop the engine.

Remove the plug (Item 1) [A] from the front of the
chaincase housing
If oil can be reached with the tip of the your finger through
the hole the oil level is correct.
If the level is low, add oil through the check plug hole until
the oil flows from the hole. Install and tighten the plug.
FAN GEARBOX
Checking And Maintaining
service interval.
Disconnect the breather hose from the fitting (Item 1) [B].
Remove the fitting (Item 1) [B] to check the lubricant level.
If the level is low, add SAE 90W gear lube through the
check plug hole until the lubricant just below the fitting
hole.
When adding the gearbox lube, make sure the level does
not go above the top of the shaft in the gearbox.
Install and tighten the fitting. Connect the breather hose.
963 Bobcat Loader

LUBRICATING THE LOADER
Procedure
Lubricate the loader as specified in the SERVICE

SCHEDULE Page 1-3 for the best performance of the
loader.
Always use a good quality lithium based multi-purpose

grease when you lubricate the loader. Apply the lubricant
until extra grease shows.
Lubricate the following locations on the loader: ,.-..

1. Rod End Lift Cylinder (Both Sides) [A].
2. Base End Lift Cylinder (Both Sides) [B].
3. Lift Arm Pivot Pin (Both Sides) [C].
4. Base End Tilt Cylinder (Both Sides) [0].
8 963 Bobcat Loader

LUBRICATING THE LOADER (Cont'd)
Procedure (Cont'd)
5. Rod End Tilt Cylinder (Both sides) [A].
6. Bob-Tach Wedge (Both Sides) [A]
P- 10241
7. Bob-Tach Pivot Pin (Both Sides) [B].
Every 250 Hours:
Add grease to the fittings (Item 1) [C].
963 Bobcat Loader

BOB-TACH
Inspection And Maintenance
Move the Bob-Tach levers to engage the wedges [A].

The levers and wedges must move freely.
The wedges must extend through the holes in the

attachment mounting frame (Item 1) [A].
A WARNING
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-Q588
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.
Inspect the mounting frame on the attachment and the

Bob-Tach, linkages and wedges for excessive wear or
damage . Replace any parts that are damaged, bent, or
missing . Keep all fasteners tight.
c Bob-Tach
J~
Look for cracked welds. Wedge
Lubricate the wedges
Wedge Must Contact

Lower Edge Of Hole
In The Attachment
B-15177
963 Bobcat Loader

Revised Mar. 99 -1-28- Service Manual
REMOTE START SWITCH
Procedure
The tool listed will be needed to do the following

procedure:
MEL 1429 - Remote Start Switch
A WARNING

death.
W-2017-{)286
The remote start switch is required when the operator cab

is in the raised position for service and the service
technician needs to start the engine. (Example: Checking
the hydraulic/hydrostatic system).
Lift and block the loader. (See Page 1-4.)
Raise the lift arms and install an approved lift arm support
device . (See Page 1-7.)
A WARNING

unless the lift arms are secured by an approved
lift arm support device. Failure to use an
approved lift arm support device can allow the
lift arms or attachment to fall and cause injury
or death. W-2059-{)598
Raise the operator cab. (See Page 1-9)
The operator cab wire harness connectors must be

separated from the engine wiring harness connector
under the cab, connect the remote start switch
connectors (Item 1) [A] to the wire harness connectors.
Start the engine using the remote start switch [8].
963 Bobcat Loader

REMOTE START SWITCH (Cont'd)
Procedure (Cont'd)
Put the traction lock override switch (Item 1) [A] in the ON
position so the traction function is locked. The wheels are

not able to turn .
Turn the key to the right and start the engine.
P-04713
Move the traction lock override switch (Item 1) [B] to the

OFF position so the traction function is unlocked. The
B
wheels are now able to turn.
The auxiliary mode switch (Item 2) [B] is used to turn the

front auxiliary quick couplers ON and OFF during relief
pressure and flow tests.
P-04714
963 Bobcat Loader

R evised Mar. 99 -1-30- Service Manual
HYDRAULIC SYSTEM
Page
Number
BICSTM VALVE
BICSTM Valve Removal And Installation ............. . . . .... . .. ... 2-31
BICSTM Valve Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30

HYDRAULIC
Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
SYSTEM
Lift Arm By-Pass Orifice . ............. .. ..... . .. .... .. ..... . ... 2-27
Lock Valve ........ .. . . ....... . .. ....... .. .. . ................. 2-28
BUCKET POSITION VALVE
Disassembly And Assembly ... . ..... .... ........... .. .......... 2-53
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-52
CONTROL PEDALS
Pedal Adjustment .. . .... . .................... . ..... . ......... . 2-65
Removal And Installation ...................... . ........ . ...... . 2-65
CONTROL PEDALS MOUNTING PANEL
Removal And Installation ...................... . .... . ....... .. .. 2-68
FRONT SIDE PANEL
Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
HYDRAULIC CONTROL VALVE
Anti-Cavitation Valve ..................................... . ... . 2-39
Anti-Cavitation Valve/Port Relief Valve ........................... 2-38
Auxiliary Electric Solenoid ...................................... 2-48
Auxil iary Spool ........................................ .. ... ... 2-47
Disassembly And Assembly ................................. ... 2-35
H-Port Auxiliary Section ............ . . . .. . .... . . ... ... . .... .... 2-49
Identification Chart .......... .. .......... . ... ..... .......... ... 2-34
Inspection .. . ...... . ...... . . .. ... . .. ... ... . .. .. .. . .. ... .... ... 2-49
Lift Spool And Detent . .. .... . .. . . .. .... .. . ... .... .. .... . . ...... 2-42
Load Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-35
Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-36
Port Relief (Tilt Section) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-40
Port Relief Valve (Lift Section) ..... . ...... .. . ... ........ .. ... ... 2-37
Removal And Installation . . ........ .. ................... . .... ... 2-32
Rubber Boot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-41
Spool Seal Installation ................... . ................ . .. . . 2-50
Tilt Spool And Centering Spring ....... . .................. . ... ... 2-46
HYDRAULIC CYLINDER
Assembly ........... . ....................................... . 2-16
Disassembly . ........ . .................................... . . . , 2- 14
Lift Cylinder Parts Identification ................................ . 2-12
Tilt Cylinder Parts Identification ................................. 2-13
HYDRAULIC PUMP
Checking The Output Of The Pump ....................... .. ... . 2-55
Disassembly And Assembly .................................... 2-58
Inspection . ..... .... . ................................ . ....... . 2-61
Removal And Installation ...................................... . 2-56
963 Bobcat Loader

HYDRAULIC SYSTEM (Cont'd)
Page
Number
HYDRAULIC FLUID RESERVOIR
Draining The Hydraulic Fluid Reservoir ........ . ................. 2-63
Removal And Installation ....................................... 2-63
HYDRAULIC SYSTEM INFORMATION
Tighten Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-4
HYDRAULIC/HYDROSTATIC FILTER
LIFT ARM BY-PASS CONTROL VALVE
LIFT CYLINDER
Checking The Lift Cylinder(s) ................................... 2-5
MAII\J RELIEF VALVE
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-25
Checking Main Relief Valve At Front Auxiliary Hydraulics . . . . . . . . . .. 2-21
Checking Main Relief Valve Control Valve ........................ 2-23
PEDAL INTERLOCK LINKAGE
Adjustment ........................... . . . . . . . . . . . . . . . . . . . . . . .. 2-67
TILT CYLINDER
Tilt Cylinder Base End Pivot Pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-11
Checking The Tilt Cylinder(s) ................................... 2-8
TILT JUNCTION BLOCK
TROUBLESHOOTING
Chart ........................................................ 2-3
Revised June 98 963 Bobcat Loader

TROUBLESHOOTING
Chart
The following troubleshooting chart is provided for

assistance in locating and correcting problems which are
A WARNING
most common . Many of the recommended procedures

must be done by authorized Bobcat Service Personnel Check for correct function after adjustments,
only. repairs or service. Failure to make correct
repairs or adjustments can cause injury or
death.
W-2004-1285
PROBLEM CAUSE
The hydraulic system will not operate. 1,2,3,5

Slow hydraulic system action . 1,3,4,5,6, 7
Hydraulic action is not smooth. 1,3,5,6
Lift arms go up slowly at full engine RPM . 1,3,4,5,6,7,9,10

The lift arms or Bob-Tach will move with the pedal in neutral position 4,9
The lift arms come down with the pedal in the neutral position. 4, 10, 11 , 12, 13
I
The bucket does not self-level. 14, 15, 16
The bucket will partially self-level. 14, 15
The bucket has no power to roll forward. 16
The bucket does not roll back. 15
Lift Arm By-Pass Valve stuck or stem bent/broken. 17
KEY TO CORRECT THE CAUSE

1. The fluid level is not correct.
2. The pedal linkage is disconnected.
3. The hydraulic pump has defect.
4. The pedal linkage is not adjusted correctly.
5. Drive belt is loose or broken .
6. Suction leak in the hydraulic system.
7. Fluid is cold.
8. Using the loader for more than its rated capacity.
9. Spool in the valve section is not centering or the centering spring is broken.
10. Internal leak at the lift cylinder(s).
11 . External leak at the lift cylinder(s).
12. Port relief seal is leaking.
13. Load check has a defect in the valve section.
14. Check the flow divider in the bucket position valve.
15. Check the unloading spool in the bucket position valve.
16. Check the relief valve in the bucket position valve.
17. Replace the manual spool cartridge.
963 Bobcat Loader

HYDRAULIC SYSTEM INFORMATION
IMPORTANT
When repairing hydrostatic and hydraulic

systems, clean the work area before
disassembly and keep all parts clean. Always
use caps and plugs on hoses, tubelines and
ports to keep dirt out. Dirt can quickly damage
the system.
1-2003-0888
Tighten Procedures
To tightening the hydraulic fittings, tubelines etc.,

See Section 9. Hydraulic Connection
Specifications , for the correct procedure and torque.
A. WARNING
Hyd raulic fluid escaping u nder pressure can

have sufficient force to enter a person 's body
by penetrating the skin. This can cause serious
injury and poss ibly death if proper medical
treatment by a phy sician familiar with this
injury is not received immediately.
W-2145-o290
963 Bobcat Load er

LIFT CYLINDER
Checking the Lift Cylinder(s)
NOTE: With the bucket attached and the the boom

raised to maximum height. The maximum
cylinder drift allowed is 1.3 inches (33 mm) in
10 minutes. Measurement will be taken at
cylinder lift rod.
A WARNING
Hydraulic fluid escaping under pressure can

have sufficient force to enter a person's body
injury and possibly death if proper medical
treatment by a physician familiar with this
W-214S-{)290
Lower the lift arms. Stop the engine. Pull up on the lift arm
by-pass control and move the lift pedal to release the
hydraulic pressure. Raise the seat bar
Check only one cylinder at a time. Disconnect the hose

which goes to the base end of the cylinder (Item 1) [A].
Install a cap (Item 1) [B) on the hose and tighten.
Engage the parking brake. Lower the seat bar. Start the
engine and push the top (toe) of the lift pedal.
If there is any leakage from the base end fitting, remove

the lift cylinder for repair. Repeat the procedure to check
the other lift cylinder.
Removal and Installation
Lower the lift arms. Stop the engine. Pull up on the lift arm
by-pass control and move the lift pedal to release the
hydraulic pressure. Raise the seat bar
Remove the bolt (Item 1) [C] from the tubeline clamp.
Disconnect the tubeline (Item 1) [0] from the rod end of

the lift cylinder. Disconnect the hose (Item 1) [A] at the
base end of the lift cylinder. Install a cap on the tubeline
and a plug in the cylinder fitting.
963 Bobcat Loader

-2-5 Service Manual
LIFT CYLINDER (Cont'd)
Removal And Installation (Cont'd)
Remove the retaining nut (Item 1) [AJ from the rod end of
the lift cylinder pivot pin.
Installation: Tighten the nutto 16-20 ft.-Ibs . (21-27 Nm)

torque.
Remove the spacer (Item 1) [B] from the retainer bolt at

the rod end pin.
Use a puller and remove the rod end and base end pins
from the lift cylinder [C].
Right Side Only: The lift arms will have to be raised using
a chain hoist or floor jack so there will be clearance when
removing the lift arm support device [D].
963 Bobcat Loader

LIFT CYLINDER (Cont'd)
Remove the retainer bolt (Item 1) [A) spacer and nut from
the base end pivot pin.
Installation: Tighten the bolt to 16-20 ft.-Ibs. (21-27

Nm) torque.
Use a puller to remove the base end pivot pin [8].
Remove the lift cylinder from the loader.
963 Bobcat Loader

TILT CYLINDER
Checking The Tilt Cylinder(s)
Remove any attachment from the Bob-Tach. Roll the

Bob-Tach fully back.
Stop the engine.
A WARNING

W-2145-0290
Right Side
Disconnect the hose (Item 1) [A] which goes to the base

end of the tilt cylinder.
Install a cap (Item 1) [B] on the hydraulic hose.
Engage the parking brake . Lower the seat bar. Start the
engine and push the bottom (heel) of the tilt pedal. If there
is leakage from the open port, remove the tilt cylinder for
repair.
Left Side
Disconnect the tubelines (Item 1) [C] from the front

hydraulic couplers.
Remove the mounting bolts (Item 2) [C] and remove the

mounting bracket and hydraulic couplers.
Install caps (Item 1) [0] on the tubelines and tighten.
Disconnect the hose (Item 2) [0] which goes to the base

end of the tilt cylinder.
963 Bobcat Loader

-2-8 Service Manual
TILT CYLINDER (Cont'd)
Checking Tilt Cylinder(s) (Cont'd)
Left Side (Cont'd)
Install a cap (Item 1) [A] on the hydraulic hose and

tighten.
Engage the parking brake. Lower the seat bar. Start the
engine and push the bottom (heel) of the tilt pedal. If there
is leakage from the open port, remove the tilt cylinder for
repair.
Removal And Installation
Put the Bob-Tach on the floor [B]. Stop the engine.
Remove the snap ring and washer at the rod end of the
tilt cylinder (Item 1) [B].
Right Side
Mark the hoses for correct installation.
Disconnect both hoses (Item 1) [C] at the tilt cylinder.
Put plugs in the ends of the hoses.
Remove the snap ring and washer from the pivot pin
(Item 2) [C].
Remove the tilt cylinder by sliding off the pivot pins.
963 Bobcat Loader

Left Side
Disconnect the tubelines (Item 1) [A] from the front

hydraulic couplers .
Remove the mounting bolts (Item 2) [A] and remove the

Disconnect the hydraulic hose (Item 3) [A] from the rod

end of the tilt cylinder. Install a cap on the hydraulic hose
and tighten .
Install caps (Item 1) [B] on the tubelines and tighten.
Remove the hydraulic hose (Item 2) [B] from the base

end of the tilt cylinder. Install a cap on the hydraulic hose
and tighten
Remove the snap ring and washer (Item 1) [C] from the
pivot pin.
Remove the tilt cylinder by sliding off the pivot pins.
963 Bobcat Loader

A
Removal and Installation (Cont'd)
Check the seal at the rod end of the tilt cylinder [AJ.
Replace the seals if damaged as needed.
N-15366
Tilt Cylinder Base End Pivot Pin
Remove the bolt at the pivot pin (Item 1) [B]. Remove the
washer.
Installation: When installing the bolt, tighten to 220-245

ft.- Ibs. (298-332 Nm) torque.
Install the bolt (without washers) into the pivot pin. Hit the
bolt with a hammer to remove the pin from the tapered
seat [C].
Remove the bolt and remove the pin (Item 1) [D) from the
lift arms.
963 Bobcat Loader

HYDRAULIC CYLINDER
Lift Cylinder Parts Identification
1. Rod 9. O-ring
2. Case 10. Washer
3. O-ring 11. Head
4. Nut 12. Seal
5. Piston 13. Seal
6. Ri ng 14. Plug
7. O-ring 15. O-ring
8. Spacer 16. Tube
8 - (§)/--------------
7-0/ /
' /
14-i4/~ / / 1 ~
15-:
/
0'- 3 //
I / 13
12-0/
15- y/ ~ - 2
,!// / ~/
W
11-
/ 10/0/
------___ 9 -
----_J
0
-2-12
HYDRAULIC CYLINDER (Cont'd)
Tilt Cylinder Parts Identification
1. Case 11. a-ring

2. Plug 12. a-ring
3. a-ring 13. Washer
~~
4. Tube 14. a-ring
5. Nut 15. Head
6. Clam p 16. Seal
7.
8.
9.
Bolt
Nut
Piston
17. Seal
18. Rod
19. Seal
~j ~I~
10. Seal 20. Bushing
MC-01 688
3
I
2 -@.'O__
--
6 5
\\'.
~/\~-----
I
7 \
'I- \
\'
@- 8 ~ ---,
\
@-9
\
S-'5 \
\ \
0- 10 ~-16
\
\ \
0- 11 0- 17
0-
\
I
12
0-
\
13 \
\
MC-01688 19 20 19
0- 14 I
\ 0- -Q-O
I I
'- \
~
TS-01233
963 Bobcat Loader

Disassemb ly
A
Use the following tools to disassemble the cylinder:
MEL 1074 - O-ri ng Seal Hook

Spanner Wrench
The lift and tilt cylinders internal components are similar,

the differences are listed below:
Tilt rod diameter is larger.

Piston relief area is slightly different.
No spacer in the tilt cylinder.
Hold the hydraulic cylinder over a drain pan and move the
rod in and out slowly to remove the fluid from the cylinder.
Put the base end of the cylinder in a vise.
Use a spanner wrench to loosen the head [A] & [B].
P--07435
Lift Cylinder: Remove the head and the rod assembly

from the cylinder [C]. Put the rod end in a vise.
IC
Lift Cylinder: Remove the nut (Item 1) [C], piston (Item 2)
[C] , spacer (Item 3) [C] and head (Item 4) [C].
'.\.. ':'lij
') ~r ~
P--07428
Tilt Cylinder: Remove the head and rod assembly from

the cylinder [0]. Put the rod end in a vise. D
Tilt Cylinder: Remove the nut (Item 1) [0], piston (Item 2)
[0] and head (Item 3) [0].
i".
J-: , -':l\:."...
4i......
P--07434
963 Bobcat Loader

Disassembly (Cont'd)
A
Standard Piston : Remove the seal (Item 1) [A], and
O-ring (Item 2) [A] from the piston (Item 3) [AJ.
P-07430
Cushion Piston: Remove the seal (Item 1) [B], and O-ring IB

(Item 2) [B] from the piston (Item 3) [B].
P-07439
Remove the thick O-ring (Item 1) [C], and the back-up IC

washer (Item 2) [C] from the groove in the head. Remove
the thin O-ring (Item 3) [C].
P-07422
Remove the wiper seat (Item 1) [D], and rod seal (Item 2)
[D]. o . ..:...~.,,~ ... yA'
Remove the O-ring (Item 3) [D] from the rod seal. ~}i
('-'.
ftJ'"' .
': ,.",(.or
~•• '~'~r
_2"
".,,'
, .
. 1'(1)
... ~
~'"
'-.:.... ,
tJ"-d
.;~.. : ;~;~I; /1
.., ••1
.. j"'
963 Bobcat Loader

Assembly
Use the following tools to assembly the cylinder:
MEL 1396 - Seal Installation Tool

MEL 1033 - Rod Seal Installation Tool
Piston Ring Compressor
Spanner Wrench
Wash the cylinder parts in solvent and air dry them.
Inspect the cylinder parts for nicks, scratches or other

damage. Replace any damaged parts.
Always install new a-rings and seals during assembly. P-07424
Lubricate all a-rings and seals with hydraulic oil during

installation. B •. ~
Install the new seal on the tool and slowly stretch it until
. (1) . .~
it fits the piston [A].
.
Allow the seal to stretch for 30 seconds before installing
it on the piston. ~ ~
~ - .....
Standard Piston: Install the seal (Item 1) [B] and a-ring
(Item 2) [B] on the piston (Item 3) [B].
P-07430
Cushion Piston: Install the seal and a-ring on the piston IC

(Item 1) [C].
Use a ring compressor to compress the seal to the correct

size . Leave the piston in the compressor for about three
minutes.
P-D7438
Install the rod seal on the rod seal tool [0].

o
NOTE: During installation the O-ring side of the seal
must be toward the inside of the cylinder.
Rotate the handles to collapse the rod seal [0].

'"
.:;,;~. .~'
1 .~ < :}
". j'
>
J
'"
','
>!,
P-D7427
963 Bobcat Loader

Assembly (Cont'd)
A
Install the rod seal in the head [A].
Install the wiper seal with the wiper toward the outside of
the head.
P-07425
Install the thin O-ring (Item 1) [B].

B
Install the back-up washer (Item 2) [B] and thick O-ring
(Item 3) [B] into the groove on the head.
~~.~
~
~-....,-
P-07422
NOTE: Clean and dry the cylinder rod threads and

install the new nut (supplied with the seal
IC
kit).
Lift Cylinder: Install the head (Item 1) [C], and spacer

(Item 2) [C].
Lift Cylinder: Install the piston (Item 3) [C], and the nut
(Item 4) [C].
Lift Cylinder: Tighten the nut (Item 4) [C] to 350 ft.-Ibs.

(475 t\lm) torque.
Tilt Cylinder: Install the head (Item 1) [0], and the piston I 0
(Item 2) [0]. The small diameter of the piston goes into the
cylinder tube first.
Tilt Cylinder: Install the nut (Item 3) [0] and tighten to

750 ft.-Ibs. (1017 Nm) torque.
963 Bobcat Loader

HYDRA ULIC CYLINDER (Cont'd)
Assembly (Cont'd)
A
Put the base end of the hydraulic cylinder in a vise .
Tighten the head using a spanner wrench [A] & [B].
P--07435
963 Bobcat Loader

TILT JUNCTION BLOCK
Remove any attachment from the Bob-Tach. Roll the
Bob-Tach fully out.
Stop the engine.
Use a floor jack and raise the lift arms.
Install jackstands (Item 1) [A] under the lift arms.
Pull up on the lift arm by-pass control and move the lift
pedal to release the hydraulic pressure.
Remove the tilt junction block mounting bolts (Item 1) [B].
Left Side
Disconnect the tubelines (Item 1) [C] from the front

hydraulic couplers.
c
Remove the mounting bolts (Item 2) [C] and remove the ~
Remove the front step mounting bolts (Item 3) [C].

0J
963 Bobcat Loader

TILT JUNCTION BLOCK (Cont'd)
Right Side
Remove the front step mounting bolts (Item 1) [A].
Remove the front step from the loader.
Installation: The cork washer (Item 1) [B] goes between

the step and the loader lift arms. The spacer (Item 2) [8]
fits into the mounting hole in the step and is tightened into
place with the mounting bolt and washer (Items 3 &4) [8].
A WARNING

by penetrat ing the skin. This can cause serious
W-2145-0290
Mark the hydraulic hoses for the correct installation.
Disconnect the hoses from the junction block (Item 1) [C].
Remove the junction block.
Put plugs in the ends of the hoses.
963 Bobcat Loader

MAIN RELIEF VALVE
Checking Main Relief Valve At Front Auxiliary

Hydraulics
The tools listed will be needed to do the following

procedure:
MEL 10003 - Hydraulic Tester
MEL 10006 - Hydraulic Test Kit
The main relief valve is a two stage pressure relief valve.
When the front auxiliary hydraulics are engaged, charge
pressure will activate the second stage of main relief
valve and the pressure will increase.
Lift and block the loader. (See Page 1-1 .)
Raise the operator cab. (See Page 1-1 .)
To check the first stage of the main relief valve , use the
following procedure :
Disconnect the charge tubeline (Item 1) JA] at the main
relief valve . Install a cap on the fitting an tighten. Install
a plug in the tubeline and tighten.
Lower the operator cab.
Connect the IN port of the hydraulic tester to the female
quick coupler (Item 1) [8].
Connect the OUT port of the hydraulic tester to the male
quick coupler (Item 2) [8].
Start the engine and run at low RPM. Push the mode
switch (Item 1) [C] (on the instrument panel) two times to
engage the front auxiliary hydraulics, the light (Item 2) [C]
will come ON.
IMPORTANT
The hydraulic tester must be in the fully open

position before you start the engine.
1-2024--0284
A WARNING

D
death.
W-2017--o286
,,~. ~!
Push the button (Item 1) [0] for fluid flow to the quick
couplers.
Watch the flow meter on the hydraulic tester to make sure

the flow is correct. Increase the engine speed to full RPM.
P-02152
963 80bcat Loader

MAIN RELIEF VALVE (Cont'd)
Checking Main Relief Valve At Front Auxiliary

Hydraulics (Cont'd)
There should be 26.2 GPM (99,2 UMin.) free flow. Turn

the restrictor control, on the tester, until the main relief
opens. The correct pressure for the first stage main relief
is 3025 PSI (20857 kPa) . Make record of this pressure.
Stop the engine. Raise the operator cab.
Remove the cap and plug . Connect the charge tubeline

(Item 1) [A] to the main relief valve.
Lower the operator cab . Start the engine.
Push the mode switch (Item 1) [8] (on the instrument

panel) two times to engage the front auxiliary hydraulics,
the light (Item 2) [8] will come Of\1.
Push the button (Item 1) [C] at the steering lever for fluid
flow to the quick couplers.
Run the engine at full RPM . There should be 26 .2 GPM

(99,2 UMin .) free flow. Turn the restrictor control, on the
tester, until the main relief valve opens. The correct
pressure for the second stage main relief valve is 3375
PSI (23270 kPa).
If the main relief valve needs to be adjusted. (See Page

2-25 for the correct procedure .)
963 Bobcat Loader

Checking Main Relief Valve At Control Valve

Raise the operator cab . (See Page 1-1 .)
The main relief valve is a two stage pressure relief valve.
When the front auxiliary hydraulics are engaged it will
activate the second stage of the relief valve.
Connect pressure gauge (Item 1) [AJ (with hose long
enough to be read from the operator seat) to the coupler
(Item 2) [AJ at the inlet port of the control valve.
Route the pressure gauge on the outside of the loader.
A WARNING

death.
W-2017~286
Sit the in operator seat. Lower the seat bar [8].
963 Bobcat Loader

Checking Main Relief Valve At Control Valve (Cont'd)
Start the engine and run at low engine idle RPM . Push the
heel of the tilt pedal (Bob-Tach fully back) Increase
engine speed to full RPM. The correct pressure should be
3025 PSI (20857 kPa) . Make record of this pressure.
With no attachments connected to the front auxiliary

quick couplers. Push the mode switch (Item 1) [A] (on the
instrument panel) two times to engage the front auxiliary
hydraulics, the light (Item 2) [A] will come ON .
Push the button (Item 1) [8] for fluid pressure to the quick
couplers. ~
The correct pressure for the main relief is 3375 PSI
(23270 kPa). Make a record of this pressure.
Stop the engine.
If the main relief needs adjustment. (See Page 2-25 for
the correct procedure.)
P-02152
963 Bobcat Loader

IMPORTANT

the system.
1-2003-{)888
The main relief valve (Item 1) [A] is located at the lower

front of the control valve .
Clean the area around the control valve.
Disconnect the charge tubeline (Item 2) [A] from the main
relief valve.
Loosen and remove the main relief valve (Item 1) [8].
Installation: Tighten the main relief valve to 35-40
ft.-Ibs. (47-54 Nm) torque.
Remove the a-rings and back-up washers from the main
relief valve [8].
N-15656
Clean the main relief valve in clean solvent. Use air
pressure to dry the valve .
Install new a-rings and back-up washers. Install the
main relief valve (Item 1) [A] and tighten .
Adjustment
If the pressure is not correct, adjust the main relief valve

using the following procedure:
NOTE: The control valve is shown removed for
photo clarity.
To adjust the first stage (low pressure setting):
Disconnect the charge tubeline (Item 2) [A].

N-15657
Remove the second stage housing (Item 1) [C].
Set the pressure by adjusting the set screw, using a 1/4

inch allen wrench (Item 1) [0].
One turn is equal to 490 PSI (3379 kPa). Turn clockwise

to increase the pressure .
Install and tighten the second stage housing.
N-15658
963 Bobcat Loader

oJ/.
Adjustment (Cont'd)
To adjust the second stage (high pressure setting):
Disconnect the charge tubeline (Item 1) [A].
Remove the fitting (Item 1) [8].

8
NOTE: The control valve is shown removed for
photo clarity.
N-15659
Remove the orifice (Item 1) [C] in the end of the second

stage housing, using a standard screwdriver.
N-15660
Set the pressure by adjusting the set screw, using a 1/4

inch allen wrench (Item 1) [0]. Press the allen wrench in
until the set screw is bottomed out in the housing and turn.
One turn is equal to 390 PSI (2689 kPa) .
Install the orifice and fitting and tighten.
Connect the charge tubeline.
Check the main relief valve pressure again. (See Page

2-21 or 2-23 for the correct procedure.)
963 Bobcat Loader

BICSTM VALVE
Lift Arm By-Pass Orifice

A
A WARNING

approved lift arm support device can allow the N-15666
or death. W-2059-0598
B
A DANGER
AVOID DEATH
• Disoonnecting or loosening any hydraufic
tubeline, hose, litting. component or a part
fa~ure can cause lift arms to aop .
• Koep oul of tho area when lift arms are
",i&oo u:ll8~& supported by 311 approved
1it1 arm support. Replace it damaged. ~"5 SW 9a 5>17343
To remove, replace or check the orifice for the lift arm

by-pass function, use the following procedure.
., :0\:
Remove the lock valve (Item 1) [A].
Installation: Tighten the lock valve to 25 ft.-Ibs. (34 Nm)
torque.
c
Remove the fitting (Item 2) [A] from the BICS valve .
The orifice (Item 1) [B] is slotted so a flat blade

screwdriver can be used to remove it.
Remove the orifice (Item 1) [C] from the valve. ~

Clean and inspect the orifice . Replace as needed.
N-15664
963 Bobcat Loader

BICSTM VALVE (Cont'd)
Lock Valve
There are two lock valves on the BICS valve , lift lock valve
(Item 1) [A] and tilt lock valve (Item 2) [A].
Loosen and remove the lock valve(s) (Item 1) [B] & [C]
from the valve.
B
Installation : Tighten the lock valve(s) to 25 ft.-Ibs. (34
Nm) torque.
c"
'-~':~
Inspect the lock valve for damage [0].

D
Replace all the O-rings and back-up washers before
installation [0].
Replace the lock valve if necessary.
963 Bobcat Loader

Check Valve
Loosen and remove the check valve (Item 1) [A].
Installation: Tighten the check valve to 20 ft.-Ibs . (27

Nm) torque.
..
.~
Inspect and clean the screen (Item 1) [8] on the end of

the check valve.
B
Inspect the check valve for damage. Replace the O-rings
and back-up washers before installation.
Replace the check valve if necessary.
P-09057
963 Bobcat Loader

BICSTM VALVE (Cont 'd)
BICSTM Valve Solenoid
Loosen the mounting nut (Item 1) [A] at the solenoid.
Remove the mounting nut (Item 1) [B] , O-ring (Item 2)

[B], solenoid (Item 3) [B) , and O-ring (Item 4) [B].
B ( ..
~
.~~
p
Loosen and remove the solenoid cartridge (Item 1) [C]
from the valve.
IC
Installation : Tighten the cartridge to 20 ft.-Ibs. (27 Nm)
torque.
N-15671
Inspect the solenoid cartridge for damage [0].
D
installation [0).
Replace the cartridge if necessary.
963 Bobcat Loader

BICS Valve Removal And Installation
Loosen the six mounting bolts (Item 1) [A] at the BICS

valve.
Remove the mounting bolts (Item 1) [B]. B
~
~
fi
N-15674
Remove the BICS valve assembly from the top of the

control valve [C]. IC
Installation: Always replace the four large O-rings (Item
1) [C] and small O-ring (Item 2) [C].
Installation: The chart below lists the correct torque

specifications and tightening sequence when reinstalling
the BICSTM valve assembly to the hydraulic control valve.
Thoroughly clean and dry bolts and threads in valve . Use
liquid adhesive LOCTITE #242.
Step Torque Sequence [0]
1 110-130 in .-Ibs.
(12,4-14,7 Nm)
2 190-210 in.-Ibs.
(21,5-23,7 Nm) 1, 2, 3, 4, 5 & 6
3* 190-210 in.-lbs.
(21,5-23,71\Im)
-
*Torque must be 190-210 in.-Ibs. (21,5-23,7 Nm) for

every bolt or repeat Step 3.
963 Bobcat Loader

device . (See Page 1-1 .)
A WARNING

or death. W-2059-0598
A DANGER
AVOID DEATH
• Disconnecting or loosening any hydraulic
tubefine, hose. fitting. component or a p.art
failure c~n cauae lift arms to drop.
• Keep oul of the area when lift arms ara
raised unla~s supported by an approved
liM arm support. Replace it damaged. >:l14S SW 98 srl1:Kl
Stop the engine . Raise the seat bar.
Drain the hydraulic fluid reservoir. (See Page 2-63.)
Disconnect the tilt linkage (Item 1) [A] at the control valve
tilt spool.
Disconnect the crossmember linkage (Item 2) [A] at the

lift spool.
Disconnect the wire harness connectors (Item 1) [8] from

the auxiliary solenoid connectors.
Disconnect the wire (Item 2) [8] from the sender.
Disconnect the hose (Item 3) [8] which goes to the lift arm
by-pass valve.
Disconnect the hoses (Items 1 & 2) [C].
Disconnect the tubeline (Item 3) [C] which goes to charge

pressure sender.
Disconnect the charge tubeline (Item 1) [0] at the main

relief valve.
963 Bobcat Loader

Disconnect the outlet hose (Item 1) [A] from the control
valve.
Disconnect the front auxiliary tubelines (Items 2 & 3) [A].
Disconnect the tilt section hoses (Items 4 & 5) [A].
Disconnect the hose (Item 1) [B] and tubellne from the lift
section of the control valve.
Disconnect the inlet hose (Item 2) [B].
Remove the top mounting bolt (Item 1) [C] and bottom

bolt from the control valve and mounting plate.
Installation:Tighten the mounting bolts to 25 ft.-Ibs. (34

Nm) torque.
Remove the control valve from the loader.
If the mounting plate (Item 1) [0] has to be removed,

remove the two mounting bolts. Remove the mounting
plate from the loader.
963 Bobcat Loader

HYDRAULIC CONTROL VALVE (Cont'd)
Identification Chart
Item 963 Loader
A1 Lift Cylinder Base End/Restrictor
A2 Tilt Cylinder Base End
A3 Auxiliary Hydraulics
B1 Lift Cylinder Rod End

01
B2 Tilt Cylinder Rod End
B3 Auxiliary Hydraulics
C1 Load Check Valve/Lift Function
C2 Load Check Valve/Tilt Function MC-02367
C3 Orificed Load Check Valve/Auxiliary Function
C4 Outlet Fluid Flow
D1 Lift Spool Detent
D2 Tilt Spool Centering Spring
D3 Auxiliary Spool/Centering Springs
I E1 Port Relief Valve - 4000 PSI

,
E2 Anti-Cavitation/Port Relief Valve - 3500 PSI
F1 Anti-Cavitation Valve
F2 Port Relief Valve
G1 Lift Spool End
G2 Tilt Spool End
G3 Auxiliary Spool/Centering Springs
H1 Auxiliary Electric Solenoid
H2 Plug/Port Relief (Optional) - 2500 PSI
MR Main Relief Valve - Dual Stage

- - -
963 Bobcat Loader

Disassembly And Assembly
Remove the BICS valve assembly from the control valve.

(See Page 2-30.)
Remove the four large O-rings (Item 1) [A] and small

O-ring (Item 2) [A]. Always replace these O-rings before
installing the BICS valve assembly.
The anti-cavitation valve , port relief valves and plugs are

at different locations in the control valve . Refer to Control
Valve Identification Chart for the correct location of the
parts . (See Page 2-34.)
IMPORTANT
8
When repairing hydrostatic and hydraulic " ~; :
the system. s
1-2003-0888
Mark each valve section, spool and related parts so that

they will be returned to its original valve section during
assembly.
N-15677
Use bolts to fasten the control valve to a work bench for
easier disassembly and assembly procedures.
Load Check Valve

c
Loosen the load check valve plug (Item 1) [8].
Installation: Always use new O-ring . tighten the plug to

35-40 ft.-Ibs. (47-54 Nm) torque.
Remove the load check plug (Item 1) [C].
Remove the spring (Item 2) [C] and poppet (Item 3) [C].
The auxiliary section (Item 4) [C] uses an orifice load

check poppet.
Cit"" N-00103
963 Bobcat Loader

HYDRAULIC CONTROL VALVE (Cont 'd)
Main Relief Valve
Loosen the main relief valve (Item 1) [A].
N-15679
Remove the main relief valve (Item 1) [8].

B
N-15680
Remove the fitting (Item 1) [C] , orifice (Item 2) [C] , and

second stage housing (Item 3) [C] from the main relief
valve housing.
Installation: Always use new O-rings. and back-up

washers. Tighten to 35-40 ft.-Ibs. (47-54 Nm) torque.
963 Bobcat Loader

Port Relief Valve (Lift Section)

A
Loosen the port relief valve (Item 1) [A].
Installation :Tighten port relief valve to 35-40 ft.-Ibs.

(47-54 Nm) torque.
Remove the port relief valve (Item 1) [B].

B
Remove the O-rings and back-up washer from the port

relief valve [C]. c 1
I
2
1
34
Installation: Always use new O-rings and back-up

washers. ( mno-o-@
-O
E-01509
1. Relief Valve
2. O-ring
3. Backup Washer
4. O-ring
N-15684
963 Bobcat Loader

A
Anti-Cavitation/Port Relief Valve
Loosen the anti-cavitation valve (Item 1) [A].
Installation: Tighten valve to 35-40 ft.-Ibs . (47-54 f\lm) I. :'·

':"
torque.
Remove the anti-cavitation/port relief valve (Item 1) [B]

from the control valve for the tilt section .
B
Remove the O-rings (Item

anti-cavitation/port relief valve.
1) [C] from the
c

washers.
-......
...
,
,
i~
N-15686
963 Bobcat Loader

Anti-Cavitation Valve
A -......
Remove the anti--cavitation valve (Item 1) [A] from the

control valve for the lift section.
Installation: Tighten anti--cavitation valve to 35-40

".
Remove the anti--cavititation valve (Item 1) [B] from the

control for the lift section.
B
N-15688
Remove the O-rings and back-up washer from the

anti--cavitation valve [C]. c 1
I
2
I 3 4

washers. ~-O-@-O .--
E-D1509
1. Anti-Cavitation Valve
2. O-ring
3. Backup Washer
4. O-ring
CD-15102
963 Bobcat Loader

Port Relief Valve (Tilt Section)
A
Loosen the port relief valve (Item 1) [A].
Installation: Tighten port relief valve to 35-40 ft.-Ibs.
(47-54 Nm) torque. ~ I) .
.. ..::...
.~ )
Remove the port relief valve (Item 1) [B].

B
Remove the O-rings and back-up washers from the port

relief valve [C].
c 1 2
I
( runo- O-@-O
I 3 4
washers.
E-01509
1. Relief Valve
2. O-ring
3. Backup Washer
4. O-ring
N-15684
963 Bobcat Loader

Rubber Boot
A
Remove the two screws (Item 1) [A] on the rubber boot
retainer.
Installation: Tighten the screws to 90-100 in .-Ibs.

(10,2-11,3 Nm) torque.
N-15690
Remove the rubber boot/retainer assembly [B].

B
N-15691
Remove the retainer plate (Item 1) [C] and large O-ring IC

(Item 2) [C].
963 Bobcat Loader

Lift Spool And Detent

A
procedure:
MEL 1278 - Detent Tool
Use a screwdriver to remove the snap ring (Item 1) [A].
Remove the washer (Item 2) [A].
. .0, "
0 .;i/ @
N-15693
Remove the screws (Item 1) [8] from the detent sleeve. ~
Installation: Tighten the screws to 90-100 in.-Ibs.
(10,2-11,3 Nm) torque.
Remove the detent sleeve (Item 2) [8].
IMPORTANT
The detent assembly has small springs and

balls. Do not lose these parts during
disassembly and assembly.
1-2012-{)284
Put a rag around the detent assembly [C]. This will

c
prevent the detent balls and spring from being lost when
the detent sleeve is removed.
Remove the detent sleeve, detent balls and spring [0].

o
N-15696
963 Bobcat Loader

Lift Spool And Detent (Cont'd)

A
Remove the spool, centering spring, back-up washer,
seal and spool assembly from the control valve [A).
N-15697
At the other end of the spool bore, remove the spool seal
(Item 1) [B].
. (if"
N-15698
Put the linkage end of the spool in the vise [C].

NOTE: Be careful when removing the detent adapter,
c
because there is spring pressure. , ~.,
:;; .'
Loosen the detent adapter [C].
.~~t' .
Remove the detent adapter, cap, and centering spring

[0]. D
963 Bobcat Loader


A -..}< ~
~ .
Remove the back-up washer and spool seal [A].
,~ .'
CD-15047
....
Remove the stud from the end of the spool [B].
B
Removal of the plastic plug:
a. Make a center point in the plug using a 1/16 inch drill.
b. Drill a hole all the way through the plug using a 7/64
inch tap drill.
c. Turn a 6-32 tap into the plug. Pull the tap and plug
out of the spool. Be careful, do not break the tap.
d. Clean all the debris from inside the spool bore.
NOTE: DO NOT USE LOCTITE ON THE STUD

THREADS. CD-15048
Installation: Slide O-ring over nipple on plastic plug.

Install the plastic plug in the spool. Install the stud so that
the end is about 0.60 inch (15,2 mm) from the spool (C].
c O-ring
0.60 inch
(15,2 mm,r--)- - - - - 4
8-14712
Put grease on all the detent component surfaces before

assembly [0]. D .if;
. , .,Ji'
, A
~:'-.!...:;\
'- .~:'> ...
u .~,,=
..../'~
CD-15049
963 Bobcat Loader

Install the detent balls and spring into the detent adapter.
Hold the detent balls in position with the tool (MEL 1278)
and install the detent adapter into the end cap [A].
Install the new spool seal (Item 1) [8] and back-up

washer (Item 2) [8].
B
---- ~ 0
~ .
"I ,
'j" i
I' ;1 . ':', ~,~"

~ ,"
CO-1S047
Install the centering spring, end cap/detent adapter on the

valve spool. Tighten the detent adapter to 90-1 00 in.-Ibs. c
(10,2-11 ,3 Nm) torque [C].
'"
Install the detent balls and spring [0].

o .. \' "
"
.. ~
,1
.'
.".~
.
• :"
,~ ~ .... ,.:,~ ' ,- - .

CO-1S0S1
963 Bobcat Loader

A
Hold the detent balls and spring in position with the tool
(MEL1278) [A].
....];t-..,. .;
CD-15052
Install the detent sleeve (Item 1) [B] over the balls and
into position.
B /
Tilt Spool A nd Centering Spring

c
Remove the end cap screws (Item 1) [C].

(10,2-11,3 Nm) torque.
Remove the end cap (Item 2) [C].
Remove the spool, centering spring, back-up washer and

spool seal [0]. D
Installation: If the centering spring bolt is removed,
tighten to 90-100 in.-Ibs. (10,2-11,3 Nm) torque. Put
grease on all the centering spring component parts.
Always use new spool seals at both ends of the spool.
N-15700
963 Bobcat Loader

-2-46 Sel"'1\ce Manual
Auxiliary Spool
A
Remove the end cap screws (Item 1) [A] & [B].
(10.2-11.3 Nm) torque .
N-15701
Remove the end cap (Item 2) [A] & [B], O-ring (Item 3)
[A] & [B].
Remove the large spring (Item 4) [A] & [B] and small
spring (Item 5) [A] & [B].
Remove the spring retainer (Item 6) [A] & [B].
Remove the auxiliary spool (Item 1) [C]. I C
963 Bobcat Loader

Auxiliary Electric Solenoid
A
Remove the nut (Item 1) [A] from the end of the solenoid.
Installation: Tighten the nut to 9-12 in.-Ibs. (1,02-1,36
Nm) torque.
4_ ....... '
N-15704
Remove the solenoid metal housing (Item 1) [8].

B
N-15705
Remove the solenoid coil (Item 1) [C] and end plate (Item
2) [C].
IC
N-15706
Remove the electric solenoid valve (Item 1) [0]. D

Installation: Tighten the electric solenoid valve to
96-144 in.-Ibs . (10,8-16 Nm) torque. Always install new
O-rings and back-up washers.
963 Bobcat Loader

H-Port - Auxiliary Section

A
Loosen the plug (Item 1) [AJ.
Installation : Tighten the plug to 35-40 ft.-Ibs . (47-54

Nm) torque.
t
'~.~'''' '
Remove the plug from the control valve [BJ.
Replace the O-ring.
~'r.
Depending on the application of the auxiliaries, the control

valve may be equipped with a port relief valve (Item 1) [C]
(H port).
Remove the port relief valve (Item 1) [OJ.
Installation: Replace the O-rings and back-up washers.

Tighten the port relief valve to 35-40 ft.-Ibs. (47-54 Nm)
torque. N-1S742
Inspection
Check the spools for wear or scratches.
Check that the spools are not loose in their bore.
Check that the centering springs are not broken.
Check that the load check valve seats are not worn.
Check the load check poppets for damage.
Check the rubber boots and retainers that they are not
worn or damaged.
Replace the parts as needed.
963 Bobcat Loader

HYDRA ULIC CONTRO L VALVE (Cont'd)
Spool Seal Installation
To install new spool seals when the centering spring (tilt

spool) or the detent assembly (lift spool) are not removed
from the spool , use the following procedure:
Check the seal surface area in the control valve (Item 1)

[A] for rust, corrosion, scratches, etc. Correct any
irregularities before continuing.
Put plastic material (Example : Plastic food wrap) on the

valve spool [8].
Put clean oil on the spool seal. Install the spool seal (Item
1) [8] on the spool. Be careful not to damage the seal on
the sharp edges.
NOTE: Seal must be installed with lip face toward

valve body. Lip face has largest outside
diameter [C].
Remove the plastic material.
Install the spool into the control valve [0].
Slide the linkage end spool seal over the rubber boot
groove.
Be careful not to damage the spool seal.
Continue assembling the control valve .
N-15700
963 Bobcat Loader

Revised Oct_ 98 -2-50- Service Manual
LIFT ARM BY-PASS CONTROL VALVE
device. (See Page 1-1.)
A WARNING

or death. W-2059-o598
B
A DANGER
AVOID DEATH
tubeline, hose, litting. ccmponsnt or a part
failure C'1n cause lift arms to crop.
• Keep out of Ilia area when lilt arms are
raised l6lla"G supported by an approved
liN ann support. Replace il damaged. !>J14S
Raise the operator cab. (See Page 1-1.) ,,~
Disconnect the hoses (Items 1 & 2) [A].

Remove the two mounting bolts (Item 3) [A].
Installation: Tighten the mounting bolts to 180-200
in.-Ibs. (21-23 Nm) torque.
Remove the lift arm by-pass valve. IMPORTANT

Remove the by-pass valve (Item 1) [B] from the valve systems, clean the work area before
block. Inspect the by-pass valve for damage and replace disassembly and keep all parts clean. Always
if necessary. use caps and plugs on hoses, tubelines and
Installation: Tighten the valve to 33-37 ft.-Ibs. (45-50 the system.
Nm) torque. 1-2003-0888
Inspect the hydraulic fittings on the valve block for
damage and replace if necessary.
963 Bobcat Loader

BUCKET POSITION VALVE
Start the engine. Raise the lift arms and install an

approved lift arm support device. (See Page 1-1.)
A WARNING

or death. W-2059-0598
A DANGER
AVOID DEATH
tube!ine. hose. fitting. ComponBnt or a part
failure com cause lift arms to d"op .
,
-" -,':::\-+
• Keep oul at the area when lift arms are
raised l.nlo"s supported by an approved
1it1 arm support. Replace it damaged. !>:1145 SW93 6117~
Stop the engine.
Disconnect the tilt base end hose (Item 1) [A).
Disconnect the tilt rod end hose (Item 2) [A].
Disconnect the tilt cylinder hoses (Items 1 & 2) [8].
Disconnect the lift hose (Item 1) [C].
Disconnect the wire harness connector form the bucket

position valve shut-off solenoid.
Disconnect the tubelines (Items 1 & 2) [0] from the tee

fitting.
Remove the mounting bolts (Item 3) [0] and nuts.
Installation: lighten the mounting bolts and nuts to 15

ft.-Ibs. (20 Nm) torque.
Remove the bucket position valve from the loader.
963 Bobcat Loader

BUCKET POSITION VALVE (Cont'd)
A
Loosen the unloading spool (Item 1) [A]
P--06568
Remove the plug , O-ring, spring and spool [8].
Use a drag link socket and loosen the plug for the flow
control spool (Item 1) [C]
P--06570
Remove the plug, O-ring and flow control spool [0]. I D
963 Bobcat Loader

BUCKET POSITION VALVE (Cont'd)
A
Disassembly And Assembly (Cont'd)
Loosen the flow adjustment valve (Item 1) [A].
Remove the flow adjustment valve and O-ring [B].

8
NOTE: A lways install new a-rings before any parts
are installed into the valve. Check the parts
for wear or damage and replace as needed.
963 Bobcat Loader

HYDRAULIC PUMP
Checking the Output of the Pump

procedure:
MEL 10003 - Hydraulic Tester
MEL 10006 - Hydraulic Test Kit
NOTE: Make sure all the air is removed from the
hydraulic system before beginning the test.
Air in the system can give an inaccurate test.
*Relief pressure must be per specification
before the test is done.
A WARNING

or death. W-205~598
A DANGER \
~~
",
AVOID DEATH
tubeline, hose. litling, component or a part
failure c:m cause lift arms 10 aop.

o Keep out of !lis area when lilt arms are
raised ISlla~s supported by an approved
lift arm support . Replace it damaged. :.:t\<> SW 93 6 711$4.3
Connect the remote start switch. (See Page 1-1 .)
Disconnect the OUTLET hose (Item 1) [A] from the

pump.
Connect the INLET hose from the tester to the OUTLET

of the pump. Connect the OUTLET hose from the tester
to the hose which was disconnected from the pump [B].
Start the engine and run at low idle RPM. Make sure the
tester is connected correctly. If no flow is indicated on the
tester, the hoses are connected wrong . With the hoses
connected correctly, increase the engine speed to full
RPM.
Warm the fluid to 140°F. (60°C.) by turning the restrictor

control on the tester to about 1000 PSI (6895 kPa). DO
NOT exceed system relief pressure. Open the restrictor
control and record the free flow (GPM) at full RPM.
Turn the restrictor down to system operating pressure .

DO NOT EXCEED SYSTEM RELIEF PRESSURE . The
highest pressure flow must be at least 80% of free flow.
0/ 0 =HIGH PRESSURE FLOW (GPM) X 100

FREE FLOW (GPM)
A low percentage may indicate a pump problem.
963 Bobcat Loader

HYDRAULIC PUMP (Cont'd)
IMPORTANT

the system.
1-2003-0888
Start the engine. Raise the lift arms and install an

approved lift arm support device . (See Page 1-1.)
A WARNING

or death. W-2059-0598
A DANGER
AVOID DEATH
lubeline. hose, titting. CCfllportBnt or a part
failure c;ln caus e lift arms to drop .
• Keep out of ltie area when lift arms are
rai&ad mts lO& supported by an approved
liN ann support . Replace it damaged. .:h.5 sw 9.!: 6 711343
Stop the engine.
Drain the fluid from the hydraulic reservoir. (See Page

2-63.)
Remove the fan driver belt shield (Item 1) [A] and the fan
belt. (See Page 7-1.)
Disconnect the inlet hose (Item 1) [B] which comes from

the hydraulic reservoir.
Disconnect the tubeline (Item 1) [C] and hose (Item 2) [C]

from the hydraulic pump fitting.
Disconnect the outlet hose (Item 1) [0] from the pump

fitting.
963 Bobcat Loader

Revjsed Mar. 99 -2-56 Service Manua'
Remove the three bolts (Item 1) [A] from the pump

mounting bracket.
Loosen the pump mounting bolts (Item 1) [B] (both sides).
NOTE: The hose fitting collars (Item 2) [B] (both

sides) may have to be removed for clearance
so the mounting bolts can be removed.
Installation: Tighten the pump mounting bolts to 30

If still installed, remove the collars (Item 1) [C] and fitting

(Item 2) [C] (both sides).
IC
Installation: Tighten the collar mounting bolts to 25
Remove the nuts (Item 1) [0] and the mounting bracket

(Item 2) [0] from the hydraulic pump.
ID
Installation: Tighten the nuts at the mounting bracket to
70 ft.-Ibs . (95 Nm) torque.
N-15712
963 Bobcat Loader


A
IMPORTANT

the system.
1-2003-0888 N- 15714
Mark the pump sections for correct assembly. B

Remove the three bolts (Item 1) [A] from the pulley.
Install the bolts (Item 1) [B) in the next set of holes in the
pulley. Turn the bolts in evenly to remove the pulley from
the hub.
.'
N-15715
Remove the pulley (Item 1) [C) and hub (Item 2) [C).
Remove the key (Item 3) [C] from the shaft.

c
Remove the two bolts (Item 1) [OJ.
Remove the two nuts (Item 2) [OJ.

o
Assembly: Tighten the bolts and nuts to 78 ft.-Ibs. (106
Nm) torque.
NOTE: If the long threaded studs are loose in the

pump mounting flange, replace the pump
assembly or remove the studs, clean the
threads, apply LOCTITE to the threads.
Install the studs in the mounting flange and
let set for 10-15 minutes before assembling
the pump. If the studs turn, the correct torque
can not be apply to the nuts when the pump
is assembled.
963 Bobcat Loader


A
Remove the end housing (Item 1) [A].
__ _ .. __ __ __• N-15718
Remove the bearing housing (Item 1) [8].
Remove the back-up seal/O-ring seal (Item 2) [8] from

B
the bearing housing.
Remove the large O-ring (Item 3) [8] from the pump

housing .
~." /., "

" ~' 3
'-'
0 r
I
N-15719
Assembly: The O-ring and back-up washer (Item 1) [C]

must be installed toward the pressure side of the pump.
Remove the drive end housing (Item 1) [D].

D
Remove the large O-ring (Item 2) [D] from the pump
housing.
Remove the bearing housing (Item 3) [D].
Remove the back-up seal/O-ring seal (Item 4) [D] from
~o
the bearing housing.
d s '.~ N-15720
963 Bobcat Loader

HYDRAULIC PU MP (Cont'd)
Disassembly and Assembly (Cont'd)
Assembly: The O-ring and back-up washer (Item 1) [A]
must be installed toward the pressure side of the pump.
Remove the drive gear (Item 1) [8] and idler gear (Item I
2) [B) from the pump housing. B
N-15721
Remove the snap ring (Item 1) [C] and seal (Item 2) [C]
from the pump end housing. IC
~o.
,I<
,1 ;
1
N-15725
Remove the snap ring (Item 1) [0] and seal (Item 2) [0]
from the pump mounting flange .
Assembly: Use the correct size driver tool to install the

shaft seals into the housings.
963 Bobcat Loader

-2--60 Service Manua\
HYDRAU LIC PUMP (Cont'd)
"A
Inspection
Wash all parts in clean solvent. Use air pressure to dry

them .
Make a visual inspection, those parts which show wear,

or damage must be replaced .
Check the drive and idler gears [A]. If excessive wear is

visible on the journals, side or face of the gears, they must
be replaced . If the splines are worn , replace the gears.
N-15722
Check the pump housing (Item 1) [8]. Check the surface IB
in the gear area for scratches, wear, etc.
N-15723
Check the bushings (Item 1) [C] in the bearing housing.
If the bushings are worn , scratched, and etc. Replace the I C
parts as needed.
963 Bobcat Loader

HYDRAULIC/HYDROSTATIC FILTER
IMPORTANT

disassembly and keep all parts clean . Always
use c aps and plugs on hoses, tubelines and
the system.
1-2003-{)888
device. (See Page 1-1 .)
A WARNING

approved lift arm s upport device can allow the
or death. W-2059-0598
Drain the fluid from the hydraulic reservoir. (See Page
2-63.)
Disconnect the wire from the sending switch (Item 1) [A].
Disconnect the hydraulic hoses (Items 2 & 3) [A).
Disconnect the hoses from the tee fitting (Item 1) [B] .
Install caps on the hydraulic fittings.
Loosen the hose clamp (Item 4) [A] and disconnect the
hose.
Remove the mounting bolts (Item 5) [A).
Installation: Tighten the mounting bolts to 25 ft.-Ibs . (34
Nm) torque.
Remove the filter housing/filter assembly.
963 Bobcat Loader

HYDRAULIC FLUID RESERVOIR
Draining The Hydraulic Fluid Reservoir
Remove the plug (Item 1) [A] at the bottom of the

hydraulic reservoir and drain the fluid into a container.
IMPORTANT

the system.
1-2003-0888
A WARNING

or death. W-2059-0598
A DANGER
AVOID DEATH ~:\,
~+
tubeline, hose, frtt ing, component or a part
failure c~n cause lift arms 10 drop .

• Keep out of Ins area when lift arms are
-raised unl05G supported by an approved
1if1 ann support. Replace it damaged. ~.5

sw 9$ 6117:w..3
Stop the engine.
Remove the plug (Item 1) [A] at the bottom of the

reservoir and drain the hydraulic fluid into a container.
Disconnect the hose (Item 2) [A].
Disconnect the three hoses (Items 3, 4 & 5) [A] from the

tee fitting at the bottom of the reservoir.
Remove the bolt (Item 1) [B] from the reservoir mounting

strap.
963 Bobcat Loader

HYDRAULIC FLUID RESERVOIR (Cont'd)
Remove the bolt (Item 1) [AJ from the mounting strap.
Remove the mounting strap and reservoir.
963 Bobcat Loader

CONTROL PEDALS
Remove the bolt and nut (Item 1) [AJ from the pedal
linkage.
Installation: Tighten the bolt and nut to 21-25 ft.-Ibs.

(28-34 Nm) torque.
Check the rubber bushing in the pedal for wear and

replace as needed.
Remove the two mounting bolts (Item 1) [8].
Remove the pedal assembly from the loader.
Pedal Adjustment
After installing the pedal , adjust so there is clearance
under the rear of the pedal and the valve spool must travel
full stroke without hitting the floor panel.
A WARNING

Adjust locking tabs on pedal control linkage so
that lift and tilt control pedals are locked in
neutral when the seat bar is up.
W-21 04-1285
NOTE: See Page 2-66 for correct procedure to

adjust the pedal interlock linkage.
963 Bobcat Loader

PEDAL INTERLOCK LINKAGE
Remove the interlock shield mounting nuts (Item 1) [A].
Installation: Tighten the shield mounting nuts to 25-28
ft.-Ibs . (34-38 Nm) torque.
Remove the interlock shield (Item 2) [A].
Remove the interlock mounting nuts (Item 1) [8] and

plastic washers from behind the nuts.
Remove the interlock (Item 2) [8] and plastic washers

from behind the interlocks.
Installation: Hold the inside plastic washer up with an

O-ring pick or a small screwdriver so the plastic washer
does not become wedged between the side panel and the
interlock nut [C].
Installation: Tighten the interlock mounting nuts to

84-95 in.-Ibs. (9,5-10 ,8 Nm) torque.
If the linkage lock mounting bolts (Item 1) [0] need

replacement , remove the front side panel. (See Page
2-67 .)
Install the new mounting bolts through the back of the side
panel.
963 Bobcat Loader

-2--66- Service Manua\
PEDAL INTERLOCK LINKAGE (Cont'd)
Adjustment
Check the pedal Interlock linkage so it is free and locks

the pedals
Check that the tab (Item 1) [A] on the linkage, so that it

slides into the slot on the interlock and holds the pedal in
locked position.
If not, loosen the bolts and nuts (Item 2) [A] and adjust the
tab for correct engagement.
Tighten the bolts and nuts to 25-28 ft.-Ibs . (34-38 Nm)

torque.
A WARNING

Adjust locking tabs on pedal control linkage so
that lift and tilt control pedals are locked in
neutral when the seat bar is up.
W-21 04-1285
The locking tab should fit into the slot of the interlock as
shown in figure [A], when adjusted correctly.
FRONT SIDE PANEL
Remove the top mounting bolt (Item 1) [B].
Loosen the bottom two mounting bolts (Item 2) [B].
Remove the front side panel (Item 1) [C] from the loader.
963 Bobcat Loader

-2~7- Service Manual
CONTROL PEDALS MOUNTING PANEL
Remove the loader control panel/steering lever

assembly. (See Page 3-1).
Remove the bolt and nut (Item 1) [A] at the lift pedal
linkage and crossbar.
Disconnect the tilt pedal linkage (Item 1) [B] from the

control valve spool.
Remove the lower front panel mounting bolts (Item 1) [C].
Remove the lower front panel.
NOTE: Parking brake pedal and wire harness tube

may have to be removed first, if the lower
front panel has not been notched out. (See
Page 4-1.)
Remove the left side interlock shield mounting nuts (Item

1) [0].

Remove the interlock shield (Item 2) [0].
Remove the three mounting bolts (Item 3) [0] from the left
side panel.
Remove the left side panel.
963 Bobcat Loader

-2--68- Service Manuat
CONTROL PEDALS MOUNTING PANEL (Cont'd)
Remove the right side interlock shield mounting nuts

(Item 1) [AJ.
Remove the interlock shield (Item 2) [A].
Remove the right side mounting bolts (Item 3) [A].
Remove the right side panel.
Remove the mounting bolt (Item 1) [8] from the left front
B ,-" .
side panel (Item 2) [8].
Remove the left front panel. (Repeat the procedure for

right side panel.)
Remove the mounting bolts (Item 1) [C] from the control IC

pedals mounting panel.
Remove the control pedal mounting panel from the

loader.
963 Bobcat Loader

lenuew a::>!I\Jas -oL-~-
Jap e01 leoq o 8 £96
HYDROSTATIC SYSTEM
Page
Number
CONTROL PANEL
DRIVE BELT
Adjusting The Drive Belt ........... . ........................... 3-63
Replacing The Drive Belt ............ . .......... . ...... . ...... " 3-63
DRIVE BELT IDLER PULLEY

HYDROSTATIC
Removal And Installation .............................. .. ..... " 3-68
SYSTEM
DRIVE BELT SHIELD
Removal And Installation ............................ . ........ . . 3-62
DRIVE BELT TENSIOt\lER PULLEY
Disassembly And Assembly ......... . ................. . ........ 3-66
Pivot Shaft . . . .... .. ......... . ................................ 3-67
Tension Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-65
HYDROSTATIC CONTROLLER
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-19
Disassembly and Assembly .......... . ......................... 3-16
Removal and Installation ....................................... 3-14
HYDROSTATIC MOTOR
Assembly ...................................... . .... . . . ...... 3-29
Disassembly ................................................. , 3-24
Flushing Valve ..................... . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-23
Inspection ........ . ........... . ................. . ...... . ...... 3-27
Removal And Installation .......... .. ... . .......... . ........... , 3-20
Shuttle Check Valve ................................... . ....... 3-22
Throttle Control ..... . ......................................... 3-22
HYDROSTATIC MOTOR COVER
HYDROSTATIC PUMP
Assembly .................... .. .............................. 3-49
Charge Relief Valve . . ............ . ........... . .......... . ..... 3-37
DA Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-37
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-38
Hydraulic Pump Removal And Installation ........................ 3-35
Hydrostatic Pump Start-Up ....... . ................. . . : . . . . . . . .. 3-59
Inspection ..... . ...... . ..................... . ................. 3-46
Removal And Installation ........ . ................. . ............ 3-34
Replenishing/High Pressure Relief Valve ... . ..................... 3-36
Timing Procedure ....................... . ..................... 3-60
HYDROSTATIC SYSTEM INFORMATION
Replenishing Valve Function ......................... . ......... , 3-4
Checking Charge Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-4

HYDROSTATIC SYSTEM (Cont'd)
Page
Number
OIL COOLER
STEERING LEVERS
Disassembly and Assembly ............................. .. ..... 3-8
STEERING LINKAGE
Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-12
TROUBLESHOOTING
Chart ...... . ..... . ..... . ........................ . ..... . ...... 3-3

-3-2- Ser"ke Manual
TROUBLESHOOTING
Chart

assistance in locating and correcting problems which are
A WARNING
most common. Many of the recommended procedures

must be done by authorized Bobcat Service Personnel Check for correct function after adjustments,
only. repairs or service. Failure to make correct
death.
W-2004-1285
PROBLEM CAUSE
1\10 drive on one side, in one direction. 1, 2
No drive on one side in both directions. 2,3,4,5
The loader does not move in a straight line. 2,3,5,6,7
The hydrostatic system is overheating. 8,9,10,11
Warning light comes ON. 8,11,12,13, 14
1. The hydrostatic pump replenishing valves not seating.
2. The steering linkage needs adjustment.
3. The hydrostatic pump has damage.
4. The final drive chains are broken.
5. The hydrostatic motor has damage.
6. The tires do not have the correct tire pressure.
7. The tires are not the same size.
8. The hydrostatic fluid is not at the correct level.
9. The oil cooler has a restriction.
10. The temperature sending switch is not operating correctly.
11. The loader is not being operated at the correct RPM.
12. The sender is defective.
13. Pump is defective or worn hydrostatics.
14. Hydraulic filter is plugged.
963 Bobcat Loader

HYDROSTATIC SYSTEM INFORMATION
A CHARGE OIL
IMPORTANT

the system. FUNCTION 1
.
Valve Moves for Charge

Oil Replacement
1-2003-0888
Rep lenishing Valve Function
~
The functions of the replenishing valves are:
1. To give replacement fluid to the low pressure side of
the hydrostatic circuit. Replacement fluid is needed
because of normal internal leakage and the
..
controlled flow to the oil cooler for cooling; Function
1 [Aj.
2. To keep high pressure fluid out of the low pressure
side of the hydrostatic circuitry; Function 2 [A].
Valve Stays on Seat to

Hold High Pressure for Drive
FUNCTION 2
B--D2804
Checking The Charge Pressure
Check the charge pressure with the engine at full RPM

and the hydraulic fluid temperature at about 1500 F. (65 0
C .).
Connect a gauge to the diagnostic coupler (Item 1) [B] to

check the left charge pump. The pressure reading should
be 319 PSI (2200 kPa) .
Connect a gauge to the diagnostic coupler (Item 2) [B] to

check the right charge pump. The pressure reading
should be 406 PSI (2868 kPa).
If the pressure is not correct, adjust the charge relief

valve. (See Page 3-37.)
The diagnostic coupler (Item 1) [C] at the rear of the

hydrostatic controller checks controller pressure. Run the
engine at full RPM and transmission not stroked. Connect
a gauge to the coupler and the normal operating pressure
should be 406 PSI (2868 kPa).
963 Bobcat Loader

CONTROL PANEL
A WARNING

death.
W-2017-o286
A WARNING

or death. W-2059-0598
Remove the engine speed control (Item 1) [A]. (See Page

7-1.)
Disconnect the right brace (Item 1) [8] from the shock

absorber mounting bolt. Reinstall the shock mounting
bolt.
Disconnect the left brace (Item 1) [C] from the shock

bolt.
Remove the brace mounting bolts (Item 1) [0] at the

controller.
Remove the brace from the loader.
963 Bobcat Loader

CONTROL PANEL (Cont'd)
Disconnect the the steering linkage clevis (Item 1) [A] at

the hydrostatic pump controllers .
Disconnect the control harness connectors (Item 1) [8]

from the right side steering lever.
NOTE: If the loader is equipped with rear auxiliary

hydraulics, also disconnect the electrical
connectors (Item 1) [C] from the left side
steering lever.
963 Bobcat Loader

Revised Oct. 98 -3~- Service Manual
CON TROL PANEL (Cont'd)
A
Loosen the jam nut at the by-pass control knob (Item 1)

[A].
Remove the control knob, jam nut and rubber washer.
Remove the control panel mounting bolt (Item 2) [A].
Remove the bolt (Item 3) [A] for clearance when

removing the control panel.
Remove the control panel mounting bolts (Item 1) [B]

from the right side of the control panel.
Remove the control panel mounting bolts (Item 1) [C]

from the left side of the control panel.
Remove the bolts (Item 2) [C] for clearance when

removing the control panel.
Installation: Tighten the control panel mounting bolts to

25-28 ft.-Ibs. (34- 38 Nm) torque .
Remove the control panel/steering lever assembly from

the loader.
963 Bobcat Loader

Revised Oct. 98 -3-7- Service Manuai
STEERING LEVERS
Disconnect the steering linkage clevis (Item 1) [A] from
the steering cross shaft.
Loosen both U-bolts (Item 1) [B] at the steering lever.
Remove the steering lever (both sides) .
Installation: The steering lever must be flush with the
back of the mounting plate on the steering cross shaft.
Remove the nut, spring and bolt (Item 1) [C] or [0] from
the neutral cam bracket. (See Page 3-10 for cam bracket
neutral adjustment.)
Check the neutral centering bracket (Item 2) [C] or [0] for

wear or damage.
963 Bobcat Loader

Revised Oct. 98 -3-8- Service Manual
STEERING LEVERS (Cont'd)
Remove the steering cross shaft mounting bolts (Item 1)

[A] (both sides) .
Installation: Tighten the mounting bolts to 15-17 ft.-Ibs.

(21-23 Nm) torque.
Remove the steering cross shaft from the control panel.

Disassemble the right and left steering shaft from the
cross shaft.
Assembly: Install new nylon bushings (Item 1) [B] as

needed at the ends of the steering shaft. Be sure to apply
grease to the cross shaft before installing the right and left
steering shaft.
, '0.
.. )~
Assembly: Check the nylon bushings (Item 1) [C] and

replace as needed. Make sure the wave washer (Item 2)
[B] is between the nylon bushings.
Check and replace the cams (Item 3) [C] if worn or

damaged. Tighten the cam jam nuts, the cams must not
rotate on the mounting bolt.
Remove the bolts and nuts (Item 1) [0] if the neutral

centering bracket needs to be replaced.
Assembly: If the neutral centering bracket is replaced,

keep the bracket vertical to be sure that the both cams
make full contact in the pocket of the detent bracket.
963 Bobcat Loader

Revised Oct. 98 -3-9 Service Manual
Standard Base Loaders Only:
Read this adjustment completely to become familiar with

the procedure before beginning the adjustment.
Assembly: Use the following procedure to adjust the

neutral bracket so both steering levers have no free play
against the cam. To remove the free play, move the right
cam to match the left cam so there is no free play
between the two cams in the pocket of the detent
centering bracket [A]. Use the following procedure to
adjust the cam free play.
Only the right side cam is adjustable in the slotted hole in

the bellcrank (Item 1) [A],. The left side cam is fixed and
will not require adjustment. The cam should not rotate on
the mounting bolt. If cam rotates, tighten the jam nut (Item
1) [B] against the cam while holding the cam mounting
bolt.
Loosen the cam mounting bolt nut (Item 2) [B] and move
the cam to the rear to get free play in the left steering lever.
Tighten the cam bolt. Use a punch and hammer, hit the
cam nut (cam mounting bolt is still tight) until the free play
is removed from the left steering lever [C].
The cam must be centered in the detent bracket pocket

[0] ID
Recheck the torque at the cam bolt to be sure it is still
tight. Check again to be sure there is no free play in the
cams. If there is any free play the neutral setting can
not be obtained.
Detent •
Bracket
Pocket •
MC-01944
963 B obcat Loader

Revised Oct_ 98 -3-10 Service Manual
Advance Hand Control (A.H.C.) Loaders Only:
Remove the bolts and nuts (Item 1) [A] if the neutral

centering bracket needs to be replaced.
Assembly: If the neutral centering bracket is replaced,

keep the bracket vertical to be sure that both cams make
full contact in the pocket of the detent bracket.
Read this adjustment completely to become familiar with

the procedure before beginning the adjustment.
Assembly: Use the following procedure to adjust the

neutral bracket so both steering levers have no free play
against the cam. To remove the free play, move the right
cam to match the left cam so there is no free play
between the two cams in the pocket of the detent
centering bracket [B]. Use the following procedure to
adjust the cam free play.
Only the right side cam is adjustable in the slotted hole in

the bellcrank (Item 1) [B],. The left side cam is fixed and
will not require adjustment.
The cam should not rotate on the mounting bolt. If cam

rotates, tighten the jam nut (Item 1) [C] against the cam
while holding the cam mounting bolt.
Loosen the cam mounting bolt nut (Item 2) [C] and move
the cam to the rear to get free play in the left steering lever.
Tighten the cam bolt. Use a punch and hammer, hit the
cam nut (cam mounting bolt is still tight) until the free play
is removed from the left steering lever [0].
The cam must be centered in the detent bracket pocket.
Recheck the torque at the cam bolt to be sure it is still

tight. Check again to be sure there is no free play in the
cams. If there is any free play the neutral setting can
not be obtained.
963 Bobcat Loader

STEERING LINKAGE
Neutral Adjustment
A WARNING

or death. W-205!Hl598
Stop the engine.
Read the neutral adjustment procedure completely to

become familiar with the procedure before beginning the
adjustment.
NOTE: If the controller has been repaired, it needs
to be adjusted before neutral can be adjusted
at the steering linkage. (See Page 3-19.)
Loosen the lock nuts (Item 1) [A] at the linkage rod clevis.
Loosen the lock nuts (Item 1) [B] at the linkage rod clevis
at the controller.
Remove the retainer pin at the clevis pin (Item 2) [B) (both
sides) and disconnect the linkage rods at the controller.
Make sure there is no freep/ay at the steering lever cams.

(See Page 3-10 .)
Adjust the linkage rod (the rod has right handed threads
at one end and left handed threads at the other end),
turning it to the right or left, until the clevis pin slides
through the controller lever and clevis without the
controller lever moving. When adjusted correctly, there
will be a small amount of freeplay at the clevis pin.
Repeat the procedure for the other side.
Tighten the lock nuts on the linkage rods.
The stop bolts must be set so the end of the steering lever
stroke force is against the stop bolt instead of the
controller lever.
The stop bolt (Item 1) [C) must be set so that with the
controller fully stroked (pushing the steering lever
forward) the bolt head is against the controller lever, then
turn the bolt about 1/2 turn further out so that the bolt limits
the end of the steering lever travel.
963 Bobcat Loader

STEERING LINKAGE (Cont'd)
Neutral Adjustment (Cont'd)

The stop bolt (Item 1) [A] must be set so that with the
controller fully stroked (pushing the steering lever
backward) the bolt head is against the controller lever,
then turn the bolt about 1/2 turn further out so that the bolt
limits the end of the steering lever travel.
Repeat the procedure for the other side.

NOTE: Before dOing the next procedure, make sure
the wheels do not touch the jackstands.
With a second person in the operator seat, seat belt

fasten, and seat bar down.
Start the engine.
Engine at full RPM and two speed switch in high range,

check the wheel RPM. Move the steering lever fully
forward with a hand held tachometer (Item 1) [B], on each
side of the loader.
If the wheel speeds are different the hydrostatic motor

must be adjusted.
Remove the motor access cover (both sides). (See Page

3-69.)
Remove the tamper proof cap and loosen the set screw
jam nut on the bottom of the motor (Item 1) [Cl
Turn the set screw out or in matching the wheel speed

from one side of the loader to the other side. About 1/4
turn on the setscrew will equal one RPM for wheel speed.
Factory specification is 92 wheel RPM (full engine RPM

and high range). DO NOT exceed this wheel RPM.
Install the new tamper proof cap after the adjustment is

done .
963 Bobcat Loader

HYDROSTATIC CONTROLLER
IMPORTANT

the system.
1-2003--0888
A WARNING

or death. W-2059--o598
Stop the engine .
Disconnect the right side brace (Item 1) [A] from the

shock absorber mounting bolt. Reinstall the shock
mounting bolt.
Disconnect the left side brace (Item 1) [B] from the shock
bolt.
Remove the two mounting bolts (Item 1) [C] from the

brace and hydrostatic controller mounting bracket.
Remove the brace from the loader.
NOTE: Mark all hoses for correct installation.
Disconnect the hose (Item 1) [0] and filter (Item 2) [0]

from the hydrostatic controller.
Disconnect the charge pressure hose (Item 3) [0] which

comes from the hydrostatic controller to the hydraulic
control valve.
963 Bobcat Loader

HYDROSTATIC CONTROLLER (Cont'd)
Disconnect the hoses (Item 1) [A] at the left hydrostatic

pump.
Disconnect the hoses (Item 1) [B] at the right hydrostatic

pump.
Disconnect the hose (Item 2) [B] from the reservoir to the

back side of the hydrostatic controller.

controller mounting bracket.
Remove the hydrostatic controller assembly from the

loader.
Installation: After the hydrostatic controller is installed,

adjust the neutral at the steering lever linkage. (See Page
3-12.)
963 Bobcat Loader

Disassembly and Assembly
Remove the nuts (Item 1) [A] and controller mounting

bracket (Item 2) [A].
NOTE: Mark all hoses for correct installation.
Remove the bolts (Item 1) [6] and lever stop plate (Item
2) [6].
Disconnect all the hoses from the hydrostatic controller.
Loosen the two bolts (Item 1) [C] at the controller housing

(both sides). c
N-16053
963 Bobcat Loader

A
Assembly: Tighten the mounting bolts to 14 ft.-Ibs. (19
Nm) torque [A].
N-16054
Remove the bolts (Item 1) [8] and controller housing

(Item 2) [8] from the center block (both sides). IB
..) .~
N-16055
Assembly: Always replace the O-rings (Item 1) [C]

before assembling the controller housing to the center
block.
N-16056
963 Bobcat Loader

A
Remove the rubber boot (Item 1) [A] from the lever.
N-16057
Loosen the lever base bolts (Item 1) [B].

B
Assembly: Put LOCTITE #242 on the bolts and tighten
the bolts to 12 ft.-Ibs . (16 Nm) torque .
'>
N-1 6058
Remove the bolts (Item 1) [C].
Remove the lever base assembly (Item 2) [C] .
Remove the lever base mounting plate (Item 3) [C].
.
0 .,-,
\2j,--:
' ,--( ' .,'
N-16059
Rem<;:>ve the plunger/guide assembly (Item 1) [0] from the I0

housing .
Remove the plunger spring assembly (Item 2) [0] from

the housing.
N-16060
963 Bobcat Loader

HYDROSl1tTIG CONTROLLER (Cont'd) IA
Disassem i,IY and Assembly (Cont'd)
Disassemole the following parts, check for wear and

replace as needed [A]:
~
.,.,".. .~ ct
~ r~
Item Description
1 GUIDE (I
'. ,• .
'I"
·., r. .
ct
" '. , I,
2 PLUNGER 4 3 2 , 1
""
3 SPOOUSPRING ASSEMBLY /,
4 RETURN SPRING
N-16061
Remove the locking discs (Item 1) [8] and disassemble

the following parts, check for wear and replace as needed IB
[8]:
Item Description
1 LOCKII\JG DISC
2 SPRII\JG GUIDE
3 CONTROL SPRING
4 SHIMS
5 SPOOL
N-16062
Adjustment
After the hydrostatic controller is assembled, you should

c
feel free play between the set screws (Item 1) [C] and top
of the plunger.
If not, loosen the lock nut (Item 2) [C] first, then loosen the
set screw (Item 1) [C] until a small amount of free play can
be felt between the plunger and set screw. If there is no
free play, steering lever neutral can not be obtained.
NOTE: Be careful when turning the set screws, they

will break if the lock nut is not loose.
N-160S7
963 Bobcat Loader

HYDROSTATIC MOTOR
IMPORTANT

the system.
1-2003-0888

B
A WARNING

or death. W-20S9-{)S98 '.~
Remove the hydrostatic motor cover. (See Page 3-{)9.)
Mark all the hoses for correct installation.
Disconnect the hose (Item 1) [A] at the bottom of the
motor.
Disconnect the hose (Item 2) [A] at the top of the motor.
Loosen the four mounting bolts at the high pressure hose
collar (Item 1) [8] (front and rear) .
Remove only two bolts and one collar (Item 1) [8] and
disconnect the high pressure hose.
Installation: Install the rear collar (Item 1) [C] and

connect the high pressure hose behind the collar and then
install the other collar and tighten the bolts to 25 ft.-Ibs .
(34 Nm) torque .
963 Bobcat Loader

HYDROSTATIC MOTOR (Cont'd)
Remove the four mounting bolts (Item 1) [A] from the

motor mounting flange.

(88-95 Nm) torque.
Remove the hydrostatic motor from the gearcase housing

[8].
963 Bobcat Loader

Throttle Control
IMPORTANT

the system.
1-2003-0888
Remove the plug (Item 1) [A].

B
Use a allen wrench and remove the top throt1le seat (Item
1) [8].
Remove the double coned throt1le pin (Item 2) [8].
Remove the bot1om throt1le seat (Item 3) [8].
Inspect all the parts and replace as needed.
Shuttle Check Valve
N-16081
Remove the top shut1le check valve plug (Item 1) [C].
Remove the shut1le check valve (Item 2) [C].
Remove the shut1le check valve seat (Item 3) [C].
c
Remove the top shut1le check valve plug (Item 4) [C].
Remove the shut1le check valve (Item 5) [C].
..
~-' il ~~
.~
~'tj 1
Remove the shut1le check valve seat (Item 6) [C].

N-16082
Remove the spring (Item 1) [0].
Ii
Remove the spool (Item 2) [0].
D I,
"
~
~
II
Assembly: Always use new O-rings before installing

" .l~
plugs.
'~ :p
4
. 1.. _"
, .<:. ,
il '
N-16083
963 Bobcat Loader

Flushing Valve
Remove the flushing relief valve spring (Item 1) [Bl
Remove the flushing relief valve (Item 2) [Bl

Bt
N-16085
Remove the plugs (Item 2) [Al

c
..~~
Remove the flushing spool springs (Item 1) [C] and
washers (Item 2) [Cl

;. 'i ..
Remove the flushing spool (Item 3) [C].

~; '. ~
~
Assembly: Always use new O-rings when installing 7
plugs . ~
3
N-16086
963 Bobcat Loader

Disassembly
A ..
IMPORTANT

the system.
1-2003--0888
Remove the four mounting bolts (Item 1) [A] at the B

flushing valve housing.
Remove the flushing valve housing (Item 1) [B] from the

motor end plate housing.
,.~~~.
Remove the three O-rings (Item 1) [C] from the end plate
housing.
Remove the bolts (Item 1) [0] from the end plate housing.
Remove the end plate housing .
963 Bobcat Loader

Remove the control lens (Item 1) [A] from the end plate
housing.
.'..
''l'
.,
N-16091
Remove the plug (Item 1) [8] and control piston (Item 2)

[8] from the end plate housing . B
~
7'
N-16093
Remove the tamper proof cap (Item 1) [C] from the

adjustment screw. IC
0-+-.'
N-16095
Measure the adjustment screw (Item 1) [0]. Make a

record of this measurement for correct assembly.
Remove the adjustment screw from the motor housing.
Remove the O-ring (Item 2) [D) from the housing.
963 Bobcat Loader

A
Install a 5 mm bolt (Item 1) [A] and washer into the center
pin in the rotating group to hold it together.
Install a bearing puller (Item 1) [B] around the motor

housing. Press the rotating group/shaft assembly from
the housing .
Remove the snap ring (Item 1) [C], washer (Item 2) [C] I

and seal (Item 3) [C] from the motor housing. C
.. - f. ~2
<~ ~
~
1 O
,
~·C> ." ." O.
.. •
. ..
'<I ;i
'
1<.
".
N-16100
~
Remove the bolt (Item 1) [0] and washer from the rotating
group.
N-16103
963 Bobcat Loader

Remove the rotating group cylinder block from the pistons

[AJ,
Remove the center pin spring from the center pin [8].
B
N-16106
Inspection
Check the pistons (Item 1) [C] for no scoring and no

pitting at the ball socket and piston body.
Check the piston retainer plate (Item 2) [C] for scoring

and no evidence of wear.
Check the piston rings (Item 3) [C] for wear.
Check the main shaft driver bearings (Item 1) [0] that they
are free of corrosion, erosion and with no damage to the
splines.
If any of the parts on the rotating group or drive shaft show

wear or damage, they must be replaced as an assembly.
963 Bobcat Loader

A
Inspection (ConI' d)
Remove the pin (Item 1) [A] from the control lens (Item
2) [A]. Check the face of the control lens for being smooth
and even, free of cracks and scoring.
Check the pin for wear.
~
J'
N-16113 N-16112
Check the cylinder block bores (Item 1) [B] that they are
:t
free of scoring and no evidence of wear. B
1
'..:
"
<iI••
'''I
:.,
Check the cylinder block (Item 1) [C] and control lens

(Item 2) [C] mating surfaces for being smooth faces and
even, and free of cracks or scoring. IC
If any of the parts on the rotating group/drive shaft
assembly show wear or damage they must be replaced
as an assembly.
Check the housing at the bearing seats (Items 1 & 2) [0]

for scoring and no evidence of wear.
963 Bobcat Loader

A
Assembly
IMPORTANT

the system.
1-2003-0888
Install the center spring into the center pin. Put grease on
the washer and install it in the cylinder block center bore
[A].
Install the cylinder block on the pistons [8].
For easier installation of the piston/piston rings into the

cylinder block, come straight down into the cylinder block
bores [C].
Make sure all the parts are fitted together correctly.
N-16115
963 Bobcat Loader

Assembly (Cont'd)
Swivel the cylinder block to the minimum angle (straight

up and down) and install the 5 mm bolt (Item 1) [AJ and
washer to hold the rotating group together.
.
.i .,"
N- 16116
~ 1:
Install a new drive shaft seal using a seal driver tool [B].
B
.
~ ,~-
j~
t;,.,
}.:~: j:~: t
N-16101
Install the washer and snap ring (Item 1) [C] into the
housing.
....
,;
A sleeve (Item 1) [D] (Example: MEL1399 Tool), two bolts
(Item 2) [D] and washers (Item 3) [D] will be needed to
install the rotating group/drive shaft assembly into the
motor housing .
The correct bolts sizes are as follows:

D
. 7/16 x 3 inch NC 14
7/16 x 2-3/4 inch NC 14
N-16119
963 Bobcat Loader

A
Assembly (Cont'd)
Start the drive shaft bearing/rotating group assembly into

the motor housing making sure the bearings and shaft
(Item 1) [A] are centered in the housing.
N-16117
Install the tool (Item 1) [B], bolt and washer(s) (Item 2) [B] I B ,,' ....-
on the end of the drive shaft.
Make sure the drive shaft bearing is being pulled straight

into the motor housing with no binding, pull the assembly
into the housing by turning the bolt until it bottoms on the
end of the drive shaft. Remove the bolt and install the
shorter bolt and continue to install the drive shaft bearing
until it is fully seated in the motor housing.
Remove the bolt, washer and tool from the drive shaft.
N-16118
Remove the bolt and washer (Item 1) [C] from the rotating
group center pin.
N-16120
Install the pin (Item 1) [0] into the control lens (Item 2) [0]. D
o
'.1 .~
N-16113
963 Bobcat Loader

Assembly (Cont'd)
Install the control piston (Item 1) [A] into the end plate
housing.
Install the plug (Item 2) [A] and tighten.
"":1.
N- 16092
Put grease on the control lens [B].
Install the control lens (Item 1) [C] into the end plate IC
housing with the pin going into the control piston .
Install the end plate housing (Item 1) [0] on the motor

housing and rotating group.
Install the end plate housing bolts.
Tighten the bolts evenly until there is a small amount of

pre-load on the rotating group cylinder block and control
lens.
This pre-load is necessary so the adjustment screw can

be installed.
963 Bobcat Loader

R e vised Oct. 98 -3-32 Service Manual
A
Assembly (Cont'd)
Install the adjustment screw (Item 1) [A] into the housing.
Adjust the adjustment screw to the correct dimension
recorded when the screw was removed . (See Page 3-25;
Fig. [0].)
Replace the tamper proof cap on the adjustment screw.
Tighten the bolts (Item 1) [8] at the end plate housing to I8

~-'-;,
Install the new O-rings (Item 1) [C].

c
Install the flushing valve (Item 1) [0].
Install the bolts (Item 2) [0] and tighten to 85 in.-Ibs. (9,6

Nm) torque.
Pour about 1 qt. (0,9 L.) of hydraulic fluid into the

hydrostatic motor case before installation.
963 Bobcat Loader

HYDROSTATIC PUMP
Remove the hydrostatic pump/engine assembly from the

loader. (See Page 7-1.)
Remove the drive belt from the pump pulley. (See Page
3-63.)
Remove the nut (Item 1) [A] and washer from the

hydrostatic pump drive shaft.
Installation: Tighten the nut to 200 ft.-Ibs . (271 Nm)

torque.
Use a puller (Item 1) [8] to remove the pulley from the

pump drive shaft.
Connect a chain hoist to the hydrostatic pump.
Remove the bolts (Item 1) [C] from the pump mounting

bracket.

(88-95 Nm) torque.
Remove the mounting bolts (Item 1) [0] at the hydraulic

pump mounting bracket.
Lift the hydrostatic pump with the chain hoist and remove
from the engine mounting bracket.
963 Bobcat Loader

HYDROSTATIC PUMP (Cont'd)
Hydraulic Pump Removal And Installation
Remove the mounting nuts (Item 1) [A] and remove the

mounting bracket (Item 2) [A] from the hydraulic pump .
Installation: Tighten the nuts (Item 1) [A] to 70 ft.-Ibs.

(96 Nm) torque.
Remove the tubeline (Item 1) [8] from the hydraulic

pump.
Remove the two mounting bolts (Item 1) [C) on either side

of the hydraulic pump.
Installation: Tighten the mounting bolts to 30 ft.-Ibs. (40

Nm) torque.
N-15848
Remove the hydraulic pump from the hydrostatic pumps

[0).
N-15849
963 Bobcat Loader

Replenishing/High Pressure Relief Valve
IMPORTANT
When repairi ng hydrostatic and hydraulic

the system.
1-2003-0888
There are four replenishing/high pressure relief valves

(Item 1) [A] in the hydrostatic pump assembly.
Two are located at the top of the pumps and two are
located at the bottom of the pumps.
Remove the plug(s) (Item 1) [8].
Remove the spring (Item 1) [C] and high pressure relief

valve (Item 2) [C] from the pump.
c II
Check for damage and replace as needed.
~
Installation: Tighten the main relief plug to 30 ft.-Ibs. (41
Nm) torque.
/',
N-16125
963 Bobcat Loader

Charge Relief Valve
IMPORTANT

use caps and plugs on hoses, tubelines and II

the system.
1-2003-0888
Loosen the charge relief valve (Item 1) [A]. 8

Remove the charge relief (Item 1) [8], seat (Item 2) [8],
shims (Item 3) [8] and spring (Item 4) [8].
Installation: Tighten the charge relief valve to 30 ft.-Ibs.

(41 Nm) torque.
N-16127
DA Controller
Loosen the DA controller (Item 2) [A].
Remove the DA controller assembly (Item 1) [C] from the

port block.
The DA controller can not be adjusted and must be

replaced as an assembly.
963 Bobcat Loader

Disassembly
IMPORTANT

the system.
1-2003--0888
Remove the bolt (Item 1) [A] from both sides of the
hydrostatic pump assembly.
Separate the two pump halves [8].
Remove the large O-ring (Item 1) [8].
Loosen the two replenishing/high pressure relief valves

(Item 1) [C].
Remove the replenishing/high pressure relief valves

(Item 1) [0] from the port block.
963 Bobcat Loader

Remove the charge relief valve (Item 1) [A), seat (Item 2)
[A) and spring (Item 3) [A) from the port block.
N-16134
Use a punch and hammer to mark the charge pump
housing and port block housing for correct installation of
the charge pump [8).
Mark the port block to the pump housing for correct

installation .
Remove the four mounting bolts (Item 1) [C] from the

charge pump.
N-16135
Remove the charge pump (Item 1) [0] from the port block.
N-16138
963 Bobcat Loader

Remove the coupler (Item 1) [A] and key from the pump
shaft.
Remove the large O-ring (Item 2) [A].
Remove the charge pump wear plate (Item 1) [B].
N-16141
Remove the large O-ring (Item 1) [C] from the charge

pump housing.
'::,
N-16142
D
Remove the four mounting bolts (item 1) [0] from the port
block.
N-16146
963 Bobcat Loader

Remove the port block (Item 1) [A] from the pump
housing.
Remove the valve plate (Item 1) [8] from the port block.
B
N-16150
Remove the large O-ring (Item 1) [C] from the pump

housing . IC
Remove the tamper proof cap (Item 2) [C] from the
adjustment screw.
0--+ ·,' 1:
N-16152
Put a mark (Item 1) [0] on the pump housing in alignment

with the notch (Item 2) [0] on the adjustment screw. This
mark is needed for correct installation of the adjustment
screw.
963 Bobcat Loader

Push down on the rotating group and remove the

eccentric adjustment screw from the housing.
N-16154
Remove the rotating group assembly from the pump

housing [8].
Remove the swashplate/bearing assembly from the

pump housing [C].
N-16159
Remove the bearing races (Item 1) [0] from the pump

housing.
963 Bobcat Loader

Revjsed Oct. 98 -3-42 Service Manual
A
Remove the four bolts (Item 1) [A] from the servo piston
cover.
Remove the lock nut at the servo piston adjustment screw

~. 18
/
I ',~
6167
Turn the servo piston cover counterclockwise to remove

it from the servo piston adjustment screw [C].
. :~.
Remove the servo piston (Item 1) [0] from the pump D

housing bore.
N-16169
963 Bobcat Loader

HYDROSTATIC PU MP (Cont'd)
A
Check the piston servo bushing(s) (Item 1) [A] for wear

and damage, if they need replacement, remove the snap
ring (Item 2) [A].
Remove the snap ring , bushing and snap ring from the
housing [8]. I8
o
Left Pump : Remove the snap ring (Item 1) [C] at the pump
drive shaft seal.
Left Pump: Use a puller with a screw tip and remove the
shaft seal from the pump housing [0].
963 Bobcat Loader

R~vis~d Oct. 98 -3-44 Service Manual
A
Left Pump: Remove the snap ring (Item 1) [A] at the drive
shaft bearing . <.
.'
Left Pump: Remove the drive shaft from the pump

housing [6].
Right Pump: Remove the snap ring (Item 1) [C] from the
drive shaft seal.
963 Bobcat Loader

Right Pump: Use a puller with a screw tip and remove the
seal from the pump housing [A].
Right Pump: Repeat the procedure from the left pump to

remove the drive shaft (Fig. [A] [B]; Page 43) .
Inspection
Clean all the parts in solvent and use air pressure to dry
B
them . DO NOT use cloth or paper because small pieces
of material can get into the system and cause damage.
Check the charge pump gears for wear and damage [B].
Check the pump housing for wear and damage ]B].
N-16144
Check the valve plate (Item 1) [C] , the surface must be

smooth and free of scratches. If scratches can be felt with
a fingernail , replace the parts.
c
Check the port block bearing (Item 2) [C] for wear, replace
as needed .
Check the swash plate (Item 1) [0] , the surface must be
smooth and free of scratches.
o
Check the servo piston (Item 2) [0] for wear or damage.
Replace the parts as needed.
~
::-!
963 Bobcat Loader

Inspection (Cont'd)
Check the swashplate bearing (Item 1) [A] for wear and
damage, replace as needed.
N-161 79 N-16181
Check the swashplate bearing (Item 1) [B] and servo

piston block (Item 2) [B] for wear and damage. Replace
the parts as needed.
.
';';"~
.... '.'
N-16180 N-16183
Check that each piston move freely in its bore [C].
Check each piston and piston shoe for wear or scratches.

c
Check the shoe plate, the shoe plate must be flat with no
signs of cracks or wear.
Check the end of the cylinder block, the surface must be
smooth and free of scratches.
N-16156
Check the cylinder block bores for wear and scratches

[0]. o
Check the spherical washer (Item 1) [0] for wear or
damage.
Check the pins (Item 2) [0] , the pins must not be bend and
the same length .
If there is any defect in the rotating group, the complete

unit must be replaced.
"f ~:,;.- it
-,..
N-16157
963 Bobcat Loader

A
Inspection (Cont'd)
Check the shaft for wear or damaged in the spline and

bearing areas [A].
Check the bearing for correct operation. Remove the

bearing from the shaft only if it is necessary to replace the
bearing [A].
N-16177
Check the servo piston busing for wear or damage [8].
Check the snap rings for not being bend [8]. Replace the
B
parts as needed .
o N-16172
963 Bobcat Loader

Assembly
IMPORTANT

disassembly and keep a" parts clean. Always
the system.
1-2003--0888
Right Pump: Install the drive shaft (Item 1) [A] into the
pump housing.
Install the snap ring (Item 2) [A].
Right Pump: Install the drive shaft seal using a bearing

driver tool [8].
Right Pump: Install the snap ring (Item 1) [C] into the
pump housing.
Left Pump: Install the drive shaft and snap ring into the
pump housing.
Left Pump: Install the drive shaft seal using a bearing

driver tool [0].
963 Bobcat Loader

Assembly (Cont'd)
Left Pump: Install the snap ring (Item 1) [A] into the
housing.
Install the snap ring (Item 1) [B] into the housing.
Install a new O-ring on the servo bushing (Item 2) [Bl
Install the servo bushing (Item 2) [B] into the pump
hoUsing.
Install the other snap ring (Item 3) [B] into the housing .
N-16171
963 Bobcat Loader

Assembly (Cont'd)
A
Install the servo piston (Item 1) [A] into the pump housing .
CD :.~
" , '~11
.s> ~"'I':r"~~1t;
" t , . .(
-'
.
:-... . ""~0'1.~. '..~._. i
- " ". "-:..... 'I.
{;~. ,!r-.,;~".r
,
. " .':, :.., ':;~" r •
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"-': 'J','
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~ .. _·c·". •
~ D N-16169
Install the servo piston cover by turning it clockwise [8].
Install the four mounting bolts (Item 1) [C] and tighten to

85 in ..- Ibs. (9,6 Nm) torque. I C
Install the bearing races (Item 1) [0] into the pump

housing. I D
963 Bobcat Loader

A
Assembly (Cont'd)
Install the bearing , servo block and linkage rod on the

swash plate [A].
Put grease on all the parts to hold them together.
N- 16182
Install the bearing (Item 1) [B] and linkage rod (Item 2) [B] IB
on the swashplate.
Put grease on all the parts to hold them together.
.
' ~~
N-16179
Remove the plug (Item 1) [C] and locating pin (Item 2) [C]
from the housing.
".
r
'0 ;
N-16186
Install the swashplate/bearing assembly into the pump

housing [0]. I D
963 Bobcat Loader

Assembly (Cont'd)
After the swashplate is installed, make sure the servo

block (Item 1) [A] is engaged in the slot in the servo piston
(Item 2) [A].
At the other side of the swashplate , align the linkage rod

(Item 1) [8] so when the slotted locating pin (Item 2) [8]
is installed it will go over the linkage rod. Install and tighten
the plug.
To set neutral at the servo piston and swashplate , do the

following procedure: IC
Put a straight edge (Item 1) [C] across the pump housing.
Use a calipers (Item 2) [C] and measure the distance on

one side of the swashplate . Then measure the other side
of the swash plate.
Turn the servo piston adjustment screw (Item 3) [C] until

both sides of the swashplate measure the same distance .
cv--.
963 Bobcat Loader

A '":":': ''::
Assembly (Cont'd)
Hold the adjustment screw and tighten the lock nut [A].
N-16167
Put a rubber band around the pistons to hold them in

position [B). I B"
N-16189
Install the rotating group assembly into the pump housing

[C].
When the rotating group is seated on the swashplate,

release the rubber band and remove it from the pistons.
963 Bobcat Loader

Assembly (Cont'd)
Put grease on the valve plate and install it on the port

block [A].
Install the port block/valve plate assembly (Item 1) [8] on

the pump housing and rotating group.
Install the four bolts into the port block and tighten evenly
until a small amount of space (Item 2) [8] is left between
the pump housing and port block.
Using a small screwdriver (Item 1) [C], make alignment

of the slot (Item 2) [C] in the valve plate with the hole the
eccentric adjustment screw will turn into housing. The
adjustment screw will turn into the slot in the valve plate.
963 Bobcat Loader

-3-55- Service Man ual
Revised Oct. 98
Assembly (Cont'd)
Install the eccentric adjustment screw into pump housing

[A].
As the eccentric adjustment screw is installed, you will

feel, no resistance and small amount of resistance as the
screw is turned into the valve plate.
Turn the adjustment screw until it bottoms in the valve

plate slot, then turn the adjustment screw back out until
the marks (Item 1) [8] are aligned.
Tighten the lock nut [B].
Install a new tamper proof cap on the eccentric

adjustment screw.
Tighten the bolts at the port block to 85 ft.-Ibs. (118 Nm)

torque [C]. c
N-16147
Install the large O-ring (Item 1) [0] on the charge pump

housing.
963 Bobcat Loader

A
Assembly (Cont'd)
Install the wear plate with the large opening (Item 1) [A]
toward the intake and pressure side of the charge pump
[B).
N- 16 141
B ". '''-,
.:,"
. ~' ,..
, ..
N- 161 40
Install the coupler (Item 1) [C] and key into the pump drive
shaft.
Install the large O-ring (Item 2) [C] on the pump housing.
N-16145
Install the charge pump into the port block [0).
Install the four mounting bolts (Item 1) [0).
p oi
N- 16 137
963 Bobcat Loader

A
Asse mbly (Cont'd)
Tighten the charge pump mounting bolts to 34 ft.-Ibs . (46

Nm) torque [A).
N-161 36
Install the large O-ring (Item 1) [B] into the charge pump.
N-161 31
Install the spring (Item 1) [C], seat (Item 2) [C] and charge
relief valve (Item 3) [C) into the port block.
Tighten the charge relief valve to 30 ft.-Ibs. (41 Nm)

torque .
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,
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,~.
Install the replenish ing/high pressure relief valves (Item

1) [0] into the port block.
Tighten the valves to 30 ft.-Ibs. (41 Nm) torque.
963 Bobcat Loader

Revised Oct_ 98 -3-58 Service Manual
Assembly (Cont'd)
Install the two hydrostatic pump halve~ together [A).
N-16130
Install the bolt (Item 1) [B] and tightenlto 75 ft .-Ibs. (102

Nm) torque (both sides) .
Hydrostatic Pump Start-Up
Disconnect the fuel shut-off solenoid at the fuel injection

pump.
Crank the engine, with the starter, for 15-20 seconds.
Connect the fuel shut-off solenoid.
Start the engine and run at idle speed for 5-7 minutes
before operating the loader. Do Not run the engine above
idle speed while doing the above procedure .
963 Bobcat Loader

Timing Procedure
Connect the remote start switch . (See Page 1-1 .)
After the hydrostatic pumps have been disassembled and

assembled, you need to set the output pressure between
the pumps so they are equal, use the following procedure.
NOTE: Mark all the hoses before disconnecting

them for correct installation.
Disconnect the hoses (Item 1) [A] & [8] at both

hydrostatic controllers. Install a tee-fitting in one
controller and re-connect both hoses to the tee-fitting on
the controller.
Disconnect the other hoses (Item 2) [A] & [8] at the

hydrostatic controllers. Install a tee-fitting in the other
port of the controller and re-connect both hoses to the
tee-fitting on the controller.
Install caps and tighten on the fittings of the controller

which is not used.
Now the output of the one controller is actuating both

pumps evenly while the other controller is not connected .
Disconnect and plug the charge pressure tubeline (Item

1) [C] coming from the rear hydrostatic pump, so the
pumps will operate only on the DA controller.
963 Bobcat Loader

Revised Dec. 98 -3-60- Service Manual
Timing Procedure (Cont'd)
Remove the hydrostatic motor cover (both sides). (See

Page 3-69 .)
At the hydrostatic motor (Item 1) [A] (both sides), remove

the G port plug (Item 1) [B] , connect a 10000 PSI (68950
kPa) gauge.
Start the engine and run at full RPM .
Engage the parking brake.

NOTE: Do not stroke the hydrostatic pump for more
than 20 seconds at a time when checking the
pressure.
Push the connected hydrostatic controller forward and
note the pressure on both gauges at the motors. If the
pressures are different, the pump timing needs to be
adjusted.
Remove the tampered proof caps (Item 1) [C] to turn the

adjustment screws.
With the engine at full RPM and the pump stroked

pressure should be approximately 3400 PSI (23443 kPa).
Be more concerned with the pressure being the same
than with the 3400 PSI (23443 kPa) pressure.
Depending on the situation one or both pumps may need

adjusting . The pump that is furthest from the nominal
3400 PSI (23443 kPa) should be adjusted first.
For example; one pump is at 3600 PSI (24882 kPa) and

the other pump is at 3300 PSI (22753 kPa) . The 3600 PSI
(24882 kPa) pump should be lowered to 3300 PSI (22753
kPa). If the pump does not drop enough to match , raise
the pressure on the other pump. Try to equal the pressure
on both pumps as close to 3400 PSI (23443 kPa) as
possible.
NOTE: A small adjustment makes a large difference

in the output pressure. This adjustment
screw (Item 1) [0] has an adjustment range
from 12 o'clock to 6 o'clock with 3 o'clock
being the nominal. Do not turn the
adjustment screw beyond the 12 or 6 o'clock
position.
To raise the pressure turn the adjustment screw (Item 1)
[0] toward the 6 o'clock positon . To lower the pressure
turn the screw toward the 12 o'clock position.
Install new tamper proof caps on the adjustment screw

after the procedure is completed.
963 Bobcat Loader

Revised Dec. 98 -3~1- Service Manual
DRIVE BELT BELT SHIELD
Open the rear door.
Remove the two mounting bolts (Item 1) [A] at the belt

shield.
Remove the three mounting bolt (Item 2) [A] at the top of

the belt shield.
Remove the bolt (Item 1) [B] at the wire harness clip.
Remove the belt shield from the loader [C].
963 Bobcat Loader

DRIVE BELT
Replacing The Drive Belt
Remove the drive belt shield. (See Page 3-62.)
The drive belt idler arm stop (Item 1) [A] is located on the
right side of the engine mounting bracket.
Loosen the bolt (Item 2) [A].
Remove the bolt (Item 3) [A] and spacer.
Slide the idler arm stop toward the front of the loader.
Loosen the spring tension bolt (Item 1) [B].
Remove the drive belt from the hydrostatic pump pulley
and the flywheel pulley.
Remove the drive belt from the loader [C].
Adjusting The Drive Belt
There is no adjustment for the spring, just make sure the

spring bolt (Item 1) [B] is tight.
Loosen the two bolts (Items 2 & 3) [A] and slide the stop
(Item 1) [A] against the idler arm. Tighten the bolts.
963 Bobcat Loader

ORIVE BELT TENSIONER PULLEY
Remove the drive belt shield. (See Page 3-62.)
Loosen the bolt (Item 1) [A] on the drive belt idler stop .
Remove the bolt (Item 2) [A] and spacer and slide the
idler arm stop toward the front of the loader.
Loosen the spring tension bolt (Item 1) [B].
Remove the spring tension bolt.
Remove the bolt (Item 1) [C] and spacer.
Remove the idler arm stop (Item 2) [C].
Remove the end cap (Item 1) [0] from the tension pulley
arm.
Installation: Fill the end cap with grease to lubricate the

pivot shaft.
963 Bobcat Loader

DRIVE BELT TENSIONER PULLEY (Cont'd)
Remove the bolt (Item 1) [A] from the drive belt tension
pulley arm and remove the assembly.
Tension Spring
Remove the tension spring assembly from the tension

B
pulley assembly by removing the snap ring and washer
(Items 1 & 2) [B].
Remove the end blocks (Item 3) [B] from the spring and
check for wear, replace if needed.
Remove the spring pivot pin (Item 4) [B] from the end
block by loosening the nut (Item 5) [B].
Check the pin for wear and replace if needed .
Check the spring for wear and replace if needed .
N-15842
963 Bobcat Loader

Remove the arm seal (Item 1) [A] and arm bushing (Item
2) [A]. Check for wear and replace if needed.
Disassemble the pulley and bearings as shown in figure

[B]. Check the parts for wear and replace if needed .
><,-'
N-15852
Remove the pulley mounting bolt (Item 1) [C] from the IC

pulley spindle (Item 2) [C] and remove the spindle from
the arm . Check the pulley spindle for wear and replace if
needed.
N-15853
963 Bobcat Loader

Revised Oct. 98 -3~6- Service Manual
Pivot Shaft
Remove the pivot shaft (Item 1) [A] from the engine

mounting bracket.
Remove the bushing (Item 1) [B] from the pivot shaft.

Check for wear and replace if needed.
N-15845
963 Bobcat Loader

Added Oct. 98 -3-67- Service Manual
DRIVE BELT IDLER PULLEY
Remove the end cap (Item 1) [A] from the drive belt idler
pulley.
Remove the mounting bolt and washer (Item 1) [B] from

the idler pulley.
Disassemble the pulley and bearings as shown in figure IC

[e]. Check the parts for wear and replace if needed.
N-15840
Check the idler shaft (Item 1) [0] for wear.
The idler shaft can be replaced by removing the mounting

bolt located on the backside of the mounting bracket.
963 Bobcat Loader

Added Oct. 98 -3-68 Service Manual
HYDROSTATIC MOTOR COVER
Remove the wheel nuts and remove the tire/wheel

assembly from the hub.
Installation: Tighten the wheel nuts to 320-350 ft.-Ibs .

(434-475 Nm) torque.
Remove the mounting bolts (Item 1) [8] from the motor

access cover.
Installation: Tighten the mounting bolts to

220-245ft.-lbs. (298-332 Nm) torque.
Remove the access cover from the loader frame.
963 Bobcat Loader

Added Oct. 98 -3-69- Service Manual
OIL COOLER
IMPORTANT

the system.
1-2003-0888
Open the rear door.
Remove the rear grill. (See Page 5-1.)
Disconnect the hose (Item 1) [A] at the oil cooler (both

sides) .
Remove the two nuts at the bolts (Item 1) [B].
Remove the oil cooler mounting bracket (Item 2) [B].
Raise the oil cooler and lift from the loader frame .
963 Bobcat Loader

Added Oct. 98 -3-7~ Service Manual
DRIVE SYSTEM
Page
Number
AXLE, BEARINGS AND SPROCKET
AXLE SEAL
Removal And Installation ... . ...... . ............................ 4-13
BRAKEITWO SPEED BLOCK

Disassembly And Assembly ... ... ... ... ...... . .... .... ......... 4-7
Removal And Installation .. .. ........... .. ........... .. ......... 4-5
CHAI NCASE FLUID

Removing The Fluid From The Chaincase ........................ 4-35
DRIVE CHAINS DRIVE

Removal And Installation . ........... .. ............ . ............ 4-21 SYSTEM
FRONT CHAINCASE COVER

Removal And Installation .......... . ............. . ............ .. 4-22
PARKING BRAKE
Disassembly And Assembly .................... . ........... . ... 4-10
PARKING BRAKE PEDAL

Removal And Installation ....................... .... ... . ...... . . 4-3
Disassembly And Assembly ..... . ...... . . . .......... .. ......... 4-4
REAR CHAINCASE COVER

Removal and Installation ............ . ................. . . . . . . . .. 4-22
REDUCTIOt\1 GEARCASE
Disassembly And Assembly ..... . ...... . ...................... . 4-26
963 Bobcat Loader

lenuew aO!I\Jas
Jap eol leoq o 8 £96
PARKING BRAKE PEDAL
Disconnect the wire harness connector (Item 1) [A] for

the parking brake.
Remove the mounting bolts (Item 1) [8] from the parking

brake pedal mounting bracket.
Open the front clean-out cover (Item 1) [C].
Pull the wire harness tube (Item 2) [C] through the

opening to remove it from under the front panel. Remove
the parking brake pedal bracket/wire harness assembly
from the loader.
963 Bobcat Loader

PARKING BRAKE PEDAL (Cont'd)

A
Loosen and remove the mounting bolt (Item 1) [A] and nut
from the spring mounting bracket (Item 2) [A].
Remove the brake pedal spring (Item 3) [A] from the

tension spring mounting bracket (Item 2) [A] and from the
brake pedal mounting bracket (Item 4) [A].
Remove the two mounting bolts , washers and nuts (Item

5) [A] from the brake pedal sensor.
Remove the harness mounting clamp (Item 1) [B] from

the pedal mounting bracket (Item 2) [B].
Remove the sensor harness from the pedal mounting

bracket.
Remove the pedal mounting bolt (Item 6) [A] , plastic

spacers and bushing nut from the brake pedal.
Remove the pedal from the pedal mounting bracket.
Photo [B] shows the parking brake disassembled to

identify the existing parts in the brake assembly.
' --;lj".-,
• ,1"",-----1
P-04156
963 Bobcat Loader

BRAKErrwo SPEED BLOCK
Disconnect the linkage rods (Item 1) [A] from the control

arms and steering levers.
Remove the bolt (Item 1) [B] and nut from the lift linkage
and crossmember linkage.
Remove the bolt (Item 1) [C] and washer from the

crossmember linkage. Remove the crossmember linkage
from the pivot.
Disconnect the wire harness connectors (Items 1 & 2) [0].
Installation: Install a new Do Not Modify sta-strap (PIN

6665527) on the wire harness connector (Item 1) [0].
963 Bobcat Loader

BRAKEfTWO SPEED BLOCK (Cont'd)
Disconnect the hose (Item 1) [A] which comes from the

control valve.
Early Model Loaders: Disconnect and remove the brake

tubeline (Item 2) [A].
Later Model Loaders: Disconnect the brake hose (Item

1) [B] at the fitting .
Disconnect the hose (Item 1) [C] which goes to the left

side hydrostatic motor.
Disconnect the hose (Item 2) [C] which goes to the right

side hydrostatic motor.
Disconnect the hose (Item 3) [C] which goes to the lift lock
valve.
Remove the four mounting bolts (Item 1) [D].
Remove the brake/two speed block assembly from the

loader.
963 Bobcat Loader


A
Remove the two bolts and nuts (Item 1) [A] from the block
and remove the block from the mounting bracket.
N-15642
Loosen the electrical solenoid nut (Item 1) [8].
Assembly: Tighten the nut to 9-12 in.-Ibs. (1 ,02-1,36

Nm) torque.
Remove the solenoid nut (Item 1) [C], O-rings (Item 2) IC

[C], and solenoid coil (Item 3) [C].
,fJ . . .
N-15640
Remove the solenoid valve (Item 1) [0] from the block.

o
Assembly: Always install new O-rings and back-up
washers. Tighten the solenoid valve to 96-144 in.-Ibs.
(10,8-16 Nm) torque.
'0
N-15641
963 Bobcat Loader

A
Loosen the traction lock solenoid nut (Item 1) [A] .
Assembly: Tighten the nut to 9-12 in.-Ibs. (1,02-1,36

Nm) torque.
N-15639
Remove the nut (Item 1) [8] and solenoid coil (Item 2) [8].
B
N-16067
Remove the solenoid valve (Item 1) [C] from the block.
Assembly: Always install new O-rings and back-up

c
washers. Tighten the solenoid valve to 96-144 in .-Ibs.
(10,8-16 Nm) torque.
.' N-16068
Remove the fitting (Item 1) [0] and the check valve (Item
2) [0] from the block. Check for correct function of the I0
check valve and replace as needed.
'p""
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;'
N-16066
963 Bobcat Loader

Revised June 98 -4-8 Service Manual
PARKING BRAKE
Remove the brake/two speed block from the center cover
on the chaincase . (See Page 4-5.)
Remove the bolts from the center cover (Item 1) [A] on
the chaincase.
Disconnect the cross-over hose (I tem 1) [8] at the fitting

on the brake housing.
Remove the two mounting bolts (Item 1) [C] and [0].
Installation: Tighten the mounting bolts to 70 ft.-Ibs. (95

Nm) torque.
963 Bobcat Loader

PARKING BRAKE (Cont'd)
Remove the parking brake (Item 1) [A] from the reduction

gearcase housing.
Installation: Install a cap on the fitting (Item 2) [A].

Connect a Port-a-Power to the hose (Item 3) [A]. Pump
the Port- a-Power until the pressure releases the brake
discs so they can be aligned on the reduction gearcase
splined shaft.
Remove the four bolts (Item 1) [B] from the brake

housing.
0'
'of
, ~
'<.' -"
.~
N-15630
Assembly: Put LOCTITE #242 and tighten the bolt to 55

ft.-Ibs . (75 Nm) torque [C].
c
N-15637
Remove the brake housing end cover (Item 1) [0].
N-15631
963 Bobcat Loader

A
Remove the springs (Item 1) [A] and spring guide (Item
2) [A] from the brake housing.
• I N-15632
Use low air pressure at the fitting to remove the piston

(Item 1) [8] from the brake housing. I B
N-15633
Remove the brake discs (Item 1) [Cl c

Assembly: When installing the discs into the housing ,
make sure all the spline teeth are in alignment.
', . N-15634
963 Bobcat Loader

--4-11 Service Manual

A
Remove the O-rings and back-up rings (Item 1) [A] from
the piston.
Assembly: Always install new O-rings and back-up IB

rings on the piston as shown in Fig. [B].
963 Bobcat Loader

AXLE SEAL

procedure:
MEL 1242 - Port-a-Power

MEL 1255 - Axle Seal Tool
Remove the wheel assembly.
Installation: Tighten the wheel nuts to 320-350 ft.-Ibs.
(434-475 Nm) torque.
Remove the three bolts from the hub end plate (Item 1)
[A].
Installation: Put LOCTITE on the bolts and tighten to

210-230 ft.-Ibs. (285-311 Nm) torque.
Remove the end plate from the hub [B].
Install a wheel nut (Item 1) [C] on two wheel studs straight

across from each other.
Use a hammer and remove the wheel studs.
Installation: After the hub has been removed, use a

hammer and install the wheel studs in the hub.
Install two long puller bolts into the hub. Install the puller
cross-bar (Item 1) [0]. Install a spacer on the end of the
axle and against the Port-a-Power ram jack (Item 2) [0].
Remove the hub from the axle.
A WARNING
NEVER STAND IN-LINE OF THE HUB WHEN

REMOVING A HUB FROM AN AXLE. The hub
has a tapered fit on the axle end and can come
off the axle with great force and cause serious
injury.
W-2186-{)395
963 Bobcat Loader

AXLE SEAL (Cont'd)
Remove the key (Item 1) [A] from the axle.
Use a drill to drill a hole in the axle seal [B].
Install a puller into the drilled hole and remove the axle
seal [C].
NOTE: Inspect the wear ring, if the ring is worn, use

the following procedure to remove it.
Use a hammer and chisel and split the wear ring [0]. Be
careful not to damage the axle surface. Remove the wear
ring from the axle.
963 Bobcat Loader

AXLE SEAL (Cont'd)
If the wear ring was removed from the axle, install a new
wear ring (Item 1) [A] into the axle seal.
Put LOCTITE on the inside diameter of the wear ring .
Install the wear ring/seal assembly or seal on the axle seal

tool (Item 1) [B].
Install the wear ring/seal or seal into the axle tube [C].
963 Bobcat Loader

AXLE, BEARINGS AN D SPROCKET

A
procedure:
MEL 1202D - Axle Tools

MEL 1242 - Port-a-Power
NOTE: The procedure shown for removal and

installation of the axle, bearings and
sprocket is for a front axle. This procedure
will also be the same for the rear axle.
Remove the control panel. (See Page 3-1.)
Remove the parking brake pedal assembly. (See Page
4-3.)
Remove the control pedals mounting panel. (See Page

2-1.)
Remove the front cover (Item 1) [A] from the chaincase

by removing the eight bolts.
Remove the fluid from the chaincase. (See Page 4-34.)
Loosen the three bolts (Item 1) [B] at the axle sprocket
before removing the axle hUb.
Remove the axle hub and seal. (See Page 4-13.)
Remove the bolts (Item 1) [B] and end plate from the axle
sprocket.
Installation: Put LOCTITE on the bolts and tighten to
210-230 ft.-Ibs. (285-311 Nm) torque.
Remove the end plate (Item 1) [C] and shim (Item 2) [C].
Installation: The correct end play for the axle is between
0.00-0.006 inch (0,152 mm). Add or replace the shim(s)

(Item 2) [C] on the end of the sprocket to get the correct
end play.
Install the Port-a-Power ram jack between the two front

sprockets [0].
Push the axle out until the ram jack is at the end of the
stroke. Retract the ram, add spacer and push axle out
again. Repeat this procedure until axle is out of the
sprocket.
963 Bobcat Loader

AXLE, BEARINGS ANO SPROCKET (Cont'd)
Remove the axle (Item 1) [A] from the axle tube.
Installation: Pack the bearing with grease before

installing the axle.
Remove the drive chain from the sprocket. Remove the

sprQcket (Item 1) [8] from the chaincase.
Remove the bearing (Item 1) [C] from the inside of the

chaincase.
Installation: Pack the bearing with grease before

installing in the cup.
Install the bearing cup puller tool (Item 1) [0]

(MEL1201-13) into the axle tube behind the bearing cup.
963 Bobcat Loader

AXLE, BEARINGS AND SPROCKET (Cont'd)
Pull the bearing cup from the axle tube [A].
Using the long driver tool handle, install the bearing cup
tool (Item 1) [B] (MEL1202-13).
Remove the inner bearing cup from the axle tube [C].
Installation: Using the correct size driver tool (Item 1) [0]

(MEL1202-12), install the outer bearing cup .
963 Bobcat Loader

-4-18- Serv\ce Manual
AXLE, BEARINGS AND SPROCKET (Cont'd)
Installation: Install the long threaded bolt into the axle

tube. Install the correct size bearing cup driver tool (Item
1) [A] (MEL 1202-11). Install the nut and washer on the
threaded bolt.
Installation: Inside the chaincase, start the inner bearing

cup into the axle tube. Install a bearing cup driver tool
(Item 1) [B] (MEL 1202-12). Install the nut and washer.
Installation: Install a wrench (Item 1) [C] on the nut and

have a second person hold the wrench.
Installation: Turn the nut on the outside of the axle tube

until the inner bearing cup is on its seat [0].
963 Bobcat Loader

AXLE, BEARINGS AN D SPROCKET (Cont'd)
A bearing puller (Item 1) [A] is needed to do the following

procedure.
Be sure the bearing puller makes good contact with the

inner race and press the bearing off the mounting surface
of the axle [A].
NOTE: Hold the axle during removal because it will

slide freely after the bearing is removed from
the mounting surface.
Installation: Install the bearing puller making sure it has

good contact with the inner race of the bearing [B]. Press
the bearing onto the mounting surface until the bearing is
fully seated .
963 Bobcat Loader

DRIVE CHAINS
A WARNING

or death . W-2059-0598
aLift and block the loader. (See Page 1-1.)
Remove the front panel/steering lever assembly. (See
Page 3-1.)
Remove the brake/two speed block assembly. (See Page
4-5.)
Remove the front cover on the chaincase. (See Page

4-22.)
Remove the hydraulic steering controller. (See Page
3-1.)
Remove the rear cover from the chaincase.
Remove the center cover from the chaincase.
Remove the fluid from the chaincase. (See Page 4-34.)
Remove the rear axle. (See Page 4-13.)
NOTE: It is necessary to remove the rear axle and

drive chain if the front chain has to be
removed [A].
963 Bobcat Loader

FRONT CHAINCASE COVER
Remove the front steering panel/steering levers

assembly. (See Page 3- 1.)
Remove the parking brake pedal assembly. (See Page

4-3.)
Remove the control pedals mounting panel. (See Page

2-1 .)
Remove the eight bolts from the front cover (Item 1) [A].
Remove the front cover.
REAR CHAINCASE COVER
Remove the joystick controller. (See Page 3-1 .)
Remove the bolts at the rear cover [8].
The rear two bolts (Item 1) [C] , also attach the front of the
fuel tank sheild. The fuel tank shield will have to be lifted
a small amount so the rear cover can be removed from
the chaincase.
963 Bobcat Loader

REDUCTION GEARCASE
A WARNING

or death. W-2059-QS98
Remove the front panel/steering lever assembly. (See
Page 3-1 .)
Remove the hydraulic foot pedals mounting panel. (See
Page 2-1 .)
Remove the brake/two speed block. (See Page 4-5.)
Remove the hydraulic/hydrostatic filter. (See Page 2-1.)
Remove the front cover from the chaincase [A].
Remove the center cover from the chaincase [8].
Remove the fluid from the chaincase. (See Page 4-34 .)
Disconnect the cross-over hose (Item 1) [C] between the
parking brakes.
Remove the hydrostatic motor. (See Page 3-1.)
Remove the front axle. (See Page 4-15 .)
Left Side Only: Disconnect the wiring harness connectors

(Item 1) [D) from the PWM module harness connectors.
Left Side Only: Remove the hose clamp (Item 2) [0].
963 Bobcat Loader

REDUCTION GEARCASE (Cont'd)
Removal And Installation (Cont 'd)
Left Side Only: Disconnect the hose (Item 1) [A] from the
bucket position valve.
Left Side Only: Disconnect the hose (Item 2) [A].
Left Side Only: Disconnect the hose (Item 1) [B] from the
bucket position valve .
Right Side Only: Remove the lift lock valve. (See Page
2-1.)
Right Side Only: Remove the hydraulic control valve.

(See Page 2- 1.)
Right Side Only: Remove the front fuel tank bracket (Item
1) [C] from the reduction gearcase.
Connect a chain (Item 1) [0] to the top cover bolts on the

reduction gearcase.
963 Bobcat Loader

Connect the lifting bar (Item 1) [A] to the chain on the

gearcase.
Connect the chain hoist (Item 2) [A] to the lifting bar.
NOTE: The lifting bar is needed so there will be

clearance for the chain hoist along side the
lift arms and operator cab.
Loosen and remove the ten mounting bolts (Item 1) [B]

from the reduction gearcase .
Installation: Tighten the reduction gearcase mounting

bolts to 220-245 ft.-Ibs . (298-332 Nm) torque.
Lift the gearcase a small amount and slide to the rear of

the loader. Remove the rear drive chain. Remove the
front drive chain.
Installation: When installing the gearcase, put grease on

the O-ring to keep it from falling off the gearcase housing.
Move the gearcase away from the chaincase and start to

lift until the gearcase has enough clearance over the
fender [AJ. Remove from the loader.
Put the gearcase on a work bench and disconnect the

lifting chains.
963 Bobcat Loader

Remove the parking brake mounting bolts (Item 1) [A].
Remove the parking brake from the gearcase.
To disassemble and assemble the parking brake, see
Page 3-1 .
Assembly: Tighten the parking brake mounting bolts to
Remove the bolts from the cover (Item 1) [B]. Remove

the cover.
Assembly: Put R. T. V. sealant (Item 1) [C] on the cover

surface on the gearcase.
<-..;
,.,-;11,
Remove the four bolts from the cover (Item 1) [0].
963 Bobcat Loader

Assembly: Put R.T.v. sealant (Item1) [A] on the cover

before installation .
Using a chisel and hammer remove the idler shaft cover

(Item 1) [8].
Assembly: Put R.T.V. sealant (Item 1) [C] on the cover

before installation.
Remove the snap ring (Item 1) [0] from the input/brake

shaft.
963 Bobcat Loader

Remove the input/brake shaft (Item 1) [A] and bearing

from the housing.
Remove the three bolts (Item 1) [8] and plate at the drive
gear shaft.
Assembly: Tighten the three bolts to 65-70 ft.-Ibs.

(88-95 Nm) torque [C].
Use a press or install a Port-a-Power ram jack (Item 1)

[0] on the drive gear shaft. Push the drive shaft out of the
bearing.
963 Bobcat Loader

Remove the bearing [A].
Remove the spacer [8].
Assembly: Install the spacer. Support the drive shaft.

Install the bearing using a hammer [C].
Remove the drive shaft (Item 1) [0] and spacer (Item 2)

[0] from the gearcase housing.
963 Bobcat Loader


procedure :
MEL 1557 - Spanner Nut Socket
Loosen and remove the outside locking spanner nut (Item

1) [A].
Remove the tab washer (Item 2) [A] from the shaft.
Remove the inside spanner nut (Item 3) [A].
Remove the large washer from the shaft.
Assembly: Install the large washer. Install the second

spanner nut (Item 3) [A] with the flat face toward the large
washer. Taper part of the nut is toward the outside.
Tighten the nut to 35 ft.-Ibs . (47 Nm) torque.
Assembly: Install the tab washer (Item 2) [A] with the

tabs toward the inside spanner nut. If a tab does make
alignment with the inside spanner nut, tighten the nut a
small amount until a tab is aligned. Bend the tab toward
the inside nut.
Assembly: Put LOCTITE on the outside spanner nut.

Install the nut (Item 1) [A] and tighten to 35 ft.-Ibs. (47
Nm) torque.
Remove the bearing (Item 1) [B] and spacer (Item 2) [B].
Remove the idler shaft from the gear and gearcase

housing [C].
Assembly: Put LOCTITE #262 on the idler shaft

(according to manufacturer's instructions) before
installing it into the gear.
963 Bobcat Loader

Remove the large gear and idler gear from the gearcase
housing [A].
Check the bearing (Item 1) [8] for wear or damage and

replace as needed.
Install a bearing puller tool under the bearing and press

the bearing from the shaft [C].
Assembly: Press the new bearing onto the shaft using a

press and bearing tool [0].
963 Bobcat loader

Remove the spacer (Item 1) [A] from the output shaft.
Install the bearing puller tool (Item 1) [B] under the

bearing and press the bearing from the output shaft.
963 Bobcat Loader

-4-32- Ser"ice Manual
Assembly: Install the bearing tool (Item 1) [A] so it will

support the inside diameter of the bearing. Press the new
bearing on the output shaft.
963 Bobcat Loader

Install a bearing puller tool under the bearing and press

the bearing from the shaft [A].
Assembly: Use a sleeve (Item 1) [B] to press the new

bearing onto the shaft.
Reverse the above procedure to assemble the reduction

gearcase.
Assembly: Check the backlash between the gears. The

correct specifications is 0.005-0.010 inch (0,13-0,28
mm).
963 Bobcat Loader

CHAINCASE FLUID
Removing The Fluid From The Chaincase
Remove the drain plug (Item 1) [A] and drain the oil into
a container.
Check the drain plug and replace if necessary.
Use the following procedure if the chaincase covers are

removed for other repair procedures: (Example; Removal
and Installation of Axle)
Use a pump to remove the chaincase fluid [B].
963 Bobcat Loader

\unuew a~!I\Jas -9£-tr
JapeOlleoqo8 £96
MAIN FRAME
Page
Number
BOB-TACH
Bob-Tach Lever And Wedge .................................. . 5-14
Bob-Tach Stops .......... . .... . ........... .. .......... . ...... 5-15
Removal And Insta"ation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-12
FRONT FUEL TANK
Fuel Level Sender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-23
Removal And Insta"ation ............ . .......................... 5-23
LIFT ARMS
Removal And Installation ........................... . ... . ....... 5-16
OPERATOR CAB
OPERATOR CAB GAS CYLINDER
Gas Cylinder Mounting Bracket ................................. 5-8
Removal And Insta"ation .. .. . ................ . ......... . ....... 5-7
MAIN
OPERATOR SEAT FRAME
REAR DOOR
Adjusting The Rear Door Latch ................................. 5-22
Removal And Insta"ation ....................... .. ... . .......... 5-21
REAR FUEL TANK
Pickup Tube Screen .......................................... , 5-25
REAR GRILL
Gas Cylinder Removal And Insta"ation ................. . ......... 5-20
SEAT BAR
Assembling Components ................ .. ....... . ....... . .... , 5-6
Compression Spring Disassembly And Assembly .............. . .. . 5-6
Removal And Insta"ation ...... . ............................... , 5-3
963 Bobcat Loader

\enuew a~!I\Jas -~-s-
Jape o l le:>q o 8 £96
SEAT BAR
Lower the seat bar (Item 1) [A] so the compression

springs (Item 2) [A] will be in a down position.
Loosen the adjustment lock nut (Item 1) [B] (both sides).
Turn the bolt (Item 1) [C] into the clevis five turns (both
sides) .
Installation: When properly adjusted the clearance

distance between the bolt head (Item 1) [C] and the seat
bar tab (Item 2) [C] is 1/16 inch (1 ,58 mm).
Tighten the adjustment lock nut (Item 3) [C] to the clevis.
Repeat above installation procedure for other side. The

compression spring is adjusted correctly when the bolt is
flush with the clevis (Item 2) [B].
Remove the retaining pin (Item 1) [0] and clevis pin (both
sides).
963 Bobcat Loader

SEAT BAR (Cont'd)
Disconnect the wiring harness connector (Item 1) [A] (left
side) .
Remove the seat bar mounting bolt (Item 2) [A] (both
sides).
Remove the sensor mounting bolt (Item 3) [A] (left side).
Installation: Make sure the two tabs (Item 1) [B] are

located in the slot on the operator cab.
Installation: Tighten the mounting bolt and nut (Item 1)

[C] to 180 - 200 in.-Ibs. (21 - 23 I\lm) torque.
To protect the paint on the operator cab from getting

scratched , install cardboard (Item 1) [0] on the right side.
Wrap tape around the left pivot end (Item 2) [0] of the seat
bar.
Wrap tape around the cab grab handle (Item 3) [0] and
the front edge of the cab (Item 4) [0].
963 Bobcat Loader

SEAT BAR (Cont'd)
A
Position the seat bar in the recess on the left side of the
cab (Item 1) [0]. Position the left side pivot end of the seat
bar between the cab and the grab handle (Item 2) [AJ.
Lift straight up on the right side (Item 3) [AJ of the seat bar.
Continue to lift on the right side of the seat bar and allow
the left side of the seat bar to rotate between the cab and
the grab handle (Item 1) [B].
Lift the right side of the seat bar until it clears the right side
screen of the cab [C].
Remove the left side of the seat bar pivot from between
the cab and grab handle and remove the seat bar from the
cab [0].
Reverse the above procedure to install the seat bar into

the operator cab.
963 Bobcat Loader

-5-5 Service Manual
SEAT BAR (Cont'd)
Assembling Components
Assemble the parts as shown for the left side of the seat
bar pivot assembly [A):
Mounting Bolt (item 1)
Washer (Item 2)
Keyed Plastic Bushing (Item 3)
Magnetic Bushing Assembly (Item 4)
Sensor Mounting Nut (Item 5)
Sensor Bracket (Item 6)
Sensor Mounting Bolt (Item 7)
Pivot Bushing (Item 8)

.,.
Mounting Bolt (Item 9)
Assemble the parts as shown for the right side of the seat
bar pivot assembly [B]:

B
Pivot Bushing (Item 2)
Mounting Bracket (Item 3)
T,2" ,.
,
,.
'9
",1
],
.
"
~
~G5
'
< . '. -
Keyed Plastic Bushing (Item 4)

'\
. .
Washer (Item 5)
A
.' "
' .. (
' 6 . 5
Compression Spring Disassembly And Assembly
Loosen the lock nut (Item 1) [C] and turn the bolt (Item 2)
[C] out of the clevis.
Assembly: Adjust the compression spring as shown on

Page 5-3; Fig. [B].
Disassemble and assemble the seat bar compression
spring and parts as shown in Fig. [0]:
Pin (Item 1)
Retaining Pin (Item 2)
Clevis (Item 3)
Lock Nut (Item 4)
Washer (Item 5)
Spring (Item 6)
Bushing (Item 7)
Bolt (Item 8)
963 Bobcat Loader

-5--6 Service Manual
OPERATOR CAB GAS CYLINDER
A
Remove the rubber stops (Item 1) [AJ (both sides).
~ j\:.
NOTE: Make sure to support the operator cab with a I B

chain hoist (Item 1) [B] when the gas cylinder
is removed so that the operator cab cannot
tip forward.
Cil
-~
..
Remove the cotter pin (Item 1) [C].
963 Bobcat Loader

-5-7 Service Manual
OPERATOR CAB GAS CYLINDER (Cont'd)
Remove the pivot pin (Item 1) [A] at the top of the gas
cylinder.
Remove the cotter pin and pivot pin (Item 1) [B) at the
bottom mounting bracket.
Remove the gas cylinders.
A WARNING
Cylinder contains high pressure gas. Do not

open. Opening cylinder can release rod and
W-2113-0288
Gas Cylinder Mounting Bracket
Upper Mounting Bracket: Remove the nuts (Item 1) [C)

and bolts, and remove the mounting bracket.
Replace the bracket as needed.
Lower Mounting Bracket: Remove the nuts (Item 1) [D)

and bolts. Remove the mounting bracket.
Replace the bracket as needed.
963 Bobcat Loader

-5-8 Service Manual
OPERATOR CAB
Remove the nut (Item 1) [A] and holddown plate (Item 2)

[A] (both sides) from the operator cab.
Installation: Tighten the nut to 40-50 ft.-Ibs . (54-68 Nm)

torque.
Disconnect the wiring harness connectors (Item 1) [8].
Disconnect the operator cab ground wire (Item 2) [8].
Install a sling (Item 1) [C] on the grab handles of the IC

operator cab. Connect a chain hoist to the sling.
Remove both gas cylinders. (See Page 5-7 .)
After the gas cylinders are removed, lower the operator

cab using the chain hoist [C].
963 Bobcat Loader

-5-9 Service Manual
Remove the nut (Item 1) [A] from the pivot bolt (both
sides).
Installation: Tighten the pivot bolt and nut to 25-35
ft .-Ibs. (34-47 Nm) torque.
Remove the pivot bolt (both sides).
Move the operator cab forward a small amount for

clearance at the pivot mounting brackets [B].
Install the pivot bolt, washer (one on each side) and nut
(Item 1) [B] (both sides).
Install the sling under the pivot bolt and pivot of the
operator cab [B].
Connect the slings to a chain hoist and remove the

operator cab from the loader [C].
963 Bobcat Loader

-5-10-- Service Manual
OPERATOR SEAT
A
Use the following procedure to remove the operator seat

from the operator cab:
Locate the operator seat sensor (Item 1) [A] on the

bottom of the seat pan .
Disconnect the seat sensor connector and remove the

seat sensor assembly. (See Page 8-1 .)
Remove the three seat mounting nuts (Item 1) [8] and

washers from the operator seat mounting studs.
Lower the operator cab and remove the operator seat

from the cab.
NOTE: There are two spacers (Item 1) [C] located

between seat track and the seat pan on each
IC
front mounting stud. Be sure not to lose the
spacers when removing the seat.
Remove the seat spring (Item 2) [C] from under the right
seat track when removing the operator seat.
Installation: Install the seat spring (Item 1) [0] with the

bend of the seat spring in the position shown.
D Operator
Seat
Inspect the seat adjustment track (Item 3) [C].
Remove the mounting bolt from each end of the track and
replace the adjustment track if necessary.
Seat
Reverse the removal procedure to install the operator Pan
seat.
\ MC-02043
963 Bobcat Loader

BOB-TACH
Put the Bob-Tach on the floor.
Remove the bolt and washer (Item 1) [A] at the pivot pin
of the rod end of the tilt cylinder (both sides).
Installation: Tighten the bolt to 125-140 ft.-Ibs .

(170-190 Nm) torque. Hit the bolt with a hammer, then
re- torque the bolt to 125-140 ft.-Ibs. (170-190 Nm)
torque.
Install the bolt (Item 1) [A] (without washer) in the pivot

pin.
Hit the bolt with a hammer to remove the pivot pin from
the Bob-Tach frame (both sides).
N-15360
Remove the bolt at the pivot pin. Remove the pivot pin
from the rod end of the tilt cylinder [0] (both sides) .
963 Bobcat Loader

BOB-TACH (Cont'd)
Remove the retainer bolt (Item 1) [A] at the Bob-Tach

pivot pin (both sides).
Installation: Tighten the retainer bolt to 16-20 ft.-Ibs.

(21-27 Nm) torque.
Remove the Bob-Tach pivot pin (Item 1) [B) (both sides).
Remove the Bob-Tach from the lift arms.
Installation: Make sure the shims (Item 1) [C) are

installed when the Bob-Tach is installed on the lift arms.
Check the bushings in the lift arms for wear and damage,
replace as needed [0).
963 Bobcat Loader

BOB-TACH (Cont'd)
Bob-Tach Lever And Wedge
Use the following procedure to remove and install the

Bob-Tach lever, spring and wedge .
NOTE: The removal procedure shown is on the right

side, the left side procedure is the same.
Use a punch and hammer, remove the roll pin (Item 1) [A]
from the clevis and wedge .
Start the engine and tilt the Bob-Tach frame forward so

it is parallel to the floor. Stop the engine.
Loosen the mounting nut (Item 1) [B] at the lever.
Installation: Tighten the nut to 25-28 ft .-Ibs. (34-38 Nm)

torque.
Remove the bolt (Item 1) [C], nut (Item 2) [C], washer
(Item 3) [C] and spring (Item 4) [C].
Remove the Bob-Tach lever (Item 5) [C].
Remove the spring/clevis assembly.
N-15369
Remove the Bob-Tach wedge (Item 1) [0] from the

Bob-Tach frame.
Check for bent, broken or worn wedge, replace as

needed.
963 Bobcat Loader

-5-14 Service Manuai
BOB-TACH (Cont'd)
Bob-Tach Lever And Wedge (Cont'd)
Put the spring/clevis assembly in a vise [A).
Remove the bolt (Item 1) [A] and disassemble the spring

and clevis.
Check all parts for wear or damage. Replace the parts as

needed [B). I B
." N-15372
Bob-Tach Stops
Remove and replace the Bob-Tach stop (Item 1) [C]

(both sides) if worn or damaged.
NOTE: The Bob-Tach stop (Item 1) [0] must contact

the lift arm at the same time the tilt cylinders
reaches full extension. Use available shims
to adjust the Bob-Tach stop and tilt cylinder
sequence as closely as possible.
963 Bobcat Loader

LIFT ARMS
IMPORTANT

the system.
1-2003-0888
Put the Bob-Tach on the floor. Remove the Bob-Tach B

from the lift arms. (See Page 5-12.)
Remove the the tilt cylinders. (See Page 2-1.)
Remove the top tubeline clamp (Item 1) [A] on the lift
arms (both sides).
Pull the tubelines down for clearance. Disconnect the
hoses from the tubelines (both sides).

..
Left Side: Remove the bolt (Item 1) [B] from the pivot pin
retainer plate.
Installation: Tighten the bolt to 16-20 ft.-Ibs . (21-27
Nm) torque.
Remove the pivot pin with a slide hammer puller [C].
Right Side: Remove the bolt (Item 1) [0] from the pivot pin
retainer plate and lift arm support device spacer (inside
the lift arm side frame).

Nm) torque.
Remove the pivot pin.
963 Bobcat Loader

LIFT ARMS (Cont'd)
Install a sling (Item 1) [AJ and chain hoist on the lift arms.
Raise the lift arms so there will be clearance for removal

of the lift arm support device.
Remove the lift arm support device from the lift arms [8].
Installation: Be sure to install the washers (if so

equipped) on both sides of the rod end of the lift cylinder IC
[C].
N-15421
963 Bobcat Loader

LIFT ARMS (Cont'd)
Install a sling (Item 1) [A] under the lift arm as shown .
Connect the chain hoist to the sling.
N-15420
Remove the bolt (Item 1) [B] from the retainer plate pivot
pin (both sides).

Nm) torque.
Remove the lift arm pivot pin (both sides).
963 Bobcat Loader

LIFT ARMS (Cont'd)
Remove the lift arms from the loader frame [A].
.,',
N-15419
963 Bobcat Loader

REAR GRILL
Gas Cylinder Removal And Installation

A
Lift the rear grill [A]. Add a support to prevent the grill from
closing when the gas cylinder is removed.
Remove the retainer clips (Item 1) [A] at both of the ball

joints ends. Remove the ball joints from the ends.
Remove the gas cylinder.
· A WARNING
Cylinder contains high pressure gas. Do not

open. Opening cylinder can release rod and
W-2113-Q288
Remove the gas cylinder.
Lower the rear grill.
Remove the retainer clips (Item 1) [B] (both sides).
Remove the pivot pin (both sides).
Remove the rear grill from the loader frame.
963 Bobcat Loader

REAR DOOR
Open the rear door.
Connect chain (Item 1) [A] to the rear door.
Connect a chain hoist (Item 2) [A] to rear door chain.
Disconnect the wiring harness connector (Item 1) [8).
963 Bobcat Loader

REAR DOOR (Cont'd)
Disconnect the ether start wiring harness connector (Item

1) [A] (if so equipped).
Remove the rear door pivot pins with a punch and

hammer.
Lift the rear door away from the loader frame and put the
door flat on the floor.
Adjusting The Rear Door Latch
Loosen the set screw (Item 1) [B].
Loosen the nut (Item 1) [C].
Turn the bolt (Item 2) [C] in or out until the door contacts
both the top and bottom of the loader frame with the lever
in the latched position .
NOTE: It takes approximately 501bs. (20 kg) of force
to push the lever down when the latch is
correctly adjusted.
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.
Tighten the set screw. Tighten the nut (Item 1) [C] to

65-70 ft.-Ibs. (88-95 Nm) torque.
963 Bobcat Loader

FRONT FUEL TANK
Remove the drain plug (Item 1) [A].
Drain the fuel into a container.
Raise the lift arm and install an approved lift arm support
A WARNING

or death. W-2059-0598
Stop the engine.
Remove the front panel/steering levers assembly. (See

Page 3-1.)
Remove the hydraulic foot pedals and foot pedal

mounting plate. (See Page 2-1.) c
Move the two hose clamps (Item 1) [B] from the hose unto
the the tube.
Disconnect the hose from the fuel tank.
Remove the two bolts (Item 2) [B] from the gearcase and
remove the bracket.
Disconnect the vent hose (Item 1) [C].
Disconnect the wire harness connector at the fuel sender
(Item 2) [C].
Remove the front fuel tank from the loader frame.
Fuel Level Sender
Loosen the fuel lever sender in the fuel tank. Remove the
sender (Item 1) [0]. from the tank.
963 Bobcat Loader

REAR FUEL TANK
Remove the drain plug (Item 1) [A].
Drain the fuel into a container.
Raise the lift arm and install an approved lift arm support
A WARNING

litt arm support device. Failure to use an
or death. W-2059--0598
Stop the engine.
Remove the engine/hydrostatic assembly from the

Disconnect the fuel fill hose (Item 1) [8] from the fuel tank.
Disconnect the vent hose (Item 2) [8], from the front fuel
tank.
Disconnect the vent hose (Item 3) [8] for the rear fuel
tank .
Remove the two bolts (Item 4) [8] from the fuel tank
shield.
Remove the bolt (Item 1) [C] from the fuel tank shield.
Remove the bolts (Item 1) [0] at the front of the tank

shield.
Remove the fuel tank shield (Item 2) [C].
963 Bobcat Loader

Revised Mar. 99 -5-24 Service Manum
REAR FUEL TANK (Cont'd)
At the lower right side (Item 1) [A], of the rear fuel tank,
disconnect the hose for the cross-over tube to the front
fuel tank.
Remove the fuel tank from the loader frame.
Pickup Tube Screen
Remove the fitting (Item 1) [B) with the pickup tube from
the fuel tank.
963 Bobcat Loader

Itmuew 3~!J\J3S -9(:-5
JapeOl .e:>qo8 £96
ELECTRICAL SYSTEM
Page
Number
ALTERNATOR
Adjusting The Alternator Belt ................................... 6-13
Alternator Output Test ......................................... 6-9
Alternator Regulator Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-10
Assembly .................................................... 6-16
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-14
Rectifier Continuity (Diode) Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-15
Rectifier (Diode) Test .......................................... 6-9
Rotor Continuity Test .......................................... 6-15
Rotor Ground Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-15
Stator Continuity Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-14
Stator Ground Test ............................................ 6-14
BATTERY
Servicing The Electrical System ................................. 6-7
Using A Booster Battery (Jump Starting) ......................... 6-8
ELECTRICAL SYSTEM INFORMATION
Description ................................................... 6-4
Fuse Location ................................................ 6-4
FRONT LIGHTS

ELECTRICAL
SYSTEM
RELAY SWITCHES
Location ..................................................... 6-4
STANDARD INSTRUMENT PANEL
STARTER
External Pinion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-22
Inspection And Repair ......................................... 6-23
Magnetic Switch Test .......................................... 6-26
No Load Test ................................................. 6-26
Parts Identification ............................................ 6-18
TROUBLESHOOTING
Chart ........................................................ 6-3
963 Bobcat Loader

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Japeol le~qo8 £96
TROUBLESHOOTING
Chart

assistance in locating and correcting problems. Many of
A WARNING
the recommended procedures must be done by

authorized Bobcat Service Personnel only. Instructions are necessary before operating or
servicing machine. Read and understand the
Operation & Maintenance Manual, Handbook
or death. W-2003-{)199
PROBLEM CAUSE
Battery will not take a charge. 1,2,3,4,5
Alternator will not charge. 1,2,5
Starter will not turn the engine. 2,3,4,6,7,8,9

-
1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is damaged.
4. The ground connection is not making a good contact.
5. The alternator is damaged.
6. The engine is locked.
7. The starter is damaged.
8. The wiring or the solenoid is damaged.
9. Check the fuses.
963 Bobcat Loader

ELECTRICAL SYSTEM INFORMATION
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.
Fuse Location
The electrical system for this model loader is protected by

fuses (Item 1) [A] located in the engine compartment.
The fuse capacity and circuits are listed below [B] & [C]:
Fuse ·~ m·
-=-"
. -" ,,--• • •••':::--...... .
Ref. Capacity Circuit -

~
'\
- ·j ,
. . i
.
, ,
1. 15AMP ENGINE "
2. 10 AMP BICSTM
3. 15 AMP BOSS
4. 10 AMP PWM
5. NOT USED
6. 25AMP ACCESSORY
7. 25AMP ACCESSORY
8. 25 AMP LIGHTS
RELAY SWITCHES
P-10300
Location
The engine wiring harness has relay switches located on

the right side frame in the engine compartment. c
There are four switches (Item 2) [A]. ~~

S
.... ~~~--
USE SPECiRED FUSES ONLY
.... ...., ~
,
o
The switches are for the starter, switch power, starting aid
and brake.
Remove the bolt from the mounting bracket on the switch

G~ L....-( --I
BI
P
bracket and remove the relay switches.
;0 I 15
BOSS
I irJ
rLJ I 2ii
A,CC£88ORY
I
6803593
6803593
963 Bobcat Loader

Revised Mar. 99 --6-4- Service Manuae
BATTERY
A WARNING
Batteries contain acid which burns eyes and

skin on contact. Wear goggles, protective
clothing and rubber gloves to keep acid off
body.
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.
W-2065-1296
Open the rear door.
Disconnect the negative battery cable (Item 1) [A].
Always disconnect the negative cable first to prevent

sparks.
Remove the ground bolt (Item 1) [B] at the wiring harness

clamp.
NOTE: To remove the battery on some early model

loaders the alternator belt shield (Item 2) [C]
must be removed.
Remove the adjusting bolt (Item 1) [C] and nut (Item 3)
[C] at the alternator.
Remove the nuts and bolts from the hold down clamp
(Item 1) [0] and remove the holddown clamp.
963 Bobcat Loader

BATTERY (Cont'd)
Disconnect the positive cable (Item 1) [A] from the

battery.
Remove the battery from the loader [B].
A WARNING

body.


quantities of water or milk. DO NOT induce
W-206~1296
963 Bobcat Loader

BATIERY (Cont'd)
Always clean the terminals and cable ends when

installing a new battery [A] and [B].
When installing the battery in the loader, do not touch any

metal parts with the battery terminal posts.
Connect and tighten the battery cables. Connect the

negative (-) cable last to prevent sparks.
A WARNING

body.


W-2065-1296 P-{)9590
Servicing The Electrical System
The battery cables must be clean and the connections

c
tight. Remove acid or corrosion from the battery and
cables with a sodium bicarbonate (baking soda) and
water solution [C].
Clean the terminals and cable ends as shown in Fig. [A]

and [B].
Check the electrolyte level in the battery. Add distilled

water as needed.
Put Battery Saver (PIN 6664458) orgrease on the battery

terminals and cable ends to prevent corrosion.
963 Bobcat Loader

BATTERY (Cont'd)
Using A Booster Battery (Jump Starting)
A WARNING

body.


W-2065-1296
Keep arcs, sparks, flames and lighted tobacco

away from batteries. When lumping 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 whire boosting, testing
or charging.
Battery gas can explode and cause serious
injury.
W-2066-1296
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 ignition must be in the OFF position. The booster

battery to be used must be 12 volt.
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.
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 Condition, Operation &
Maintenance Manual.
After the engine has started, remove the ground (-) cable
(Item 4) [A] first.
Remove the cable from the starter.
963 Bobcat Loader

ALTERNATOR
Alternator Output Test
A WARNING

death.
W-2017--Q286
Test the alternator in the following sequence:
Alternator Output Test
Rectifier (Diode) Test
Alternator Regulator Test
Disconnect the negative (-) cable from the battery.
Disconnect the red wire from the alternator. Connect that
wire to the negative (-) side (Item 1) [A] of the ammeter.
Connect the positive (+) side of the ammeter to the output
terminal on the alternator (Item 2) [A].
Disconnect the fuel stop solenoid connector.
Connect the negative (-) cable to the battery.
Turn on the lights and crank the engine for 30 seconds to
discharge the battery.
Connect the fuel stop solenoid, start the engine and run
at 2600 RPM .
The ammeter reading should be between 45-55 amps. @
2600 RPM.
If the reading is low, remove the screws and pull the
regulator cover away from the alternator.
Rectifier (Diode) Test

The alternator is removed from the loader for photo clarity
purposes [8].
Install the wires in their original location on the back of the

alternator.
Remove the regulator cover from the back of the

alternator [8].
Connect a jumper wire (Item 1) [C] to the alternator output

terminal and the regulator terminal.
Connect the battery negative (-) cable.
Start the engine and run at 2600 RPM.
If the reading is within 45-55 amps . at 2600 RPM replace

the rectifier (diode) assembly or replace the alternator.
If the reading is low, do the Alternator Regulator Test.
963 80bcat Loader

-6-9 Service Manual
ALTERNATOR (Cont'd)
Alternator Regulator Test
A WARNING
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.
W-205O-1285
Connect the positive (+) voltmeter lead to the positive (+)

battery terminal [A].
Connect the negative (-) voltmeter lead to the negative
(-) battery terminal [A].
Start the engine and run at 1500-2000 RPM.
The voltmeter should read between 13.9-14.7 volts.
If the reading is low, stop the engine and disconnect the
battery negative (-) cable.
The alternator is removed from the loader for clarity
purposes [B].
Remove the wires from the back of the alternator.
Remove the regulator cover from the back of the

alternator.
Install the wires on the back of the alternator.
Connect a jumper wire (Item 1) [B] from the brush

terminal to the ground stud.
Connect the negative (-) battery cable and start the

engine. Run at 1500 RPM.
If the voltmeter reading is 14.5 or above, replace the

regulator.
If the voltmeter reading is below 14.5, repair or replace the

alternator.
963 Bobcat Loader

ALTERNATOR (Cont'd)
IMPORTANT
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.
1-2023-1285
Open the rear door.
Disconnect the negative (-) cable (Item 1) [A) from the

battery.
Disconnect the harness connector (Item 1) [B] from the

alternator connector.
Disconnect the red wire (Item 1) [C] from the alternator.
Remove the ground bolt (Item 1) [0] at the wiring harness

clamp.
963 Bobcat Loader

ALTERNATOR (Cont'd)
Remove the adjustment bolt (Item 1) [A] and nut (Item 2)
[A] at the alternator.
Remove the alternator belt shield (Item 3) [A).
Remove the alternator belt (Item 1) [B) from the pulley.
Remove the spacer (Item 1) [C) and mounting bolt (Item

2) [C).
Remove the alternator from the mounting bracket.
963 Bobcat Loader

-6-12- Service Man ua~
ALTERNATOR (Cont'd)
Adjusting the Alternator Belt
Stop the engine.
Open the rear door.
Loosen the alternator mounting bolt (Item 1) [A].
Loosen the adjustment bolt (Item 2) [A].
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 Ibs. (66 N) of force.
Tighten the adjustment bolt and mounting bolt.
Close the rear door.
963 Bobcat Loader

ALTERNATOR (Cont'd)
1. Nut 9. Rectifier (Diode)

Disassembly
2. Pulley 10. Case Half (Rear)
3. Fan 11. Condenser Assy.
Disassemble the alternator. (See Parts Identification [A].)
4. Bolt 12. Strap
5. Case Half (Front) 13. Regulator
Remove the regulator cover and regulator.
6. Bearing 14. Brush
7. Rotor 15. Cover
Remove the four bolts holding halves together.
8. Stator
Pry the halves apart.
Use a soft jaw vise to hold rotor while removing pulley nut.
/@-----®--~- --0-:
-----------------~
1 23 I
Remove front case half from the rotor using a plastic
hammer.
,- ---
Un-solder the stator leads from the rectifier. Remove the
stator.
I
:
~o-5I . ~
4' ~
L_ (1)--~~\D\
:I
~2 -~--®-- ~---
_I .!f !,Q
~o I
7
$I ,t -, 8
-
I
I
o 6 II
,_ _------ -------------------- J
: /12
I ,---«>--C(c
~ _0c:=3 r-'" 13-' -
c----~:t~ ::d------~~-;
: : - ..
I r-':'''': __ -...J
-=_'§.~:!...=-..:--
I
I fi'lh-
c
I L...-":lr~,"
:.::;'"
1
@A :I
10I ,_----- --!-~~- .J

L._",-...J I
9
~--
I
. - - .. -~- ..
I .. - - ' - ..
I
L
15 --- C-03312
Stator Continuity Test
Use an ohmmeter to test the stator.
Touch the probes to two of the bare stator wires [B].
Move one of the probes to the third wire.
The readings should be the same.
If there is no continuity, replace the stator.
P-01369
Stator Ground Test
Touch one probe to a bare stator lead and the other probe
to the bare metal surface of the stator [C].
There should be no continuity.
Replace the stator if there is continuity.
963 Bobcat Loader

--6-14- Service Manual
ALTERNATOR (Cont'd)
Rotor Continuity Test

A ...it
Use an ohmmeter to test the rotor.
Touch the probes to the slip rings [A].
The ohmmeter should read between 3.0-33.0 ohms .
If there is no continuity replace the rotor.
:':}
P-D1365
Rotor Ground Test B

Touch one probe to one of the slip rings and the other
probe to the rotor shaft [B].
There should be no continuity.

., '
Replace the rotor if there is continuity.
P-D1378
Rectifier Continuity (Diode) Test
NOTE: In the diode tests there should be continuity

c "
in one direction only. If the diode being
tested shows no continuity or continuity in
both directions, replace the rectifier
assembly.
Touch the probes to the terminals of each diode and read

the meter [C].
Reverse the probes to check the diode in the other

direction.
There should be continuity in one direction only.
Touch one probe to the diode and the other probe to the
connected heat sink and read the meter [0].
, !I
direction.
...
P-D1370
963 Bobcat Loader

ALTERNATOR (Cont'd)
Rectifier Continuity (Diode) Test (Cont'd)
Touch one probe to the diode and the other probe to the
connected heat sink and read the meter [A].

direction .
Assembly
Reverse the order of disassembly.
Do not assemble the rear case half.
Place the rotor in soft jaws when tightening the shaft nut.
Tighten to 50 ft.-Ibs . (68 Nm) torque [8].
Install the rear case half and the remaining parts.
963 Bobcat Loader

STARTER
Open the rear door.
Remove the drive belt shield. (See Page 3-1 .)
Disconnect the positive (+) cable (Item 1) [A] from the
starter solenoid .
Disconnect the wires (Item 1) [B] from the starter solenoid

terminal.
Disconnect the ground cable (Item 2) [B] at the starter

mounting bolt.
Remove the nuts (Item 1) [C] & [0] and mounting bolts
(flywheel side) from the starter.
Remove the starter.
963 Bobcat Loader

STARTER (Cont'd)
Parts Identification
1 Felt Washer
2.
3.
4.
Bearing
Armature
Bearing 6
8
I
~
r ~
9 10
5. Field Windings
I
Housing Assy. I ~
6. Cover
~ ~/~
7. Brush Holder
8. Cover 11. Brushes
9. Bolt
4 . . 12. Cover
10. Bolt 13. Gasket
I. . ,~~
( , 14. Screw
" ® ,
/ -1
15.
16.
Pinion Shaft
Nut
/ 17. Washer
1 /
/
18. Nut
/
I /
19. Washer
~,,~" /
/
./
20. Roller
( "~ /
/
I I /
: 2 /
I
II
I
I
I
I
I
I / /
/"
"
//
//
/
/
/
I ' 0,I
II,
17
16
?1
~ " Ij ,
11
vI ,," 18 , o"(})I ' ~
11
22
I
/ 1
// I
,,/ I
25 16 // I
24 17 /// I
// I
23 // I
I / I
I /// I
I / I
~/
I // 35 '
1 /
/ ) /
I / /
~I /
I " 34
21 . Retainer
: /",,/ 33
~
22. Pinion
I
~ "
23. Ball
31 24. Spring
I "
30
~,,/
~"~I \
25.
26.
Housing
Screw
27. Washer
I ,,/
/~,,~ 32 28.
29.
O-ring
Housing
30. Gear
/ Ii:( 31. Spring
CI "
/,," 32. O-ring
33. Drive
29 34. Spring
35. Shaft
O-<l2297
963 Bobcat Loader

STARTER (Cont'd)
Disconnect the wire from the magnetic switch [A].
Assembly: Tighten the nut to 52-86 in .-Ibs. (5,9-9,7
Nm) torque. Securely put the rubber boot over the

terminal.
B-14441
Remove the through bolts from the drive end frame [B]. 8
Assembly: Tighten the through bolts to 60-104 in.-Ibs.
(6,8-11,8 Nm) torque.
B-14474
Remove the field windings housing from the magnetic

switch [C].
B-14442
Assembly: When installing the field windings housing to

the magnetic switch, engage the tab (Item 1) [0] on the D
field windings housing with the notch in the magnetic
switch.
- m-
B-14468
963 Bobcat Loader

STARTER (Cont'd)
Remove the drive end frame from the magnetic switch
[A].
B-14446
Remove the overrunning clutch from the drive end frame

[B].
NOTE: If the pinion is installed on the drive end
frame (externally attached to the overrunning
clutch shaft), it will be necessary to remove
the pinion prior to removing the
over-running clutch. (See Page 6-23.)
B-14447
Remove the steel ball from the overrunning clutch [C] .
B-14448
Remove the pinion (Item 1) [0] from the drive end frame .
8-14449
963 Bobcat Loader

-6-20 Service Man ual
STARTER (Cont'd)
A
Remove the retainer and rollers from the drive end frame
[A].
8-14450
Remove the return spring from the magnetic switch [8].
Assembly: Reverse the order of disassembly. Before

reassembling , put grease on the following parts:
Overrunning Clutch
Retainer and Rollers
Steel Ball
Return Spring
Armature Bearing
Felt Washer
8-14451
963 Bobcat Loader

STARTER (Cont'd)
External Pinion
If the pinion is installed on the drive end frame (externally

attached to overrunning clutch shaft), it will be necessary
to remove the pinion prior to removing the overrunning
clutch.
Push down on the drive end frame [A].
8-14452
While pressing down on the starter pinion, tap the collar

using a pipe (Item 1) [B].
8-14453
Remove the snap ring (Item 1) [C].
After the snap ring is removed, the pinion, overrunning

clutch, shaft, washer, and spring can be removed.
963 Bobcat Loader

--6-22- Service Manual
STARTER (Cont'd)
Inspection And Repair

A
ARMATURE:
Armature Short-Circuit Test: Use a growler tester, put the

armature on the growler and hold a hack saw blade
against the armature core while slowly rotating the
armature [A] . A short circuited armature causes the blade
to vibrate and be attracted to the core. An armature which
is short-circuited must be replaced.
Armature Winding Ground Test: Use a circuit tester, touch

one probe to a commutator segment and the other probe
to the armature core [B]. There should be no continuity.
If there is continuity, the armature is grounded and must
be replaced.
Armature Winding Continuity Test: Use a circuit tester,

touch the probes to two commutator segments [C]. There c
should be continuity at any point. If there is no continuity,
the winding is open-circuited, replace the armature.
8-14457
Commutator Run-Out Test: Check the commutator

run-out as shown in [0]. D
Service Limit - 0.02 inches (0,5 mm)
If the commutator exceeds the service limit, repair as

needed.
963 Bobcat Loader

STARTER (Cont'd)
Inspection And Repair (Cont'd)
ARMATURE (Cant' d)
Measure the commutator outer diameter [A].
Service Limit - 1.38 inches (35 mm)
If it is worn, replace the armature.
8-14459
Measure the segment mica depth (Item 1) [B].
B
Service Limit - 0.008 inches (0,2 mm)
If it is worn, undercut the segment mica.
Check the commutator surface for burned spots which
kF""-&- -=:: CD
usually indicates an open-circuit, and correct it using
#400 sand paper.
8-14460
Check the bearings for wear and damage [C].

c
If the bearings are worn or damaged, they should be
replaced.
B-14461
Use a press as shown in [0], replace the worn or

damaged bearing(s). 0 f Press
U .-Bearing
.-Armature
I B-14439
963 Bobcat Loader
STARTER (Cont'd)
Inspection And Repair (Cont'd)
FIELD WINDINGS:
Check the field windings for wear and damage.
Check all the connections for clean and tight solder joints.
Field Winding Ground Test: Use a circuit tester, touch one

probe to the field winding end of the brush and the other
probe to the surface of the field windings housing [A].
There should be no continuity. If there is continuity, the
field windings are grounded .
Replace the field windings.
Field Windings Continuity Test: Use a circuit tester, touch

one probe to the wi re and the other probe to the brush [8].
There should be continuity. If there is no continuity, the
field windings are open--circuited.
Replace the field windings.
BRUSH AND BRUSH HOLDER:

c
Measure the brush length.
Service Limit - 0.512 inches (13 mm)
If it exceeds the limit, replace the brush holder or field

windings assembly.
Check brush springs, for damage or rust. Replace as

needed.
Brush Holder Insulation Test: Use a circuit tester, touch

one probe to the positive brush holder plate and the other
probe to the holder plate [C]. There should be no
continuity. If there is continuity, replace or repair.
OVERRUNNING CLUTCH:
D
Inspect the pinion , it must rotate freely in the direction of
the starter rotation and locked in the opposite rotation [0].
963 Bobcat Loader

STARTER (Cont'd)
Magnetic Switch Test
The following tests should be done without the armature

assembly.
NOTE: Each test should be performed a short time

(3 to 5 seconds) to prevent the magnetic
switch winding from burning. Each test
should be performed with 12 volts.
Pull-In Test: Connect the wires as shown in [A]. When

connecting Terminal C and M.T. are closed, the pinion 8-14471
should engage.
Hold-In Test: With the same conditions as in the pull-in B

test, open the connecting Terminal C [8]. The pinion
should remain in the engaged position.
Return Test: With the same conditions as in the hold-in

test, open the connecting Terminal 50 [C]. The pinion
should return immediately.
c
M.T. Main Terminal to which the main cable from the

battery is connected.
C C-Terminal to which the wire from the field

windings is connected.
50 50-Terminal to which the wire from the starting M.T.

switch or stator relay is connected.
8-14469
No Load Test D Ammeter
The following test should be done after reassembling the

starter: E:LJ 50
-I
Clamp the starter in a vise. Use a 12 volt battery and
(C§))
ammeter, connect the positive wire of the battery, and the
I
ammeter to the 50 Terminal [0]. Connect the negative
wire to the starter body. I,
'~I
The starter should show smooth and steady rotation
immediately after the pinion is engaged, it should draw
+ I~,
,L._. J
less than the specified current.
Service Limit - 220 Amp. Maximum Draw Starter
8-14440
963 Bobcat Loader

STANDARD INSTRUMENT PANEL
Pry the rubber light mount loose from the operator cab
(both sides) [A].
Lower the light from the operator cab and locate the three
instrument panel mounting bolts (Item 1) [8] (both sides).
Remove the three mounting bolts (Item 1) [8].
Installation: Be careful not to overtighten the instrument

panel mounting bolts to prevent stripping the threaded
holes in the panels.
Mark all wires for ease of assembly.
Pull the left instrument panel down and disconnect the

wire harness connectors from the panel. Remove the
panel [C].
Mark all wires for ease of assembly.
Repeat steps [A] and [8]. Pull the right instrument panel
down and disconnect the wire harness connectors from
the panel. Remove the panel [0].
Reverse the removal procedure to install the instrument

panel.
963 Bobcat Loader

FRONT LIG HT S

A
The front lights are mounted in the upper corners of the
operator cab [A].
Pry the rubber light mount free from the operator cab [B].
Pull the light down and remove the three mounting bolts
(Item 1) [C] from the instrument panel.
Disconnect the front light connector from the instrument

panel. Remove the front light from the operator cab.
Reverse the removal procedure to install the front light.
963 Bobcat Loader

--6-28- Service Manua'
ENGINE SERVICE
Page
Number
AIR CLEANER HOUSING
Removal And Installation ...................... . . ........ . ...... 7-9
BLOWER FAN
Removal And Installation . .. ..... .. ..... . ........... .. .......... 7-18
CAMSHAFT AND TAPPETS
Installation .... . .. . . . .... . ..... . .... . ....... .... ........ . . . ... 7-65
Removal ...... . . . ........ .. ......... . .. . ...... . ...... . . ...... 7-64
COOLANT RECOVERY TANK
Removal And Installation . ........ . . . .. . ...... .. ....... . ..... . .. 7-10
COOLI NG SYSTEM
Description ... . ............ . . ........ . .............. .. .... . ... 7-76
Thermostat Removal and Installation ..... . ......... . . . . . ........ 7-77
Thermostat Testing .. . . . ....... . ... . . ..... ......... .. ........ .. 7-77
Water Pump Installation ........ .... ........... .. ..... .. .... .. .. 7-78
Water Pump Removal . ........ . ............ . . ............ . .... 7-78
CRANKSHAFT AND BEARINGS
Checking Crankshaft End Play ......... . .......... . .. .. ......... 7-75
Description ...... . ............................. .. . . ......... .. 7-71
Installation ...... . . . .......... . . . ........... ... .......... ... . . 7-73
Inspection Of Crankshaft And Bearings ...... .. ......... . . .. ..... 7-72
Rear Oil Seal Housing Positioning .. . ...... .. .. . ...... . . . . . ...... 7-74
Rear Oil Seal Installation . . ............ . ........ . .... .. .... . .... 7-74
Rear Oil Seal Removal .............. . . . .......... . . ......... . . . 7-74
Removal ........ .. ........................... . .. . ...... ... . . . 7-71
CYLINDER HEAD
ENGINE
Installation . .. ......... .... ........... . ..... . ..... .. ... . ...... 7-51
SERVICE
Removal ..... . ..... . .. . . . ......... . . ......... . .. . . . ......... . 7-49
Inspection ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-51
ENGINE
Removal And Installation .. . ............ .. .. . ......... . . ........ 7-42
ENGINE BLOCK
Cylinder Liner Inspection .............. . .......... . ......... . ... 7-89
Cylinder Liner Installation ................. . ............. . . . . . .. 7-90
Cylinder Liner Removal ..... .. . . ......... . .......... . . ... ...... 7-89
Description .......... . . . ......... . ........ . .......... . ........ 7-87
Disassembly And Assembly ....... . . . ........ . . . .. . . . ........ .. 7-87
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7-88
Piston Cooling Jet Alignment .... . ...... . .... .. ........... .. . ... 7-88
Piston Cooling Jet Installation . . .......... ..... .......... .. ...... 7-88
Piston Cooling Jet Removal . . .......... . . . .......... .. ......... 7-88
ENGINE MOUNTING BRACKET
963 Bobcat Loader

ENGINE SERVICE (Cont'd)
Page
Number
ENGINE MUFFLER
Exhaust Extension Pipe .. . . .......... . ...................... . . . 7-8
Removal And Installation .. . . . . . ... . .... . .. . . .. ....... .. . . ..... . 7-7
ENGINE OIL COOLER
Disassembly and Assembly .. .. ........... . .......... .. . . ...... 7-81
Removal and Installation . ......... .. ........... . . . ....... .. . .. . 7-79
ENGINE SPEED CONTROL
Removal And Installation ... . ....... .. ....... . .... .. .......... .. 7-6
EXHAUST MANIFOLD
Removal and Installation . ............. . ......... .. .. . ....... . . . 7-48
FAN DRIVE TENSION PULLEY
Removal And Installation . .. . ......... .. ..... . .......... . ...... . 7-14
FAN GEARBOX
Assembly .... ... . ....... . ....... . .... . ........... .. .......... 7-25
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7-19
Checking Backlash ... .. ............. . .. . ....... . ........... .. , 7-30
FAN GEARBOX/BLOWER HOUSING
Removal And Installation .. . ......... .. .......... . .. . . . ..... . ... 7-16
FLYWHEEL
Removal And Installation ............ ... ........... .. .......... ' 7-32
Ring Gear Installation ....... .. .......... . . . ....... . ... .. ..... . . 7-33
Ring Gear Removal . . ........... .. ........ . ... . ............ . .. 7-33
FUEL LIFT PUMP
Checking ............ .. ...... . .. ... ..... . .......... . ...... . ... 7-35
Removal And Installation .. . ........ . .... . .......... .. .......... 7-35
FUEL INJECTION PUMP
Removal And Installation .. . .. . .......... . .. . ........ ... .... . ... 7-36
FUEL INJECTOR NOZZLES
Checking ..... . .......... . . .. .......... . .......... . ... . ...... . 7-41
Removal and Installation .... . .... .. .... . ..... ... ............. . . 7-39
INTAKE MANIFOLD
Removal and Installation 7-47
LUBRICATION SYSTEM
Description .......... .. .... . ..... .. ......................... . , 7-82
Oil Filter Adapter Installation . ..... . .... . . . ...................... 7-83
Oil Filter Adapter Removal ............................ . .. . ..... 7-83
Oil Pan Removal And Installation ...... . ............... . ........ . 7-83
Oil Pressure Relief Valve Disassembly And Assembly ... . .......... 7-86
Oil Pump Disassembly And Assembly ........ . . . ........... . .... 7-86
Oil Pump Installation .... . ........... .. ........................ . 7-85
Oil Pump Removal ........ . . . ............ . . . ..... ' .... . ....... 7-84
Oil Screen And Pick-up Tube .... . . . ........ . ... . .......... .. ... 7-84
963 Bobcat Loader

ENGINE SERVICE (Cont'd)
Page
Number
PISTONS AND CONNECTING RODS
Assembly .................................................... 7-69
Checking Piston Height ........................................ 7-70
Connecting Rod Bushing Replacement .......................... 7-69
Connecting Rod Inspection ..................................... 7-69
Description ................................................... 7-66
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7-67
Installation ................................................... 7-69
Piston Ring End Gap .......................................... 7-67
Piston Ring Installation ......................................... 7-67
Piston Ring Groove Clearance .................................. 7-68
Removal ..................................................... 7-66
RADIATOR
ROCKER SHAFT
TIIVlII\JG CASE AND DRIVE ASSEMBLY
Description ................................................... 7-60
Front Oil Seal Installation ....................................... 7-62
Front Oil Seal Removal ........................................ 7-62
Timing Case And Gear Installation .............................. 7-63
Timing Case And Gear Removal ................................ 7-62
Timing Cover Installation ....................................... 7-61
Timing Cover Removal ......................................... 7-60
TROUBLESHOOTING
Chart ........................................................ 7-5
TURBOCHARGER
Description ................................................... 7-92
Removal and Installation ....................................... 7-92
Troubleshooting ............................................... 7-91
VALVE, VALVE GUIDES AND SPRINGS
Assembly .................................................... 7-58
Changing Valve Springs (With Cylinder Head Installed) ............ 7-59
Checking Valve Depth ......................................... 7-56
Checking Valve Guides ........................................ 7-56
Checking Valve Springs ........................................ 7-55
Checking Valves ............................................... 7-58
Cutting A Valve Seat ........................................... 7-58
Valve Removal ................................................ 7-55
Valve Guide Installation ........................................ 7-57
Valve Guide Removal .......................................... 7-57
VALVE CLEARANCE
Adjustment ................................................... 7-34

I,muew a:l!II..1as -v-l-
Japeol le:>q o 8 £96
TROUBLESHOOTING
Chart
The following troubleshooting chart is provided as an assistance in locating and correcting problems which are most com
mon . Many of the recommended procedures must be done by authorized Service personnel only.
PROBLEM CAUSE
Slow crankinq speed. 1, 2 3,4
Enqine will not start (cold) 2, 5, 6, 7
Engine will not start 1, 2,3, 4,5,6,7, 8,9,10
Difficult to start. 1 2 3, 4,5,6,7, 8,9,10,11 , 12,13,14, 15,16 18,19,20,21
No ~ower from enqine 9,11,15, 16,17,18, 19,21,22, 25,26 , 27
Enqine mis-firing. 11, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24
Too much fuel consumption. 7 16 17 18 20 21 22 28 29 30
Black exhaust. 16,17,18,19, 20,22,25, 27
Blue/white exhaust. 4, 7,16,18,19,22,31,32
Low oil pressure. 4 31 32 33 34 35 37 38 39 48 51
Enaine knockina. 4 5 17 18 19 20 23 34 35 36 37 38
Enqine running rough. 7,8, 9, 10, 11,12,13,14,20,21,22, 25 , 26,27,28,29,40,52
Vibration. 16 30 50 51 52
High oil pressure. 4,33,36
Overheatina. 18 19 20 22 25 31 33 46 47 48 49
Too much crankcase pressure. 25 35 36 42
Poor compression. 17 18 22 23 30 32 34 35 36 44
Start and stop. 9 11 13 15 17 22 23 30
Excessive oil consumption. 4, 22,32,36,40,41 , 42, 43, 44,45
KEY TO CORRECT CAUSE
1. Batte~ capacity low.

27. Poor boost pressure.
2. Bad e ectncal connections.
28. Fuel leak.
3. Faulty starter motor.
29. Lubrication oil diluted by fuel.
4. Incorrect grade of oil.
30. Sticking valves.
5. Incorrect grade of fuel.
31. Leaking head gasket.
6. Incorrect use of cold starting equipment.
32. Worn valve gUides/stems.
7. Faul~ cold starting equipment.
33. Faulty thermostat.
8. Insu icient fuel in tank.
34. Incorrect piston height.
9. Faulty stop control.
35. Broken/worn piston rings
10. Broken fuel injection pump drive.
36. Worn cylinder liners.
11. Air in the fuel ststem.
37. Worn wrist pins.
12. Restricted fuel eed.
38. Excessive camshaft end play.
13. Fuel tank vent blocked.
39. Excessive timing gear backlash .
14. Plu~ged fuel filters.
40. Oil leaks.
15. Fau ty fuel pump.
41. New or rebuilt engine not broken in.
16. Low compression.
42. Plugged breather pipe.
17. Incorrect valve clearance.
43. Glazed cylinder liners.
18. Incorrect valve timing.
44. Worn pistons.
19. Incorrect fuel pump timing.
45. Worn valve stem seals.
20. Faulty Injectors.
46. Coolant level low.
21. Faulty fuel injection pump.
47. Faulty water pump.
22. Plu~ged air filter.
48. Loose or broken blower fan belt.
23. Bro en or weak valve springs.
49. Radiator cooling fins plugged.
24. Overheating.
50. Damaged blower fan.
25. Restricted exhaust System.
51. Loose flywheel.
26. Water in fuel.
52. Broken engine mounts.
- --- - - - - - - - - - - - - I
963 Bobcat Loader

ENGINE SPEED CONTROL
device . (See Page 1-1.)
Remove the two mounting bolts (Item 1) [A).
Mark the front side of the stop bracket (Item 1) [B) and
remove the stop bracket
Instal/ation: It is important for the front and rear side of

the stop bracket to be located correctly.
Remove the bolts (Item 2) [B].
Instal/ation: Tighten the bolts evenly until the speed

control lever moves backward and forward at a
comfortable tension.
Remove the speed control lever (Item 1) [C), wave

washers (Item 2) [C) and mounting bracket (Item 3) [C).
Disconnect the throttle linkage from the throttle arm (Item

4) [C).
NOTE: Do not lubricate the speed control parts

when assembling.
963 Bobcat Loader

ENGINE MUFFLER
Open the rear door.
Lift the rear grill.
Drain the cooling system (See Page 1-1 .)
Remove the hose clamps (Item 1) [A].
Remove the U-clamps (Item 2) [A].
Remove the coolant tube (Item 3) [A].
Remove the mounting bolt (Item 1) [B] on the top left side
of the engine heat shield.
Remove the mounting bolts (Item 1) [C] and remove the

coolant tube mounting bracket (Item 2) [C].
Remove the mounting bolts (Item 1) [0] from the
thermostat housing (Item 2) [0].
Remove the hose clamp (Item 3) [0].
Remove the thermostat housing .
963 Bobcat Loader

ENGINE MUFFLER (eont'd)
Removal And Installation (eont'd)
Remove the mounting bolts (Item 1) [A] from the muffler

and exhaust extension pipe.
Remove the muffler mounting bracket bolts (Item 2) [Al
Remove the four mounting bolts (Item 1) [B] that hold the
muffler and heat shield bracket to the engine block.
Remove the heat shield bracket (Item 2) [B].
Remove the muffler.
Exhaust Extension Pipe
Remove the heat shield from the engine.
Remove the mounting bolts (Item 1) [A] from the muffler

and extension pipe.
Remove the mounting bolt (Item 1) [e] and heat shield

bracket (Item 2) [el
Remove the other two mounting bolts (Item 3) [e] and

remove the exhaust extension pipe from the
tubrocharger.
963 Bobcat Loader

AIR CLEANER HOUSING
Open the rear door.
Disconnect the intake hose (Item 1) [A] from the air
cleaner housing.
Remove the bolt and nut from the mounting strap (Item
2) [A] (both sides) .
Remove the air cleaner housing from the mounting

straps.
Remove the two bolts from the mounting strap (Item 1)

[8].
Remove the mounting strap.
Repeat procedure for the other mounting strap.
963 Bobcat Loader

COOLANT RECOVERY TANK
Remove the bolts (Item1) [A] from the coolant recovery

tank mounting bracket (Item 2) [A].
Remove the bracket from the loader.
Remove the coolant recovery tank as shown in figure [8].
Disconnect the hose (Item 1) [C] that attaches to the

bottom of the coolant tank from the radiator. I C
963 Bobcat Loader

RADIATOR
Remove the oil cooler. (See Page 2-1.)
Connect a hose to the drain valve (Item 1) [A] on the

engine block.
Open the drain valve and drain the coolant into a

container [8].
Installation: 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 0 F. (-3JO
C.) freeze protection . Mix the coolant in a separate
container. (See SPECIFICATIONS Page 9-1 for correct
capacity.)
Installation: Fill the radiator with the premixed coolant

until full. Open the vent plug (Item 1) [C] to remove the air
from the engine block. Tighten the vent plug . Continue to
fill the radiator until full. Install the radiator cap.
A WARNING

W-2103-1285
963 Bobcat Loader

RADIATOR (Cont'd)
A ... ; a l
Remove the hose clamp (Item 1) [A] from the right side
radiator hose.
Remove the hose clamp (Item 1) [B] from the right side
radiator hose.
Remove the radiator hose.
N-15791
Remove the left side radiator hose clamp (Item 1) [C].
Remove the radiator hose from the radiator.
Remove the hose clamp (Item 1) [0] from the coolant

tube (Item 2) [0].
Remove the lower hose (Item 3) [0] from the coolant

tube.
Remove the U-clamps (Item 4) [0] and remove the

coolant tube.
963 Bobcat Loader

RADIATOR (Cont'd)
Remove the mounting bolts (Item 1) [A] from the radiator

mounting bracket (Item 2) [A].
Remove the radiator mounting bracket.
======~ ,..-.,.~... --~---

Remove the radiator mounting bolts (Item 1) [8] from the
bottom of the radiator.
B fl ·
Remove the radiator.
963 Bobcat Loader

FAN DRIVE TENSION PULLEY
Remove the fan drive belt from the hydraulic pump pulley.
Remove the two bolts (Item 1) [A] from the fan gearbox
housing.
Remove the two bolts (Item 1) [B] (inside the blower

housing).
Remove the fan tensioner pulley and belt from the loader
[C].
N-15732
Remove the idler pulley bolt (Item 1) [0] and nut (Item 2) I0
[0].
Remove the pulley (Item 3) [0] and belt guide (Item 4) [0].
N-15733
963 Bobcat Loader

-7-14 Serv i ce Manual
FAN DRIVE TENSIONER PULLEY (Cont'd)

A
Remove the spacers, bushing and washers from the
pulley [A].
P-04956
Installation: Put a small amount of grease around the

outside edge (Item 1) [B] on the grease ring (both sides).
Remove the bolt (Item 1) [C] , arm (Item 2) [C] and spring
(Item 3) [C] from the mounting bracket.
/D
N-15734
Check all the parts for wear and damage and replace as
needed [D]. I0
See the Parts Microfiche for the correct part numbers.
N-00303
963 Bobcat Loader

FAN GEARBOX/BLOWER HOUSING
Stop the engine.
Remove the hydraulic fluid reservoir. (See Page 2-1.)
Remove the two mounting bolts (Item 1) [A] from the front
of the fan drive mounting plate.
Remove the two nuts (Item 1) [B] at the rear of the fan
drive mounting plate.
Remove the fan/fan gearbox assembly from the blower

housing [C].
Disconnect the fuel fill hose (Item 1) [0].
Remove the two bolts (Item 2) [0] and remove the fan
gearbox mounting plate (Item 3) [0].
963 Bobcat Loader

FAN GEARBOX/BLOWER HOUSING (Cont'd)
Disconnect the fuel tank vent hose (Item 1) [A].
Later Model Loaders: Remove the oil cooler from the

Remove the nuts (Item 1) [8] and mounting bolts (Item 1)

[C] from the blower housing.
,)
*'
.~
Early Model Loaders: Remove the mounting bolts (Item

1) [C] (the bolts have blind nuts under the oil cooler) from
the blower housing.
Remove the blower housing from the loader frame [0].
963 Bobcat Loader

BLOWER FAN
Remove the lock nut (Item 1) [A] and spacer.
Instal/ation: Tighten the nut to 45-55 ft.-Ibs. (61-75 Nm)
. torque.
Install the puller (Item 1) [B] on the fan as shown.
Tighten the puller bolts evenly to loosen the fan from the
shaft.
Remove the fan from the tapered shaft [C].
Remove the three bolts and nuts (Item 1) [0], to remove

the fan gearbox from the mounting plate.
963 Bobcat Loader

-7-18- Service Manua\
FAN GEARBOX
Disassembly
Remove the three pulley bolts (Item 1) [A]. Turn them into
the next set of holes on the pulley. lighten the bolts evenly
until the pulley is removed from the hub.
N-15761
Loosen the set screw, using a allen wrench (Item 1) [B].
Remove the hub from the fan gearbox shaft [C].

c
, ~~
N-15763
963 Bobcat Loader

FAN GEARBOX (Cont'd)
A
NOTE: When repairing the gearbox order the

following as needed:
1. Complete Assembly
2. Long Housing Assembly
3. Long Housing
4. Short Housing Assembly (See Note Below)
5. Internal Parts
NOTE: The short housing is only available as an

assembly. See the parts microfiche for part
numbers.
NOTE: Be sure to count the number and thickness of

shims during disassembly. Install the shims I B
in the original location during assembly.
Long Housing
Remove the four mounting bolts and the part number tag
[A).
Remove the oil from the gearbox.
A WARNING

Wear safety goggles to prevent eye injury
when drilling or grinding.
W-21 08-1186
Drill an 1/8 inch (3 mm) hole in the seal. Use a slide

hammer tool to remove the seal [B).
Remove the small snap ring [C).
963 Bobcat Loader

A
Remove the small shims [A).
Remove the screw and washer from the shaft [B).
P-02966
Support the lower flange and press the shaft from the IC
bearing [C).
NOTE: The gear and the other bearing (pulley end)

will be removed with the shaft. .
Support the bearing and press the shaft from the bearing I0
[0).
P-03298
963 Bobcat Loader

Short Housing
Remove the end cap [A].
Use care not to damage the housing.
A WARNING

Wear safety goggles to prevent eye injury
when drilling or grinding.
W-2108-1186
Drill an 1/8 inch (3 mm) hole in the seal. Use a slide

hammer tool to remove the seal [8].
Remove the large snap ring from the flange end of the
housing [C].
Remove the large shims from the housing [OJ.
NOTE: Use the same size and thickness of shims

during assembly.
P--02969
963 Bobcat Loader

FAN GEAR BOX (Cont'd)
Remove the screw and washer (Item 1) [A] from the
shaft.
Remove the snap ring from the cap end of the housing I8
[B].
Press the shaft from the housing [C].

NOTE: Both bearings may come out of the housing
with the shaft. If one bearing remains in the
housing, use a non metal object to tap the
bearing from the housing.
P-02998
Press the bearing from the tapered end of the shaft [0].
o
P-03088
963 Bobcat Loader

A
Press the bearing , shims and gear from the shaft [A].
P-Q3001
Remove the key (Item 1) [B] from the shaft. B
P-Q2972
963 Bobcat Loader

A
Assembly
NOTE: Always replace seals during assembly.

Replace the parts in the gearbox as needed.
NOTE: Do not install the seals and cap in the

housing until after the backlash has been
checked.
NOTE: Use care when pressing the bearings into the

aluminum housing. The housing can be
damaged if too much pressure is used.
NOTE: For procedures requiring the use of LOCTITE

adhesive, thoroughly clean and dry affected
parts before the application of LOCTITE.
Long Housing
Press a bearing on the short keyed end of the long shaft
[A].
Install the long housing on the shaft [B).
Be sure the bearing is seated in the bore at the lower end
of the housing .
Install a bearing on the long keyed end of the shaft [C].
Support the lower bearing and press the other bearing in

the housing until the bearings seat in the housing [C].
Install on the bearing, the same number and size shims ID
that were removed during disassembly [0].
963 Bobcat Loader

Assembly (Cont'd)
A
Install the small snap ring in the groove above the shims
[A].
Install the gear key in the flange end of the shaft [B].
Align the key and gear. While supporting the bearing on

the other end, press the gear on the shaft until it seats
against the bearing [C].
P-02967
Install the washer [0].
Put liquid adhesive (LOCTITE #242) on the screw

threads: Install and tighten the screw [0].
P-02966
963 Bobcat Loader

Assembly (Cont'd)
A
Short Housing
Install a bearing in the flanged end of the housing [A] .
Install the large shims on the bearing (flanged end) [8].
P-02969
Install the large snap ring in the groove above the shims
[C].
" P-02970
Install the short key (Item 1) [0].
Align and press the gear on the shaft (teeth toward the
tapered end of the shaft) [0].
P-02971
963 Bobcat Loader

Assembly (Cont'd)
After the gear is seated, drive the key down inside the
gear key way [A].
NOTE: This will prevent damage to the shims when

the bearing is installed later.
P--Q2975
Install the shaft in the housing, tapered end in the bearing

at the round flange end of the housing [B]. B
P--Q2976
Install on the shaft, the same number and size shims that IC
were removed during disassembly [C].
P--Q2977
Install a bearing on the gear end of the shaft [0].
P--Q2974
963 Bobcat Loader

Assembly (Cont'd)
Install the snap ring in the groove above the bearing [A].
P-02973
Install the washer (Item 1) [8] on the shaft. Put liquid

adhesive (LOCTITE #242) on the screw threads and
install the screw [8].
963 Bobcat Loader

A
Checking Backlash
NOTE: For procedures requiring the use of LOCTITE
adhesive, thoroughly clean and dry affected
parts before the application of LOCTITE.
The backlash tolerance between the gears should be
0.005-0.008 inch (0,127-0,203 mm) .
To check the gear backlash use the following procedure:
Put the short housing in a vise, square flange facing up

as shown [A].
Install the same size and number of square shims (if

present during disassembly) between the two housings
[B].
Set the long housing on the short housing with a small

amount of liquid adhesive (LOCTITE #242) between the
mounting surfaces.
NOTE: If square shims are used, put a small amount
of the liquid adhesive on both sides of all
shims.
Install the four mounting bolts through the flange holes

[C].
Install the part number tag [C].
Install and tighten the nut to 25-28 ft.-Ibs. (34-38 Nm)

torque.
Install the long key (Item 1) [0] and the pulley (Item 2) [0].
Install a bolt in the set screw hole to maintain a 1 .000 inch

(25,4 mm) distance from the shaft center to the bolt head
(to be used with a dial indicator) [0].
963 Bobcat Loader

-7-30 Service M anual
Checking 8acklash (Cont'd)
A
Put the fan nut (Item 1) [A] on the shaft and tighten snugly.
Install a locking pliers on the fan nut and support the
handle against the long housing [A].
P--{)2982
Using a magnetic based dial indicator mounted on a

bench vise, touch the dial stem on the bolt (Item 1) [8]. IB
Hold the locking pliers against the long housing and rotate
the pulley back and forth to read the dial gauge [8].
t-=..
If the backlash is GREATER than 0.008 inch (0,203 mm),
do the following:
1. Remove a square shim(s) (if present) between the
two housings.
2. Remove a large shim(s) from the tapered end of the
short shaft and add a small shim(s) of the same
thickness between the bearing and the gear on the
screw end of the shaft.
If the backlash is LESS thanO.005 inch (0,127 mm) do the

following:
1. Add a square shim(s) between the two housings.
2. Remove a small shim(s) between the bearing and
the gear on the screw end of the short shaft and add
a large shim(s) of the same thickness between the
snap ring and the bearing on the tapered end of the
shaft.
963 Bobcat Loader

FLYWHEEL
Remove the drive belt. (See Page 3- 1.)
Remove the two opposite bolts (Item 1) [A] from the

flywheel.
Install two guide studs (Item 1) [B] in the flywheel to

prevent the flywheel from falling .
Remove the remainder of the bolts from the flywheel.
Installation: Tighten the flywheel bolts to 77 ft.-Ibs . (105

Nm) of torque.
Remove the flywheel by sliding outward over the guide
pins figure [C].
Check the flywheel and ring gear for wear or damage.
Replace as needed.
963 Bobcat Loader

FLYWHEEL (Cont'd)
A
~((Q)~@
~~
Install a dial indicator to check the flywheel run out [A].
Flywheel run out must be less than 0.012 inch (0,30 mm) .
Check the alignment of the flywheel face [B].
The misalignment must not be more than 0.001 inch (0 ,03 @

mm) total indicator reading for every 1.0 inch (25 mm) of
the flywheel radius from the crankshaft axis to the dial
gauge plunger.
B-D5559
Example: The misalignment must not be greater than
0.008 inch (0 ,203 mm) at 8 inches . (203 mm) from the
centerline of the crankshaft towards the outside of the
flywheel.
During this check keep the crankshaft pressed toward the

front so crankshaft end play will not affect the reading.
Ring Gear Removal
Before the ring gear is removed note the position of the

chamfer on the teeth .
Heat the ring gear enough to expand it and hit it with a

hammer evenly to remove it.
Be careful not to damage the flywheel during this

operation.
Ring Gear Installation
The ring gear is a heat expansion fit on the flywheel.
Do not heat the ring gear to a temperature greater than

480 0 F (250 0 C) make sure the ring gear chamfer is in the
correct position.
ENGINE MOUNTING BRACKET
Remove the drive belt. (See Page 3-1.)
Remove the hydrostatic pump. (See Page 3-1.)
Remove the belt tension assembly. (See Page 3-1 .)
Remove the idler pulley assembly. (See Page 3-1 .)
Remove the starter. (See Page 6-1 .)
Remove the flywheel housing mounting bolts (Item 1) [C].
Remove the flywheel housing from the engine.
Installation: Tighten the flywheel housing bolts to 52
ft.-Ibs . (70 Nm) torque.
963 Bobcat Loader

VALVE CLEARANCE
Adjustment
A
Adjust the valve clearance as follows:
Loosen the lock nut (Item 1) [A).
Turn the adjustment screw (Item 2) [A] until the correct
clearance is obtained.
NOTE: The clearance is measured between the

rocker arm and valve stem tip (Item 3) [A].
Adjust the valve clearance as follows:
0.008 inch (0,20 mm) Intake B-{)5568

0.018 inch (0,45 mm) Exhaust
Use the following sequence to set the valves [B] & [C]:
a. With the rocker arm rocking (valves 7 & 8) on No.4

cylinder set clearance at No.1 cylinder (valves' & 2) .
b. With the rocker arm rocking (valves 3 & 4) on No.2

cylinder set clearance at No.3 cylinder (valves 5 & 6).
c. With the rocker arm rocking (valves 1 & 2) on No.1

®®
cylinder set clearance at No.4 cylinder (valves 7 & 8). 00 0 oQo oQo oQo
d. With the rocker arm rocking (valves 5 & 6) on No.3
cylinder set clearance at No.2 cylinder (valves 3 & 4).
B-{)5569
~ Cylinder Number 1 2 3 4
Valve Number 1 2 3 4 5 6 7 8
Valve
I = Intake I E I E I E I E
E = Exhaust
963 Bobcat Loader

FUEL LIFT PUMP
Checking
Install a gauge to the outlet side of the lift pump. Turn the
engine for 10 seconds.
Standard Pressure .. ..... .. .. 6-10 PSI (41-70 kPa)
Minimum Pressure 3.75 PSI (25 kPa).
Remove the hydrostatic pump/engine assembly. (See

Page 7-42 .)
Remove the mounting bolts (Item 1) [A] from the engine

heat shields (Items 2 & 3) [A].
Remove the engine heat shields.
Remove the heat shield mounting bracket (Item 1) [B]

from the engine turbocharger by removing the two
mounting nuts (Item 2) [B].
Remove the hose clamp (Item 1) [C] from the

turbocharger air inlet hose (Item 2) [C].
Remove the air inlet hose from the turbocharger.
Disconnect the fuel in-let hose (Item 1) [0] from the lift
pump.
Disconnect the fuel tubeline (Item 2) [0] going to the fuel

filter.
Remove the four mounting bolts (Inset) [0].
Installation: Tighten the bolts to 16 ft.-Ibs. (22 Nm)

torque .
Remove the fuel lift pump.
963 Bobcat Loader

FUEL INJECTION PUMP

A

procedure:
MEL 1540 - Timing Tool
Disconnect the negative (-) cable from the battery. (See

Page 6-1)
Remove the nuts (Item 1) [A] from the water pump
mounting bolts.
Installation: Tighten the nuts to 16 ft.-Ibs . (22 Nm)
torque.
Remove the mounting bolts (Item 1) [8] from the front
side of the water pump.
torque .
Remove the water pump from the engine.
Turn the crankshaft over slowly until the hole (Item 1) [C]
in the fuel injection pump gear, timing plate and the hole
in the hub, align with a hole in the body of the fuel injection
pump .
NOTE: Do not loosen the nut (Item 2) [C] from the

fuel injection pump. The timing of the fuel
injection pump comes set from the factory.
Insert a timing pin (Item 1) [0] into the aligned holes.
NOTE: The dimensions of the timing pin are 8 mm

0.0. x 127 mm long.
963 Bobcat Loader

FUEL INJECTION PUMP (Cont'd)
Disconnect the tubeline (Item 1) [A] from the top of the

fuel injector pump.
Disconnect the tubeline (Item 2) [A] from the injector

pump.
Disconnect the tubeline (Items 3, 4 & 5) [A] from the top

side of the fuel filter.
Remove the mounting bolts (Item 6) [A] from the fuel filter
mounting bracket.
Remove the fuel filter mounting bracket and fuel filter from
the engine.
Disconnect the injector tubelines (Item 1) [B] from the

injector pump.
Installation: Tighten the tubeline fittings to 16 ft.-Ibs. (22

Nm) torque .
Disconnect the injector tubelines (Item 1) [C] from the

injectors.
Installation: Tighten the tubeline fittings to 16 ft .-Ibs. (22

Nm) torque.
Disconnect the fuel tubeline (Item 2) [C] and remove the

tubeline.
Remove the injector tubelines from the engine.
Disconnect the electrical connections (Item 1) [0] from

the temperature sender.
Remove the mounting nuts (Item 2) [0] from the injection

pump .
Installation: Tighten the nuts to 16 ft .-Ibs. (22 Nm)

torque.
963 Bobcat Loader

FU EL INJECTION PUMP (Cont'd)
Remove the mounting bolts (Item 1) [A] from the fuel

injection pump gear.
torque .
Remove the fuel pump and timing pin from the engine .
963 Bobcat Loader

FUEL INJECTOR NOZZLES
A WARNING
Diesel fuel or hydraulic fluid under pressure

can penetrate skin or eyes causing serious
injury. Fluid leaks under pressure may not be
visible. Use a piece of 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.
W-2074-1285

fuel injection pump.

pump .
Disconnect the tubelines (Items 3,4, & 5) [A] from the fuel
filter housing.
Disconnect the injector tubelines (Item 1) [B] from the

injector pump.
Installation: Tighten the tubeline fittings to 16 ft.-Ibs. (22

Nm) toraue.
IMPORTANT
Do not bend the high pressure fuel injection

tubes when removing or installing them.
1-202!Hl289
Disconnect the injector tubelines (Item 1) [C] from the fuel

injectors.
Disconnect the fuel return tubeline (Item 2) [C] and

remove the tubeline.
Remove the high pressure injector tubelines from the

engine .
Disconnect the fuel return tubeline (Item 1) [0] at the fuel

injectors.
Remove the fuel return tubeline from the engine.
963 Bobcat Loader

FUEL INJECTOR (Cont'd)
Installation: Always replace the copper gaskets (Item 1)

[A] at the fuel return tubeline.
Loosen the nut (Item 1) [B] at the fuel injector and remove
it from the cylinder head.
Installation: lighten the nut to 23 ft.-Ibs . (30 Nm) torque.
Installation: Always replace the copper washer (Item 1)

[C] at the nozzle .
N-16407
Installation: Make sure the ball (Item 1) [0] , in the

injector body, is aligned with the notch (Item 2) [0] in the
cylinder head when the fuel injector is installed.
963 Bobcat Loader

FUEL INJECTOR (Cont'd)
A
Checking
IMPORTANT -~~~
Do not disassemble or test the fuel injector
nozzles unless you have the correct service
and testing tools.
1-2027--0284
The tools listed will be needed to do the following 8--08971

procedure;
OEM1 064 - Injection Nozzle Tester

OEM 1065 - Accessory Set
WRONG CORRECT
Connect the nozzle to the test pump, in a down position

[A).
Operate the test pump until the nozzle valve opens:
Injection Working Pressure

4263 PSI (29393 kPa)
A WARNING
8-13330
Diesel fuel or hydraulic fluid under pressure
can penetrate skin or eyes causing serious
injury. Fluid leaks under pressure may not be
visible. Use a piece of 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.
W-2074-1285
Check the nozzle spray pattern [8):
The spray pattern must be uniform from the nozzle.
The nozzles are dirty or defective:

If the spray pattern is not uniform.
If the fuel drips from the end of the nozzle.
If the spray is solid stream instead of a mist.
963 Bobcat Loader

ENGINE
Raise the lift arms and install the lift arm support device.
(See Page 1-1.)
A WARNING

Drain the hydraulic reservoir. (See Page 2-1.)
Remove the battery. (See Page 6-1 .)
Remove the engine coolant. (See Page 1-1.)
Remove the air cleaner housing. (See Page 7-9.)
Remove the engine muffler. (See Page 7-7.)
Disconnect the hose (Item 1) [A] and the hydraulic hose
(Item 2) [A] from the top of the hydrostatic pump.
Disconnect the hose (Item 3) [A] from the top of the

hydraulic pump.
Disconnect the hose (Item 1) [B) from the front of the

hydrostatic pump.
Disconnect the hose (Item 2) [B) from the front side of the
hydraulic pump.
Disconnect the high pressure hoses (Item 1) [C) from the

front of the hydrostatic pumps.
NOTE: When removing and installing the high

pressure hoses protect the O-rings from
damage.
963 Bobcat Loader

ENGINE (Cont'd)
Disconnect the engine wiring harness (Item 1) [A] from

the loader cab wiring harness.
Disconnect the wiring harness (Item 1) [B] from the

hydraulic filter sending switch .
Disconnect the wiring harness (Item 2) [B] from the

loader PWM wiring harness.
Disconnect the wiring harness (Item 1) [C] from the

hydraulic control valve sender.
Disconnect the wiring harness (Item 2) [C] from the

charge pressure sender.
963 Bobcat Loader

ENGINE (Cont'd)
Disconnect and remove the engine throttle rod (Item 1)

[A].
Disconnect the wiring harness (Item 2) [A] from the rear

door to the fuse/relay harness.
Remove the mounting bolts (Item 3) [A] from the fuse/

relay mounting bracket.
Position the fuse/relay bracket and harness on the engine

and will be removed with the engine and pump package.
Remove the left side front engine mounting bolt (Item 1)

[B].
Remove the left side rear engine mounting bolt (Item 1)

[C].
963 Bobcat Loader

ENGINE (Cont'd)
Disconnect and cap the hoses (Item 1) [A] from the fuel
filter.
mounting bracket.
Remove the fuel filter and fuel filter mounting bracket from
the loader.
Remove the right side engine mounting bolts (Item 1) [B].
, ,
963 Bobcat Loader

ENGINE (Cont'd)
Connect a chain into the engine eye hooks (Item 1) [0].
Install a chain hoist.
Lift the engine a small amount. Slide the engine and

hydrostatic pump assembly to the rear to give the engine
clearance at the loader frame .
Lift and remove the engine and hydrostatic pump

assembly from the loader.
963 Bobcat Loader

INTAKE MANIFOLD
Remove the turbocharger. (See Page 7-92 .)
Disconnect the tubeline (Item 1) [A] from the intake

manifold.
Remove the four mounting bolts (Item 1) [B] from the

intake manifold housing.
Installation: lighten the mounting bolts to 33 ft.-Ibs. (44

Nm) torque.
Remove the mounting bolt (Item 1) [C] from the inside of

the intake manifold.
Remove all the mounting bolts from the intake manifold

(Item 2) [C].
Installation: lighten the mounting bolts to 33 ft.-Ibs. (44

Nm) torque.
Remove the intake manifold from the cylinder [0].
Installation: Always replace the intake manifold gasket.
963 Bobcat Loader

EXHAUST MANIFOLD
Removal and Insta"ation
Remove the turbocharger. (See Page 7-92.)
Remove the intake manifold. (See Page 7-47.)
Remove all the nuts from the exhaust manifold (Item 1)
[A].
Installation: Tighten the nuts to 37 ft.-Ibs . (50 Nm)

torque.
963 Bobcat Loader

CYLINDER HEAD
Removal
Remove the oil cooler. (See Page 7-79.)
Remove the intake manifold . (See Page 7-47.)
Remove the exhaust manifold. (See Page 7-48.)
fuel injector pump.
pump.
Disconnect the tubeline (Items 3, 4 & 5) [A] from the top
side of the fuel filter.
mounting bracket.
Remove the fuel filter mounting bracket and fuel filter from
the engine.
Disconnect the injector tubelines (Item 1) [B) from the
injector pump.
Disconnect the injector tubelines (Item 1) [C) from the

injectors.
Disconnect the fuel tubeline (Item 2) [C) and remove the

tubeline.
Remove the injector tube lines from the engine.
IMPORTANT

1-2029-0289
Remove the fuel injectors. (See Page 7-39.)
963 Bobcat Loader

CYLINDER HEAD (Cont'd)
Removal (Cont'd)
Remove the three rocker cover retaining nuts (Item 1) [A].
Remove the four nuts (Item 1) [B] and remove the rocker
shaft assembly [B]. (See Page 7-54) for disassembly
and assembly of the rocker shaft assembly.)
Remove the push rods [C].
Starting with bolt (number 22) [0] and working down ,

remove the head bolts.
NOTE: There are three different length head bolts. - I (-- ,-- - --) - - ( - - -", - - { ...-- - -.....;- - - (--- --)-.... \
Figure [0] shows the three different bolt I I '7@l1S 1@18 ,.-(~\" '-Z@l2' 1@13 I I
lengths: S short; M medium & L long bolts. J \
,,\
,@19
'-': =--,
I I
vI I
...... ~@'
=
-.:::;:r; 9
/~ ~
II '~;I
I
..... ,
~f
(@}1
~,;;,
I I
1'-"
'- ,
~
", M\3
=:;:,;
I
;::
I, ~I
• '- I
1/
I /
q)
14"~/
m
/ ,
Check the head bolts for distortion and damage. Replace

I !(~\--/ -\ (---" ~- /~' - (~\- l~l ( ....y -( ----...~ (
I \~ ) ( ) \. / \ ) \ . . ) \. ) "- I \ ./ I I
as needed. "- ~-.:::.-~ ~ _

-- - ---- - -- . -----~
.= _ ~~ _ -==:::_ .=::. _ ~ _ .::::::,...:::/" J
@ '20 t@)\ 10
", ,y @7 (@ 4
~"
15(®.... ,
Lift off the cylinder head and clean the bottom face.
(':t§121 (@ 22_ ~1 11 ~112~L ~~ (@s _ (@ 17') ~1 16"")
'-./ I ~ I '" t ) 0' ~ II ~I\ - .... ( \" ""l./ - ') \ ~
L- _ _ _ _ _ - - -i I l\--- ~/_ .J '- -
Remove the valves from the cylinder head. (See Page - -'
7-55.)
l 8-05561
963 Bobcat loader

-7-50 SerVlce Manual
A
Inspection
1 1 1 1 3
Put a straight edge on the cylinder head as shown in [A].
Using a feeler gauge between the straight edge and head, II ''/ ''''':;:' '1 ' '1' ~G~ 't' __~?: 't' I 2
check for warpage .
Maximum allowed (Item 1) [A] is 0.003 inches (0,08 mm),

(Item 2) [A] is 0 .006 inches (0,15 mm) and (Item 3) [A] is
0 .006 inches (0,15 mm) . 'I .. ;;> <" I . \) 1". .. r",.... . ill 2
The head may be machined removing only a minimum

3
amount. Head thickness must not be less than 4.035
inches (102,5 mm).
8--05564
Completely clean the rest of the head.
Check for cracks or other damage. B
Installation
Make sure the mating surfaces of the head and block are
clean.
Clean the engine block bolt bores with the correct size tap
to ensure correct torque for the cylinder head bolts.
-----
Clean any debris out of the cylinder bores. ~
~
NOTE: The locating pins (Item 1) [8] are pressed in ~
the engine block so the head gasket (Item 2)
[8] can be positioned correctly. @ e
The head gasket is installed with no sealer.
Place the head gasket in position with the Front Top (Item
2) [A] marks in the correct position.
Lower the cylinder head in position. -I r---r----)- -(--')- - - {.. ---- -...;- - - (...----..)---,
II I\ 'r@\18
'<:: ~,
1@18
/ ... ~
<"_"
(\
r:@i2'
'""',
~
r@13 I
J ~
Figure [C] shows the three different bolt lengths: S-short; "'- '\
(019
I I
1' '@J'9 1,-"
-1 1
=
(@) 1 I'~"
I
~)3
'\;."f I /'0.q )
14'=-/
I <~
;::'-::7
I I
"--:"
M-medium and L-Iong. ,
I t(~\--/ - \ I/' ..... \-~~ , - ( ~\--r~\ (-.....)--( ........ ~ r
. ...... '<:::.#!..... '- ~ . ..... I
I \~ ) ( J \ / \ ) ,, ) , , ) " I \ /. } I
Install all the cylinder head bolts in the correct location I~~~'~ - ~-' / _~~ ~ ~ -=~~
[C]. @:l120 f@\10 f@\7 (@')'4 15(®
d' "'" '># ~~ _~
Following the bolt tightening sequence shown in [C]. ( ':~121 1@l' 22. ~111 ~\lCL (®16 ~'5 _ (@ 17'l ~'16-~1
,-/,"" ~I ""~l' ) 0' "' 1f~1'- v -~ ( \""l/ ~;'\ ~
Tighten all cylinder head bolts to 80 ft.-Ibs. (108 Nm) - --' ~ _ -- -- _ --' I 1\ - - - ~ /- J '-- -
torque .
8--05561
Additional tightening of the head bolts requires the use of
a torque angle gauge (Item 1) [0]. Tighten the short bolts
150°, medium bolts 180° and long bolts 21 0°, in the same
sequence as shown in [0].
963 Bobcat Loader

Installation (Cont'd)
A
If no angle gauge is available make a suitable mark on the S M L
head bolt corner. Make another mark on the cylinder head I
~ '~
the correct number of flats away [A]. Turn the head bolt
until the lines match.
1 I
8--05563
Tighten short bolts 2.5 flats , medium bolts 3 flats , and long
bolts 3.5 flats in the same sequence as shown in [B].
B
I-
-I (~( - ~;- - ( -- "'1- - I ~ -- ';- - - (-- -)---\
!' I\ '(@ils
-. : : Y, 1@l8
/__ '/
,_,
( "
'-C®2'
~ =--,
i@13
'J::- ~
I
) '"
I
",
0 19 1'
,,
-) 1
I I =
{fM\\9 1 ' ) 1 riM\ll 1'-"
I
" M )3 I'''j'
"'(I). )
~ 1'
14l ~
I I G~ I I I
~ ~? \'=/
11r~\ --/ - \ ( - " ~- /~, - (~\-/~\ (----)--;-----) r
,\..:::J , ..... t '- I \\JI '- I ,'- I
\. .
I \",
ri\\1 20
~
I (, )
-=--_.::::...- -= \ ~___
((m\lO
- = -=-_
/ \",)
_--=- ==- '-..~/
\._1 , _ I
-=
{~\7 (~\4
= \~/ J
_ Y ____J
15\@\
I
Y g ~ g g
('-f3121 (@' 22. {§jIll (®\12-L~16 ~5 _ (@ 17-\ ~' 16-"')
,
~ /,= I
-' L
"" '"
_ ~- _
t ) 0'
_ _
" '" 'I ~I\
_ I I
-
1\ - -
-
-
(
~ /
\" "'l_A
....I " -
~:1 '-..
-
r 8--05561
Install the push rods [C].
Make sure the push rods seat in the tappet sockets.
Install the rocker arm shaft. lighten the rocker arm nuts
(Item 1) [0] to 55 ft.-Ibs. (75 Nm) torque.
NOTE: Make sure the oil feed line seal (Item 2) [0] is
correctly positioned in the cylinder head.
The valve lash adjustment must be checked after the

cylinder head is installed. (See Page 7-34.)
963 Bobcat Loader

CYLINDER HEAD
Install the fuel injectors. (See Page 7-39.)
IMPORTANT

1-2029-{)289
Install the injector tubelines on the engine.
Connect the fuel tubeline (Item 1) [A].
Tighten tubeline fittings to 16 ft.-Ibs. (22 Nm) torque.
Connect the injector tubelines (Item 2) [A].
Connect the injector tubelines (Item 1) [8] to the injection
pump.
Install the fuel filter mounting bracket and fuel filter using
the mounting bolts (Item 1) [C].
Connect the tubelines (Items 2, 3, & 4) [C] to the filter
housing.
Connect the tubeline (Item 5) [C] to the injection pump.
Connect the tubeline (Item 6) [C] to the top of the injection
pump.
Install the exhaust manifold. (See Page 7-48.)
Install the intake manifold . (See Page 7-47.)
Install the oil cooler. (See Page 7-79.)
Install the turbocharger. (See Page 7-92.)
963 Bobcat Loader

ROCKER SHAFT
A
Remove the clips (Item 1) [A] from both ends of the shaft.
Remove the location screw (Item 2) [A] for the oil supply
connection.
Remove the rocker arm (Item 3) [A], mount bracket (Item
c"
4) [A], rocker arm (Item 3) [A] and spring (Item 5) [A].
Continue to disassemble the rocker shaft.
Clean and inspect all components for damage and wear.
Check the clearance between the rocker arms and shaft.

P-08719
Using a press and adapter, remove the old bushing and
press in the new one making sure the oil holes line up.
Shaft 0.0.... 0.7485-0.7495 inch (19,01-19,04 mm)
Rocker Arm Bushing Bore Oia. 0.8751-0.8763 inch
(22,23-22 ,26 mm)
0.0. of Bushing ...... . . .... . ... 0.8771-0.8783 inch

(22,28-22,31 mm)
Rocker Arm Bushing Clearance 0 .0008-0.0035 inch

(0,020-0,089 mm)
1.0. of Reamed Rocker Bushing 0.7503-0.7520 inch

(19 ,06-19,10 mm)
Clearance Between Rocker Arm Bushing

& Shaft .... . .. . 0.001-0.0035 inch (0,03-0,09 mm)
If the clearance is more than 0.005 inch (0.13 mm)

replace the bushing(s) .
963 Bobcat Loader

VALVES, VALVE GUIDES AND SPRINGS
A
Valve Removal
NOTE: Mark all components so they can be returned

to the same position.
Using a valve spring compressor compress the springs

~,
r~ .~
. ....~ J
and remove the retainers (Item 1) [A]. i tCi 16 , --=
Release the compressor and remove the valve spring cap
(Item 2) [A], outer spring (Item 3) [A] inner spring (Item
4) [A], valve seal (Item 5) [A], valve seat washer (Item 6)
[A] and the valve (Item 7) [A].
~ ~.
Clean and inspect all components.

P-08720
Checking Valve Springs
Use the following chart [B]:
Valve Springs (Outer):

Compressed Height . .. ........ 1.41 inch (35,8 mm)
Installed Pressure ..... . 39.5--43.7Ibs. (176-195 N)
Valve Springs (Inner):

Compressed Height ... ........ 1.34 inch (34,0 mm)
Installed Pressure ...... . .. 20-23 Ibs. (89-104 Nm)
inch
(mm) Inner Sprin
8-05552
963 Bobcat Loader

VALVES, VALVE GUIDES AND SPRINGS (Cont'd)
Checking Valve Depth
Check the valve depth as shown in [Al
The maximum depth is 0.073 inch (1 ,85 mm) for both
intake and exhaust valves.
If the valve is below the limits, install a new valve and
recheck the valve depth. If it is still below limits a new

valve seat insert must be installed.
When the depth is less than 0.050-0.063 inch (1 ,27-1 ,60

mm) the seat may be ground to lower the valve depth.
Checking Valve Guides
The valve guides can be checked for wear with either of

the operations listed in [8] or [C].
Ie
r
Use the following chart to check valve guides.
Inside Diameter
(Item 1) [8] .. 0.3744-0.3764 inch (9,51-9,56 mm)
3
Outside Diameter
121~
(Item 2) [8] .. 0.6260-0.6264 inch (15,90-15,91 mm)
Interference fit of valve guide to cylinder head:

0.0018-0.0027 inch (0,047-0 ,007 mm)
Overall Length: (Item 3) [8]

Intake .. .......... . . .. .... 2.281 inch (57,94 mm) S--0555 1
Exhaust. . . . . . . . . . . . . . . . . .. 2.406 inch (61,10 mm)
Protrusion from bottom recess for valve spring:

(Item 4) [8] . . . . . . . . . . . . . . . . . . . .. 0.585-0.596 inch
c
(14,85-15,15 mm)
I nfJI-Q
Valve Guide Bore ...... .. ...... . 0.6248-0.6256 inch
(15,87-15,89 mm)
~lQ~
I
/
I
/
I I
To check the valve guides for wear using a valve.

l
r-
Io..
Set up dial indicator gauge (Item 1) [C] as shown .
Lift the valve (Item 2) [C] 0.60 inches (15,0 mm) and move
the valve in and away from the gauge (Item 1) [C]. Record
this reading.
If the clearance exceeds 0.002-0.007 inches

S--05 566
(0,25-0,069 mm) for intake or 0.004-0 .008 inches
(0,40-0,084 mm) for exhaust (Item 3) [C] the valve guide
needs to be replaced.
963 Bobcat Loader

Valve Guide Removal

A
Install a valve guide removal/installation tool (Item 1) [A]
on the valve guide (Item 2) [A].
Pull the guide (Item 2) [A] out of the cylinder head.
8-05549
Valve Guide Installation
Clean the guide bore in the head. B

Lubricate the outer surface of the new guide (Item 1) [B]
with engine oil.
Put the guide in position on the valve guide

removal/installation tool (Item 2) [B].
Pull the guide into the cylinder head.
When correctly positioned the top of the guide should

extend 0.594 inch (15,1 mm) above the valve spring seat.
(As Shown On Page 7-56 [B].)
8-05548
963 Bobcat Loader

A
Checking Valves
NOTE: If the valves do not meet specifications they

need to be replaced. They cannot be ground.
Use the following chart [A] to check the valve dimensions:
Ref. Valve
1.
Specifications
Intake ... 4 .829-4.854 inch (122,66-123,30 mm)
fl~ ,
2
2.
Exhaust . 4.829-4.854 inch (122,66-123,30 mm)
Intake. . . .. 0.3725-0.3536 inch (8,95-8,98 mm)

Exhaust ... 0.3519-0.3528 inch (8,93-8,96 mm)
lrf !~ 1 --I I 8-05567
3. Intake. . . .. 1.688-1 .698 inch (42,88-43,12 mm)
Exhaust ... 1.609-1.619 inch (40,88-41,12 mm)
4. Int.!Exh. (Production) ... . . . ... 0.055-0.07 inch
(1,40-1 ,70 mm)
Int.!Exh. (Service Max.) .... ... . .... 0.077 inch
(1,95 mm)
Intake/Exhaust Valve Face Angle . . . . . . . . . . . . . .. 45°
Cutting A Valve Seat
Before any work is done the valve guides must meet
specifications or have been replaced.
Install the pilot in the valve guide.
Select the correct size cutter.
Valve Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46°
Carefully turn the cutter in a clockwise direction using
even downward pressure. Keep the valve seat as narrow
as possible [B].
Remove any cutting debris.
Install the valve and lightly tap.
~0
_ t" ao
Check the valve depth to make sure that it is within limits.
(See Page 7-56.)
NOTE: If the valve seat is to worn or damaged, a new

valve seat insert can be installed.
d $' ~:'
. .~-:
P-08720
Assembly
Lubricate the valve stems (Item 1) [C] with clean engine

oil and install them in the respective guides.
Install the spring seat washers (Item 2) [C].
Install new valve seals (Item 3) [C].
A WARNING
Install the inner and outer springs (Items 4 & 5) [C] on the
washers with dampener coils (Item 6) [C] toward the Wear safety glasses to prevent eye injury when
cylinder head. any of the following conditions exist:
• When fluids are under pressure.
Place the valve caps on the springs (Item 7) [C].
• Flying debris or loose material is present.

Using a valve spring compressor compress the springs
• Engine is running.
and install the retainers (Item 8) [C].
• Tools are being used.
W-2019-1285
963 Bobcat Loader

-7-58-- Service Manual
A
Changing Valve Springs (With Cylinder Head
Installed)
Remove the rocker cover.
Rotate the crankshaft clockwise until the intake valve has

opened and the exhaust valve has not fully closed. In this
position the piston (Item 1) [A] will be at approximately
T.D.C.
Remove the rocker shaft assembly.
8--05565
Install the valve spring compressor and adaptor [B].
Compress the valve springs and remove the retainers .
NOTE: Do not rotate the crankshaft while the valve

springs are removed.
Release the compressor and remove the valve spring(s) .
Place the new valve springs in position .
Compress the valve springs and install the retainers.
963 Bobcat Loader

TIMING CASE AND DRIVE ASSEMBLY
Description
The timing case and cover are made of aluminum and in

most applications, the timing gears are made of steel. The
drive from the crankshaft passes to the idler gear, to the
camshaft gear, to the gear on the fuel injection pump and
to the water pump.
The camshaft and fuel injection pump run at half the

speed of the crankshaft.
Timing Cover Removal
Remove the crankshaft pulley (Item 1) [A].
Remove the water pump . (See Page 7-78 .)
Remove the timing cover bolts (Item 1) [B].
Remove the cover (Item 1) [C] and gasket. •
963 Bobcat Loader

-7--60- Service Manual
TIMING CASE AND DRIVE ASSEMBLY (Cont'd)
Timing Cover Installation

A
~
procedure:
MEL 1537 - Timing Cover Centralizing Tool
To install the timing cover, the tool will be needed to center ,~

~~G
the timing cover around the crankshaft.
~55571
NOTE: If the cover is not centered correctly the
'10"
backlash between the injection pump gear
and water pump gear will be affected. This
can cause seizure of the injection pump. I I
Clean the gasket mating surfaces.
Place the gasket and timing cover on the engine.
Hold the timing cover in position and install two bolts that
are on opposite sides of the cover. Do not tighten the
bolts.
Install the tool (Item 1) [A] in the oil seal housing.
Using the special washer (Item 2) [A], install the
crankshaft pulley bolts (Item 3) [A] and tighten evenly to
center the cover.
Install the remainder of the cover bolts, tighten the bolts
to 16 ft.-Ibs. (22 Nm) torque.
Remove the too\.
Install the water pump. (See Page 7-78.)
Install the crankshaft pulley (Item 1) [8].
Tighten the crankshaft pulley bolts (Item 2) [8] to 85
963 Bobcat Loader

TIMING CASE AND DRIVE ASSEMBLY (Cont'd)
Front Oil Seal Removal
Remove the crankshaft pulley.
Remove the oil seal using a seal removal tool.
Do not damage the edge of the seal housing.
Front Oil Seal Installation
Clean the oil seal housing .
Lubricate and place the new seal in the housing. Make

sure the spring loaded lip faces toward the engine.
Place the seal tool (Item 1) [A] against the seal.
Using the three hole washer (Item 2) [A] , install the

crankshaft bolts and tighten evenly until the face of the
seal tool is against the face of the seal housing.
NOTE: The standard seal is installed to a depth of I q.

0.266/0.285 inch (6,7517,25 mm) from the front
face of the oil seal housing. If there is wear on
the seal surface of the crankshaft pulley the
seal can be installed to a depth of 0.366 inch
(9,3 mm)
Clean and lubricate the seal surface of the crankshaft
pulley before installing.
Timing Case And Gear Removal
Remove the timing cover. (See Page 7-60.)
Rotate the crank shaft until the timing marks (Item 1) [B]
are lined up.
Remove the fuel injection pump gear (Item 2) [B].
Remove the three bolts (Item 3) [B] from the idler gear
(Item 4) [B].
Remove the idler gear (Item 4) [B].
NOTE: Do not turn the crankshaft with the idler gear

removed.
Remove the cam gear retaining bolt (Item 5) [B].
Remove the cam gear (Item 1) [C].
963 Bobcat Loader

TIMING CASE ANO ORIVE ASSEMBLY (Cont'd)
Timing Case And Gear Removal (Cont'd)
A
Remove all the timing case bolts [A].
Remove the two bolts (Item 1) [A] from the front of the oil
pan.
P-0873T
Remove the timing case (Item 1) [B] and gasket (Item 2)

[B] from the engine . Do not allow the idler gear hub (Item
3) [B] and camshaft thrust washer (Item 4) [B] to fall.
Timing Case And Gear Installation
Clean the mating surfaces. If the oil pan was not removed
trim the oil gasket flush with the block.
Using the three idler gear bolts, position the idler hub
(Item 3) [B] with the lubrication hole on top. Press the hub
on by tightening the bolts evenly.
Install the camshaft thrust washer (Item 4) [B].
Install the case cover gasket (Item 2) [B] and trim the
bottom to fit. Apply sealant to the bottom ends of the
gasket.
Place the timing case (Item 1) [B] in position. Make sure

it's positioned correctly against the block.
Tighten the eight millimeter bolts to 16 ft.-Ibs. (22 Nm)

torque.
Tighten the ten millimeter bolts to 33 ft.-Ibs. (44 Nm)

torque.
Tighten the two oil pan bolts (Item 1) [A] to 16 ft.-Ibs. (22
Nm) torque.
Install the cam gear (Item 1) [C].
Install the cam gear retaining bolt (Item 1) [0]. Tighten to

Install the idler gear (Item 2) [0].
Install the idler gear retaining bolts (Item 3) [0]. Tighten
to 33 ft.-Ibs. (44 Nm) torque.
Place the fuel injection pump gear (Item 4) [0] in the case.
NOTE: Make sure all the timing marks (Item 5) [0] are
'. '..
in correct alignment.
Install the timing case cover. (See Page 7-61 .)
963 Bobcat Loader

CAMSHAFT AND TAPPETS
Removal
A
Remove the timing case cover. (See Page 7-60.)
Remove the fuel injection pump. (See Page 7-36.)
Remove the timing case. (See Page 7-60 .)
Remove the rocker cover, rocker assembly and push
rods. (See Page 7-54.)
Remove the fuel pump and gasket.
Turn the engine over and remove the oil pan mounting
bolts [A].
Remove the oil pan and gasket.
Installation: Tighten the oil pan mounting bolts to 16
ft-.lbs . (22 Nm) torque.
Remove the camshaft thrust washer (Item 1) [B].
Carefully remove the camshaft (Item 1) [C].
Remove the tappets (Item1) [0] from the block.
~''''')-~
963 Bobcat Loader

CAMSHAFT AND TAPPETS (Cont'd)
Installation
A .. • ~

Clean and inspect the camshaft and tappets for
excessive wear and damage.
Inspect the camshaft bushing for excessive wear and

damage .
NOTE: Only the front camshaft journal bore has a
bushing.
Clearance between the camshaft journals , the bushing
and camshaft bore is 0.0025-0.0055 inch (0,06-0,14
mm).
Make sure all components are clean and lubricated with

clean engine oil.
Install the tappets (Item 1) [A].
Carefully install the camshaft (Item 1) [B].
Install the camshaft thrust washer (Item 1) [C]. Make sure

that the dowel pin (Item 2) [C] lines up with the hole in the
thrust washer.
Install the timing case. (See Page 7-63.)
Check camshaft end play. The end play for a new engine
is 0.004 - 0.016 inch (0,10 - 0,41 mm), service limits
0.021 inch (0,53 mm).
Install the fuel pump and gasket. Tighten the bolts (Item
1) [0] to 16 ft.-Ibs . (22 Nm) torque.
Install the timing gears. (See Page 7-63.)
Install the injection pump. (See Page 7-36.)
Install the push rods and rocker assembly. (See Page
7-51.)
Install the timing cover. (See Page 7-61.)
Install the oil pan. (See Page 7-83.)
963 Bobcat Loader

PISTONS AND CONNECTING RODS
A
Description
The pistons have a Quadram combustion chamber. They

have two compression rings and one oil control ring. The
top ring groove has a hard metal insert to reduce wear.
Full floating piston pins are used and are retained by snap
rings .
Controlled expansion pistons have a steel insert ring in

the piston skirt. The connecting rods are molybdenum
steel. The connecting rods on the turbocharged engines
have wedge shaped small ends . The location of the
bearing caps to the connecting rods is made by serrations
and the cap is retained by two bolts.
The pistons used in the 1000 series engines have two

compression rings and one oil control ring. All the rings
are above the piston pin. Each of the three piston rings
have different design features . Always use the engine
identification number to order new parts.
Removal
Remove the cylinder head . (See Page 7-49.)
Remove all the carbon from the top of the cylinder liners.
Remove the oil pan . (See Page 7-83.)
Remove the oil pick up screen and tube (Item 1) [A].
Mark and remove the connecting rod caps (Item 1) [B].
NOTE: Do not allow the connecting rods to hit the

cooling jets.
Turn the connecting rods 90° to prevent contact with the

piston cooling jets (Item 1) [C]. Push the piston and rod
assemblies out the top of the cylinder.
Inspect the crankshaft journals (Item 1) [0] for wear or

damage.
D
NOTE: Keep all parts together so they can be
replaced in their original position.
NOTE: Before installing the pistons check cylinder

bore for wear or damage. (See Page 7-89.)
963 Bobcat Loader

PISTON AND CONNECTING ROD (Cont'd)
Disassembly
A
Mark the piston to indicate the cylinder number (Item 1)
[A] as shown on the connecting rod .
B-05570
Remove the piston rings (Item 1) [8] with a ring expander.
Remove the snap rings (Item 2) [8] which retain the

B
piston pin.
Push the piston pin (Item 3) [8] out by hand. If the pin
doesn't push out easily, heat the piston to 100°-120° F
(40°-50° C) for easier removal.
Remove the connecting rod (Item 4) [8].
P-08747
Piston Ring End Gap c

Place the piston rings in the upper part of the cylinder to
check the end gap [C].
Top Ring End Gap . . ...... ...... .. 0.014-0.028 inch

(0,35-0,70 mm)
Second Ring End Gap . . .. . . ...... 0 .012-0 .030 inch
(0,30-0,76 mm)
Third Ring End Gap ... . .. ....... . 0 .010-0.031 inch ®
(0,25-0,75 mm)
) ® @
@
B-05571
Piston Ring Installation

o
Install the spring of the oil control ring in the bottom groove
with the latch pin inside both ends of the spring [0].
B-05572
963 Bobcat Loader

A
Piston Ring Installation (Cont'd)
Use a ring expander to install the piston rings. '--ff: )~

~2 1 ~~
Install the oil spring on the bottom groove of the piston
with the latch pin inside both ends of the spring.
Install the oil control ring over the spring (Item 1) [A].
Make su re the ring gap is 180 0 from the latch pin.
Install the cast iron ring with the tapered face (Item 2) [A]
in the second groove with the word TOP or symbol facing
~ ~ ~~
..
the top of the piston.

8--05575
New second rings have a green identification mark, which
must be on the left of the ring gap after the ring is installed
and the piston is upright.
The second ring has an external step at the bottom of the

tapered face.
Place the chromium ring (Item 3) [A] with the symbol or

word TOP up when installed on the piston.
The top ring (Item 3) [A] has an internal step.
New top rings have a red or blue identification mark,

which must be on the left of the ring gap after the ring is
installed and the piston is uptight.
Make sure the ring gaps are 120 0 apart.
Piston Ring Groove Clearance
With the piston rings installed, check the groove

clearance [8].
Top Ring ............ ......... .... .. ..... . Wedge
Second Ring Side Clearance . . . . .. 0.003 - 0.004 inch

(0,07 - 0,10 mm)
Third Ring Side Clearance ........ 0.002 - 0.003 inch

(0,05 - 0,07 mm)
963 Bobcat Loader

A
Connecting Rod Inspection
Checking the connecting rod for distortion [A].
NOTE: The large and small end bores must be

t .....
-5-"
(127 mm)
~ - -1-
(127 mm)
,
square and parallel within the limits of ± 0.01 0 ~ ~
inch (0,25 mm). 0.010"
0.010"
•
(±o.25 mm)
(±0.25 mm)
Measure this 5.0 inch (127 mm) on each side of the
connecting rod axis on a test fixture.
With the piston pin bushing installed the limit is reduced

to ± 0.0025 inch (0,06 mm).
8--05577
Check the pin bushing for wear or damage. Replace as
needed.
8
Connecting Rod Bushing Replacement
Press out the old bushing . Clean the bore and remove any
burrs.
Press in the new bushing making sure the oil feed holes
line up.
Ream the bushing to get the proper clearance of 0.0008

- 0.0017 inch (0,02 - 0,043 mm) between the small end
bushing and piston pin .
-.
Assembly .* P--08747
Install the connecting rod (Item 1) [B], piston pin (Item 2)

[B] and two snap rings (Item 3) [B] in the piston. I C
Installation
Apply a light coat of oil to the piston and piston rings.
NOTE: Make sure the piston ring end gaps are 120 0
apart.
Install the ring compressor over the piston rings [C].
Carefully place the connecting rod in the cylinder and

using a hammer handle, push the piston in the bore. = ~~
=~
8--05578
When the piston has cleared the cooling jet, rotate the
piston assembly so that the arrow or FRONT mark is I D
toward the front of the engine [0].
c==J
® ~
@
®
® @ ®
8--05579
963 B obcat Loader

Clean the bearing surfaces and crank pin. Lubricate the
crank pin (Item 1) [A] with clean engine oil.
Install the upper and lower bearing shells in position

making sure the locating tang (Item 1) [B] is in the correct I8
position.
NOTE: New connecting rod nuts must be installed

each time the rod caps are removed.
Install the caps (Item 1) [C] and nuts. Gradually tighten

the nuts to 45 ft.-Ibs. (61 Nm) torque . Tighten to a final
torque of 92 ft.-Ibs. (125 Nm) .
Rotate the crankshaft. The crankshaft must rotate

smoothly.
Install the oil pick up tube and screen (Item 1) [OJ.
Install the oil pan. (See Page 7-83.) 8-05580
Checking Piston Height
Rotate the crankshaft until the piston is approximately at

top dead center (T.D.C.).
Using a dial indication gauge , pre-load the plunger on the

top surface of the block and zero the gauge.
Carefully move the dial gauge so that the plunger is on top

of the piston above the axis of the piston pin.
Rotate the crankshaft to bring the piston to it's highest

point. Record this gauge reading.
The quadram piston when install, the top surface of the

piston is slightly above the surface of the cylinder block.
For the Quadram piston engines, the height above the

surface of the block should be 0.005 to 0.014 inch (0,14
to 0,36 mm). I D
NOTE: Two Quadram piston heights can be used. In
the factory H- high or L -low. In service only
L pistons are supplied.
If a L piston is used in place of an H piston the
height may be up to 0.0075 inch (0,19 mm)
below the bottom limit. The top of the piston
can not be machined.
If the original piston is being reused, install

the piston with the original connecting rod in
the cylinder bore that it was removed from.
Install the cylinder head. (See Page 7-51.)
963 Bobcat Loader

CRANKSHAFT AND BEARINGS
Description
A
The crankshaft is a chrome-moly forging which has five

main journals. End play is controlled by two half thrust
washers on both sides of the center main bearing.
The main bearings have steel backs with a aluminiuml tin
bearing material. The main bearing caps are made of cast
iron.
The front and rear oil seals are viton lip seals with a dust
lip to the outside of the main lip.
Removal
Remove the water pump. (See Page 7-78.)
Remove timing case cover. (See Page 7-60.)
Remove the timing gears and timing case. (See Page
7-60.)
Remove the flywheel. (See Page 7-32.)
Remove the pistons and connecting rods (See Page
7-66), keeping them in order.
Remove the rear oil seal housing (Item 1) [A].
Remove the two bolts (Item 1) [B] retaining the bridge
piece.
Remove the bridge piece.
Mark the main bearing caps (Item 1) [C] for correct
installation .
Remove the main bearing cap bolts.
Remove the main bearing caps (Item 1) [0].
963 Bobcat Loader

CRANKSHAFT AND BEARINGS (Cont'd)
Removal (Cont'd)
Remove the thrust washers from the sides of the center

main bearing bore [Al
Remove the crankshaft [B].
Remove the crankshaft bearings from the engine block

[C].
Keep the bearings with their respective caps for

installation.
Inspection Of Crankshaft And Bearings
Check the crankshaft for wear [0]. The maximum wear D

and out of round of the crank journals is 0.0016 inch (0,04
mm) .
The main journals and the crank pins of standard size can
be machined 0.010 inch (0,25 mm) 0.020 inch (0,50 mm)
or 0.030 inch (0,75 mm) .
NOTE: See SPECIFICATIONS Section, Page 9-1 for
more crankshaft specifications.
A-02763
963 Bobcat Loader

Inspection Of Crankshaft And Bearings (Cont'd)
Check the oil clearance of the bearings.
All Main Bearings

0.0022 - 0.0046 inch (0,057 - 0,117 mm)
Thrust Washer Thickness

Standard 0.089 - 0.091 inch (2,26 - 2,31 mm)
Oversize 0.096 - 0.098 inch (2,45 - 2,50 mm)
Installation
Clean the main bearing bores and install the upper

bearing shells in position. Lubricate the bearings with
clean engine oil [A].
NOTE: Only the upper half of the bearings has oil

lubrication holes and must be installed in the
cylinder block.
Make sure the main journals are clean and install the
crankshaft in the block [B].
Make sure the locating pins for the main caps are in
position.
Clean and install the upper and lower thrust bearings on

each side of the center main bearing [C].
Clean the main caps and install the bearings.
Lubricate the bearings with clean engine oil.
Install the main cap bolts and torque in steps working from
the center outward.
Step 1 65 ft.-Ibs. (88 Nm)

Step 2 125 ft.-Ibs. (170 Nm)
Step 3 185 ft.-Ibs. (250 Nm)
Clean the bridge piece and apply a bead of LOCTITE

#518 in the corners and around the thread holes on the
block.
Install the bridge piece, and using a straight edge, align

the bridge with the cylinder block [0]. Tighten the bridge
retaining bolts to 12 ft.-Ibs. (16 Nm) torque.
963 Bobcat Loader

Inject LOCTITE #518 into the groove (Item 1) [A] at each

end of the bridge piece . Continue to inject sealant until it
leaves the lower groove (Item 2) [A] at the front and rear
of the piece.
Rear Oil Seal Removal
Remove the bolts that retain the seal housing. Remove

the housing .
Inspect the seal for wear or damage . Replace even if

there is only a small nick or scratch.
Inspect the crankshaft flange for damage.
Clean the block, seal housing, and crankshaft.
Rear Oil Seal Housing Positioning

procedure;
MEL 1532 - Rear Crankshaft Seal Installation Tool
The seal can be installed from flush with the housing face
(Item 1) [B] to 0.27 inch (6,86 mm) (Item 2) [B] back from
~
the housing face. Install seal so that the seal lip does not
line up with any worn areas on the crankshaft. ----. .--@ 8--05581
Install the seal in the seal housing using the seal

installation tool. Seat the seal to the correct depth [C].
Rear Oil Seal Installation
Install the new seal in the housing.
Make sure the dowels (Item 1) [0] are in the block
~I~I~
correctly.
Install the new gasket (Item 2) [0] on the housing (Item

3) [0].
~I\-~
I nstall the seal replacer tool (PD 145-3) (Item 4) [0] on the
crankshaft.
Lubricate the seal , tool, and crankshaft with clean engine

oil.
Camfully push the seal and housing (Item 3) [0] over the
tool and crankshaft and into position on the dowels.
Remove the tool. c1fIr 8--05582
963 Bobcat Loader

A
Rear Oil Seal Installation (Cont'd)
Tighten the bolts (Item 1) [A] to 16 ft .-Ibs . (22 Nm) torque.
Checking Crankshaft End Play

8
The axial movement of the crankshaft is controlled by two
half thrust washers placed on both sides of the center
main bearing.
Install a dial indicator on the end of the crankshaft [B].
Pry the crankshaft to the rear of the cylinder block and set
the dial indicator to zero.
Remove the pry bar and record the dial indicator reading
[C].
IC
The end play specification is 0.0075 inch (0,019 mm)
maximum.
If end play is excessive there is over size thrust washers

available to reduce movement.
The end play can also be checked using a feeler gauge

[0].
Pry the crankshaft to the rear of the cylinder block and
measure the distance between the thrust washer and
crankshaft.
963 Bobcat Loader

COOLING SYSTEM
Description
Coolant from the radiator passes through the centrifugal

water pump (Item 1) [A], to assist the flow of the coolant
through the system.
The water pump is gear driven from the gear off the fuel
injection pump.
From the water pump, the coolant passes through a

passage in the timing case.
The coolant passes through a passage in the left side of

the cylinder block to the rear of the cylinder block.
The oil cooler (Item 1) [B] is installed on the left side of the
engine. Coolant from the by-pass connection at the rear
of the coolant pump passes through a pipe to the oil
cooler.
The coolant then passes around the cylinders and in the

cylinder head. The coolant leaves the cylinder head at the
front and passes into the thermostat housing (Item 2) [C].
If the thermostat is closed , the coolant goes directly

through a by-pass to the inlet side of the water pump. If
the thermostat is open, the thermostat closes the
by-pass and the coolant passes to the radiator.
963 Bobcat Loader

COOLING SYSTEM (Cont'd)
Thermostat Removal and Installation

A
Drain the engine coolant until it is below the thermostat
level.
Remove the bolts (Item 1) [A] and thermostat housing.
Installation: Make sure all gasket surfaces are clean.

Replace the gasket before installing the thermostat
housing.
Remove the housing and thermostat (Item 1) [B].

B
Remove the six mounting bolts at the coolant housing

(Item 1) [C].
Remove coolant housing (Item 1) [0] from the engine

block.
Thermostat Testing
Hang the thermostats in a suitable container filled with

coolant.
Heat the coolant gradually. Use a thermometer to check

the temperature when it starts to open and when it's fully
open.
If the thermostats do not operate correctly they must be

replaced.
NOTE: Identify thermostat temperature by the

stamping on the by-pass valve.
963 Bobcat Loader
COOLING SYSTEM (Cont'd)
Water Pump Removal

A
Remove the coolant from the cooling system.
Remove the nuts (Item 1) [A].
':
Remove the mounting bolts (Item 1) [8] from the water

pump.
Loosen the hose clamp (Item 1) [C].
Remove the water pump.
Water Pump Installation
Clean the gasket surfaces and replace the O-ring .
Install the water pump in the timing cover. The pump is a

tighten fit in the cover and is pulled into position by
tightening the bolts evenly.
Pipe thread sealant must be applies to the pump

mounting bolts before installation.
Install the water pump bolts (Item 1) [8] and tighten to 16

Install the two nuts (Item 1) [A] and tighten to 16 ft.-Ibs .

(22 Nm) torque.
Tighten the hose clamp (Item 1) [C].
963 Bobcat Loader

ENGINE OIL COOLER
Remove the bolt and nut (Item 1) [A] that hold the
low-pressure fuel pipes to the top of the cooler.
Remove the support bracket (Item 1) [B] for the oil cooler.
Loosen the hose clamp (Item 1) [C] at the front of the oil
cooler.
Remove the front cooler mounting bolt (Item 1) [0].
Remove the cooler mounting bolts (Item 2) [0].
Installation: Tighten the mounting bolts to 16 ft.-Ibs . (22

Nm) torque.
963 Bobcat Loader

ENGINE OIL COOLER (Cont'd)
Remove the oil cooler from the engine block [A].
Installation: Install new O-rings for the inlet (Item 1) [A]
and outlet (Item 2) [A] connections. Replace the gasket

(Item 3) [A] for the oil pipe flange.
Remove the hose and clamp (Item 1) [B].
Check the hose for damage and replace as needed.
Installation: Put a small amount of oil on the hose (Item
1) [B] before installing the oil cooler.
963 Bobcat Loader

OIL COOLER (Cont'd)
Remove the bolts (Item 1) [AJ from the cover.
Assembly: Tighten the bolts to 96 in.-Ibs. (11 Nm)

torque.
Remove the cover from the element [B]. B
Remove the self-locking nuts (Item 1) [C] on the back of

the oil cooler.
Assembly: Tighten the nuts to 42 ft.-Ibs. (58 Nm) torque.
Remove the cooler element from the housing [D].
Assembly: Replace the O-rings (Item 1) [D] on the

flange of the element. Replace the O-rings (Item 2) [D]
on the studs of the element.
N-16397
963 Bobcat Loader

LUBRICATION SYSTEM
Description
Engine Lubrication System
Pressure lubrication is supplied by a rotor type pump

(Item 1) [A] which is driven through an idler gear from the
crankshaft gear.
Engine oil from the oil pan sump passes through a strainer
(Item 2) [A] and pipe to the suction side of the pump.
The engine oil passes from the outlet side of the pump
through a pipe to a relief valve (Item 3) [A], which is
installed in the bottom left side of the cylinder block. The
relief valves opens if the oil pressure is too high; this
allows some of the engine oil to return to the sump.
From the relief valve, engine oil passes to a plate type oil
cooler (Item 1) [B].
Oil flows through the oil tubes (Item 2) [B] to the filter.
The engine oil passes from the filter (Item 1) [C] to the
cylinder block.
The oil passes to the main bearings of the crankshaft and

through passages in the crankshaft to the big end
bearings. The pistons and the cylinder bores are
lubricated by splash and oil mist.
Engine oil passes from the main bearings through

passages in the cylinder block to the journals of the
camshaft. Engine oil passes from the center journal of the
camshaft through a passage in the cylinder block and
cylinder head to a restriction in the pedestal of the rocker
shaft, at a reduced pressure, to feed the rocker bushing.
The oil passes through a passage in the rocker shaft to
the bearings of the rocker levers. The valve stems, valve
springs and the tappets are lubricated by splash and oil
mist.
The hub of the idler gear is lubricated by oil from the

cylinder block and the timing gears are splash lubricated.
The turbocharger is lubricated by oil after the filter. Oil is

supplied from a connection on the right side of the cylinder
block through an external pipe to the turbocharger. The
oil passes through the turbocharger and returns through
a pipe to the oil pan sump .
Turbocharged engines have piston cooling jets (Item 1)

[0]. These jets are connected to the oil pressure rail and
spray lubricating oil inside the pistons to keep them cool.
963 Bobcat Loader

LUBRICATION SYSTEM (Cont'd)
Oil Filter Adapter Removal
Remove the oil filter.
Remove the oil cooler pipes (Item 1) [A] from the filter
adapter. Disconnect the turbocharger oil supply line.
Remove the four bolts (Item 1) [8] and the filter adapter
(Item 2) [B].
Oil Filter Adapter Installation
Clean the filter adapter (Item 1) [C] and the block

mounting surfaces (Item 2) [C].
Using a new gasket, install the adapter (Item 1) [C] on the

block.
Connect the turbocharger oil supply line .
Connect the oil cooler lines to the filter adapter.
Install the oil filter.
Oil Pan Removal And Installation

o
Remove the oil pan retaining bolts [D].
Remove the pan and gasket.
Clean the pan in solvent and dry with compressed air.
Clean the block surface.
Installation: Place a new gasket on the oil pan. Place two

bolts on each side to position the oil pan correctly. Install
the remaining bolts. Tighten the bolts to 16 ft.-Ibs . (22
Nm) torque [D].
963 Bobcat Loader

Oil Screen And Pick-up Tube
Remove the bolt (Item 1) [A] that holds the bracket (Item
2) [A] to the main bearing cap.
Remove the bolts (Item 3) [A] from the pick-up tube
flange .
Remove the pick-up tube (Item 4) [A] and gasket.
Wash the assembly in solvent and dry with compressed
air.
Check the tube and strainer for cracks or other damage.
Replace as necessary.
Loosely assemble the bracket (Item 2) [A] with the
pick-up tube to the main bearing cap.
Install the pick up tube gasket and mounting bolts (Item
3) [A].
Tighten the mounting bolts to 16 ft .-Ibs. (22 Nm) torque.
Tighten the bolt (Item 1) [A] for the pick-up tube bracket.
Tighten the bolt to 16 ft.-Ibs. (22 Nm) torque.
Oil Pump Removal
NOTE: The oil pump has a channel in the body of the

pump. Oil from the front main bearing passes
down the channel of the pump to an oil hole
in the idler shaft for lubrication of the idler
shaft bushing.
Remove the oil pan. (See Page 7-83.)
Remove the oil pressure relief valve (Item 1) [B].
Remove the oil screen and pick-up tube.
The oil pump is installed on the number 1 main bearing
cap.
NOTE: The pump can be removed with the main

bearing cap if a spanner wrench is available
that will allow the torque to be applied
directly to the main cap bolts.
If there is no spanner wrench , the front timing case cover

must be removed . (See Page 7--60.)
Remove the snap ring (Item 1) [C] , idler gear (Item 2) [C],
and washer.
Remove the bolts and oil pump.
963 Bobcat Loader

Oil Pump Installation

A
Fill the pump with engine oil.
If the number one main cap was removed, reinstall and
tighten to 185 ft.-Ibs. (250 Nm) torque.
Install the pump on the main cap and tighten to 16 ft.-Ibs.
(22 Nm) torque.
Check the idler gear and bushing for wear.
Lubricate with clean engine oil and install the washer, idler
gear (Item 2) [A] and snap ring (Item 1) [A) .
Check the backlash between oil pump and idler gears.
There must be a minimum of 0.003 inch (0,076 mm).
Check that there is a minimum of 0.003 inch (0 ,076 mm)
backlash between the idler gear and oil pump gear [B].
End play for the idler gear should be 0.0005/0.0253 inch
(0,012/0,643 mm).
Install the oil screen and pick-up tube. (See Page 7-84.)
Install the pressure relief valve.
Install the oil pan. (See Page 7-83.)
963 Bobcat Loader

Oil Pump Disassembly And Assembly
NOTE: If any part is worn enough to effect

performance replace the complete oil pump.
Remove the cover of the oil pump.

®
Remove the outer rotor and thoroughly clean . Check for
cracks or other damage.
Install the outer rotor and check the outer rotor to body
clearance [A).
o
/
Clearance between the outer rotor and body must be
0.006-0.013 inch (0 ,15-0,34 mm).
Check the inner rotor to outer rotor clearance [B].
Clearance between the inner rotor and outer rotor must

be 0.0015 - 0.005 inch (0,04-0,13 mm).
B-{)5592
Check the rotor end play [C).
Rotor end play must be 0.001-0.004 inch (0,03-0,10

mm).
Install the cover and tighten the bolts to 16 ft.-Ibs. (22 Nm)
torque.
Oil Pressure
Assembly
Relief Valve Disassembly And
o
Press the end plate (Item 1) [0] in the valve body (Item
2) [0] and remove the snap ring (Item 3) [0].
Remove the end plate (Item 1) [0], spring (Item 4) [0],

Pft
and plunger (Item 5) [0] from the body (Item 2) [0].
Clean the parts in solvent and dry with compressed air. ftp(i)
Lubricate the bore of the valve body (Item 2) [0] , plunger
@)r
°1
(Item 5) [0] and the end plate (Item 1) [0] with clean
engine oil before assembly.
B-{)5606
963 Bobcat Loader

ENGINE BLOCK
Description
A
The cylinder block is made of cast iron and provides full
length support for the dry liners. •
The liners (Item 1) [A] are made of cast iron. Production
liners are a press fit and service liners are a transion fit.
Both types of liners are honed with silicon carbide tools to
a specially controlled finish to ensure long engine life and
low oil consumption.
A bushing (Item 1) [8] is installed in the cylinder block for

the front camshaft journal while the other camshaft
journals run directly in the block.
Remove the water pump . (See Page 7-78.)
Remove the oil cooler. (See Page 7-79 .)
Remove the oil filter and oil pan. (See Page 7-83.)
Remove the fuel pump. (See Page 7-35.)
Remove the starter. (See Page 6-1 .)
Remove the cylinder head. (See Page 7-49.)

P-Q8742
Remove the timing case and gears . (See Page 7-60.)
Remove the piston and connecting rod assemblies. (See
Page 7-66.)
Remove the camshaft and tappets. (See Page 7-64.)
Remove the engine mounting bracket and flywheel. (See
Page 7-32.)
Remove the rear oil seal and the crankshaft. (See Page
7-71 .)
963 Bobcat Loader

ENGINE BLOCK (Cont'd)
Piston Cooling Jet Removal
Remove the piston cooling jet assembly (Item 1) [A] from

the engine block.
Inspect the jet tube (Item 1) [B] , mount bolt (Item 2) [B] I
and alignment pin (Item 3) [B] for damage . Replace as B
needed.
Piston Cooling Jet Installation
Clean all parts in solvent and dry with compressed air.
Install the cooling jet (Item 1) [8] being sure it is seated

correctly on the dowel (Item 3) [B] in the block.
Install the mounting bolt (Item 2) [8] and tighten to 15

ft .-Ibs. (20 Nm) torque.
Piston Cooling Jet Alignment
Insert a 0.067 inch (1,70 mm) diameter rod of suitable

C o.
length, in the jet.
The tip of the rod must extend out the top of the cylinder
in an area 1.30 inch (33 mm) in height and 0.8 inch (21
mm) of width to provide proper cooling jet alignment to
cool the pistons [C].
.:
Inspection
Clean all passages of coolant and oil.
Check the block for cracks or other damage.
NOTE: The top face of the block must not be

machined. This will affect liner flange depth
and piston height above the top face of the
cylinder block.
Check the camshaft bushing for wear. If the bushing

needs to be replaced , press out old one. Press a new one
in, insuring that the oil holes line up.
963 Bobcat Loader

ENGINE BLOCK (Cont'd)
Cylinder Liner Inspection

A
The condition of a cylinder liner is decided by: ,:-:~
:'!I I'.
• The amount and location of polished areas.

• Wear.
• Damage to the liner wall .
NOTE: It is not necessary to replace the liners if: The

honed finish can be clearly seen. Engine
performance and oil consumption is
acceptable.
Examine the liner surface (Item 1) [A] for cracks, deep

scratches and polished areas where the honed finish is
worn away.
B
Check the cylinder liner bore for out of round or wear
beyond service limits [B]. The inside diameter of the
service liner should be 3.937-3.939 inch (100,00-100,06
mm).
A flex type hone may be used to clean up small scoring

or pitting.
Damaged or worn liners must be replaced.
Cylinder Liner Removal
NOTE: Where several liners are to be removed or a B-D4066

very tight production liner is found, a press
should be used.
When one liner is replaced, a hand tool is available and

the following procedure can be done with the crank shaft
installed.
Rotate the crankshaft (if installed) to provide access to

the liner and protect the crank pin from damage.
Place the tool (Item 1) [C] over the center of the liner (Item
2) [C]. Make sure the flat bearing race (Item 3) [C] is
against the bottom of the recess.
Install the rod (Item 4) [C] through the handle (Item 5) [C].
Place the adapter (Item 6) [C] under the cylinder liner.

Tighten the nut and washer. Turn the handle and pull out
.-cD
the old liner.
lli-0
rr'l .
J l \B,1
'i/ I \ II II
Ir \II 1R r I
/I \\ I,I
/
B-D5556
963 Bobcat Loader

ENGINE BLOCK (Conl'd)
Cylinder Liner Installation

A
Clean the cylinder bore and the outside of the liner.
Lubricate the cylinder bore with engine oil.
Start the liner (Item 1) [A] in the bore . Make sure it is
started straight.
With the adapter (Item 2) [A] on the top of the liner, place
the bearing (Item 3) [A] in the recess at the top.
Place the threaded rod (Item 4) [A] through the handle

(Item 5) [A] and liner (Item 1) [A].
Adjust the rod until it is below the bottom of the block

surface.
Install the adapter (Item 6) [A] on the rod. Center the

adapter against the bottom of the block.
Tighten the nut and washer.
Turn the handle and press the liner in the bore , stopping
when approximately 2 inch (50 mm) remain. Apply

LOCTITE #603 to the outer surface below the flange and
to the flange recess.
Continue to press the liner into position. Remove the tool.
NOTE: Do Not hit the cylinder liners with a hammer.

They will be damaged.
B--05555
Check liner protrusion with a dial gauge [B].

B
The liner may have 0.004 inch (0 ,10 mm) protrusion or

recession from the block face.
Allow 15 minutes before measuring the bore. The liner will

take six hours to reach full strength .
The inside diameter of the service liner should be

3 .937-3.939 in. (100,00- 100,06 mm).
New piston rings must be used when the cylinder liners

have been replaced.
The measurement must be from the flange (Item 1) [B]

of the cylinder liner, not the top of the flame ring (Item 2)
[B].
IMPORTANT
For the first five hours after the new liners have
been installed:
• Do not operate at full load.
• Do not operate at high speed.
• Do not allow engine to idle for extended
periods. 1-2117-1196
963 Bobcat Loader

TURBOCHARGER
Troubleshooting
The chart below is given to assist in the correct diagnosis of turbocharger faults.
If the inside of the intake manifold is wet, check that there is not a fuel leak from the starting aid.
PROBLEM CAUSE
Not enough power 1, 4,5,6 , 7, 8 , 9, 10, 11 , 18, 20 , 21 , 22,25,26 , 27, 28
Black Smoke 1,4,5, 6 , 7 , 8, 9,10,11,18 , 20, 21 , 22,25 , 26 , 27,28
Blue Smoke 1, 2,4, 6, 8, 9 , 17, 19, 20,21 , 22, 30,31 , 32
High Lubricating Oil Consumption 2, 8 , 15, 17,19,20, 28,29, 31 , 32
Two Much Lubricatinq Oil At Turbine End 2, 7 , 8, 17,19, 20,22 , 28 , 30,31,32
Two Much Lubricating Oil At Compressor End 1,2, 4,5, 6, 8,19,20 , 21,28,31 , 32
Not Enough Lubrication 8 12 14 15 16 23 24 29 32 33 34 35
Lubricatinq Oil In The Exhaust Manifold 2 , 7,17, 18, 19, 20,22, 28 , 31,32
Inside The Induction Manifold Wet 1, 2 , 3, 4 , 5, 6, 8, 10, 11, 17, 18, 19, 20, 21, 28, 32 , 36, 37
Damaged Compressor Impeller 3 , 4 , 6,8, 12, 15, 16, 20,21 , 23,24, 29,32,33 , 35 , 36
Damaged Turbine Rotor 7,8,12 , 13, 14, 15,16, 18, 20, 22,23, 24, 25 , 27,29,
32, 33,35, 36
Rotating Assembly Does Not Turn Freely 3 , 6 , 7,8, 12, 13, 14, 15, 16, 18,20, 21,22, 23,24,
29 , 32, 33,34, 35
Worn Bearings, Bearing Bores, Journals 6, 7,8, 12,13,14,15, 16,23, 24, 29,33, 34, 35
Noise From Turbocharger 1, 3,4,5,6,7, 8,9, 10, 11,12,13, 14, 15,16, 17,18, 20,
21,22,23,24,29 , 32,33 , 34,35
Sludge or Carbon Deposit In Bearing Housing 2,11 , 13,14, 15,17,18, 24,29,33, 34, 35
KEY TO CORRECT CAUSE
1. Air filter element dirty. 22 . Excessive carbon behind turbine rotor.

2. Restricted crankcase breather. 23. Engine speed raised too rapidly at initial start.
3. Air filter element missing, leaking or not sealing
24. Insufficient engine idle period.
correctly. Loose connection to turbocharger.
25 . Faulty fuel injection pump.
4 . Internal distortion or restriction in pipe from air
26. Worn or damaged fuel injectors.
filter to turbocharger.
27. Valves burned.
5. Damaged/restricted crossover pipe, turbocharger 28 . Worn piston rings .
to induction manifold. 29. Lubricating oil leakage from supply pipe.
6. Restriction between air filter and turbocharger.
30. Excessive starting fluid (on initial engine
start).
31 . Excessive engine idle period .
7. Restriction in exhaust system. 32. Restriction in turbocharger bearing housing.
8. Turbocharger loose or clamps/setscrews loose. 33. Restriction in lubricating oil filter.
9. Induction manifold cracked or loose,
34. Engine stopped too soon from high load.
flanges distorted .
35 . Insufficient lubricating oil.
10. Exhaust manifold cracked or loose, 36. Fuel leakage from fuelled starting aid.
flanges distorted. 37. Crack in back plate of compressor.
11. Restricted exhaust system.
12. Delay of lubricating oil to turbocharger
at engine start.
13. Insufficient lubrication.
14. Dirty lubricating oil.
15. Incorrect lubricating oil.
16. Restricted lubricating oil supply pipe.
17. Restricted lubricating oil drain pipe.
18. Turbine housing damage or restricted.
19. Leakage from turbocharger seals.
20. Worn turbocharger bearings.
21. Excessive dirt in turbocharger housing.
963 Bobcat Loader

TURBOCHARGER (Cont'd)
Description
A WARNING
Turbochargers operate at high speed and high

temperatures. Keep fingers, tools and other
objects away from the inlet and outlet ports.
Avoid contact with hot surfaces.
W-2257-1196
The turbocharger (Item 1) [A] is placed between the

exhaust and intake manifolds. It is driven by hot exhaust
gases and supplies air at more than atmospheric
pressure to the intake. It is lubricated by oil from the main
gallery.
The oil flows from the filter adapter through the bearing
housing and returns to the engine block.
The turbocharger should only be serviced by an

authorized dealer or repair shop.
Remove the nuts (Item 2) [A] and remove the heat shield
(Item 3) [A].
Remove the bolts (Item 1) [B] from the extension tube

and muffler.
Remove the extension tube (Item 2) [B].
Disconnect the air cleaner hose (Item 1) [C] from the

turbocharger.
963 Bobcat Loader

TURBOCHARGER (Cont'd)
Thoroughly clean the turbocharger.
Loosen the hose clamps at the compressor outlet hose

(Item 1) [A].
Disconnect the oil supply tubeline (Item 1) [B].
Installation: Fill the bearing housing with clean oil

through the oil supply port.
Remove the oil return line (Item 1) [C].
Remove the four nuts (Item 1) [0] for the turbocharger to

exhaust manifold flange.
Installation: Apply anti-seize compound to the mounting

studs. Tighten the nuts to 33 ft.-Ibs . (44 Nm) torque.
Remove the turbocharger and gasket from the exhaust

manifold.
The turbocharger must only be serviced by an authorized

repair shop.
Before starting the engine, disconnect the electrical stop

control. Crank the engine until oil pressure is obtained.
Stop cranking and reconnect the stop control.
963 Bobcat Loader

lenuew a:>!I\Jas -to6-L-
JapeOl le:>qo8 £96
SYSTEMS ANALYSIS
Page
Number
BICSTM SYSTEM CONTROLLER
System Controller Test ..... . ........... . ........... .. . . ..... .. . 8-7
Removal And Installation . ........ . .. . ........... . ........... . . . 8-8
BICSTM (With Press To Operate Button)
Additional Inspection For Advance Hand Controls . . . .. .......... . . 8-3
Inspecting The BICSTM Controller (Eng. STOPPED-Key ON) .. . . ... 8- 3
Inspecting Deactivation Of The Auxiliary Hydraulic System
(Engine STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Inspecting The Lift Arm By-Pass Control ...... ... ................ 8-3
Inspecting The Seat Bar Sensors (Engine RUNNING) . . ........... 8-3
Inspecting The Traction Lock (Engine RUNNING) ... . .......... . . . 8-3
Maintenance ..... . .......... . . . ........ . ... ... ........ ... . ... 8-3
Troubleshooting Chart .................. . . . .......... .. ........ 8-4
BICSTM (Without Press To Operate Button)
Inspecting The BICSTM Controller (Eng. STOPPED-Key ON) ....... 8-5
Inspecting Deactivation Of The Auxiliary Hydraulic System
(Engine STOPPED - Key ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8-5
Inspecting The Lift Arm By-Pass Control ... .. .................... 8-5
Inspecting The Seat And Seat Bar Sensors (Engine RUNNING) ..... 8-5
Inspecting The Traction Lock (Engine RUNNING) ... .............. 8-5
Maintenance . ..... . ....... . . ........... .. ............ .. ...... 8-5
Troubleshooting Chart .. ... ...... ... . . . . ......... .... .......... 8-4
BOSS® DIAGNOSTIC TOOL
Procedure ....... . ..... . ........... . .. . ........ . .............. 8-18
BOSS® INSTRUMENT PANEL
Removal and Installation . .. . ............ . ......... . . .. ......... 8-23
BOSS® UNIT
Removal and Installation 8-22
ELECTRICAUHYDRAULIC CONTROLS REFERENCE

SYSTEMS
Controls Identification Chart . . . ......... . .......... . .. . ......... 8-28

ANALYSIS
PWM CONTROL HANDLE
Handle Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8-27
PWM ELECTRIC SOLENOID
Solenoid Coil Testing ..... . . ..... . ...... . . . ........ . .. . .. . ..... 8-27
PWM MODULE
Description .. . .. . .......... . ......................... . .
.... . .. 8-24
PWM TROUBLESHOOTING
Chart ....... . .. . .. . ..... . . . .............. . ....... . . ... . . ..... 8-26
Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8-25
BICS-BOBCAT INTERLOCK CONTROL SYSTEM

BOSS-BOBCAT OPERATION SENSING SYSTEM
PWM-PULSE WITH MODULATION

-8-1 Service Manual
SYSTEMS ANALYSIS (Cont'd)
Page
Number
RPM SENSOR
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8-18
SEAT BAR SENSOR
BICSTM Controller Seat Bar Sensor Circuit Test ..... . . ... . ......... 8-12
Removal And Installation .... . ..... . ..... . ........... . .... .. ... , 8-11
Seat Bar Sensor Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8-10
Troubleshooting Guide . . ... . ..... .. ......... .. ............. . ... 8-9
SEAT SENSOR
BICSTM Controller Seat Sensor Circuit Test .. . .. . ........ . ........ 8-16
Removal And Installation .. . ... . . . ...... . ..... . .. . ........ . ... . , 8-15
Seat Sensor Test . ..... .. .... . ..... . ...... . ........ . ........... 8-14
Troubleshooting Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
SENDER AND SENSOR
Service Checks . . .. . .. ..... .. .... . .......... . ... . .. . ..... . .... 8-18
SERVICE CODES
Chart ..... .. ... ... .... . . .... .. .... .. ... . ............ . . . ... .. . 8-19
TRACTION LOCK
Troubleshooting Guide ... ... ......... . ....... . .... . . ..... .. .. " 8-17
TROUBLESHOOTING THE BOSS® & LCD DISPLAY
Chart ... .. .......... .. .... . ...... . ..... . ..... .. . . ........ . ... 8-21

BICSTM (With Press To Operate Button)
Inspecting The BICSTM Controller (Engine STOPPED
- Key ON)
1. Sit in the operator's seat. Turn key ON, lower the
seat bar and disengage the parking brake pedal.
Press the green PRESS TO OPERATE Button. All
five BICS controller lights should be ON (Items 1, 2,
3,4& 5) [A].
2. Engage the parking brake pedal and raise the seat
bar fully. System Activated (Item 1). Seat Bar (Item
2) , Valve (Item 3) and Traction lights (Item 4) [A]
should be OFF.
NOTE: Record what lights are blinking (if any) and

number of blinl<s. Refer to Page 8-4.
3. Exit the loader and press Traction Lock Override
button. Traction light (Item 4)JA] should be ON.
Press override butfon again an Traction light (Item
4) [A] should be OFF.
Inspecting Deactivation Of The Auxiliary Hydraulics

System (Engine STOPPED - Key ON)
4. Sit in the o[)erator's seat. Lower the Seat Bar. Press
the green PRESS TO OPERATE Button. Press the
A WARNING
auxITiary hydraulics switch. The auxiliary switch light
will come ON. Raise the Seat Bar. The light should
be OFF.
Inspecting The Seat Bar Sensor (Engine RUNNING)
The Bobcat Interlock Control System
5. Sit in the operator's seat. Lower the seat bar. (BICSTM) must deactivate the lift, tilt and
Engage the parking brake pedal. Fasten the seat traction drive functions. If it does not, contact
belt.
your dealer for service. DO NOT modify the
6. Start the engine and operate at low idle. Press the system.
green PRESS TO OPERATE Button. While raising

W-2151-{)394
the lift arms, raise the Seat Bar fully. The lift arms
should stop. Repeat using the tilt function.
Inspecting The Traction Lock (Engine RUNNING)
7. Fasten the seat belt. disengage the parking brake
pedal, press the green PRESS TO OPERATE
Button and raise the Seat Bar fully. Move the
steering levers slowly forward and backward. The
Traction lock should be engaged. Lower the Seat
Bar. Press the green PRESS TO OPERATE Button.
8. Engage the parking brake pedal and move the
Traction lock should be engaged.
Inspecting The Lift Arm By-Pass Control

9. Raise the lift arms 6 feet (2 meters) 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.
Additional Inspection For Advanced Hand Controls

10. Sit in the o))erator's seat and fasten the Seat Belt.
Lower the Seat Bal)..,start the engine and press the
green PRESS TO uPERATE Button.
11. Raise the lift arms about 6 feet (2 meters) off the
ground.
12. Turn the key OFF and wait for the engine to come
to a complete stop.
13. Turn the key ON. Press the green PRESS TO
OPERATE Button , move the left hand control
toward the operator. The lift arms should not lower.
14. Move the right hand control away from the operator.
The bucket (or attachment) should not tilt forward.
963 Bobcat Loader

BICSTM (With Press To Operate Button) (Cont'd)
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.
Flashing Indicator Means System Problem

Effect on Operation (See Your Bobcat Dealer for Service) I
of Loader
Indicator When Light Is Numbero
Light Light ON Light OFF OFF Flashes Cause I
System PRESS TO PRESS TO Lift and tilt functions 2 Seat sensor circuit shorted to battery I
Activated OPERA TE button OPERATE button will not operate. voltage* .
is activated not activated 3 Seat sensor circuit shorted to ground
Seat Bar Seat Bar Down Seat Bar Up Lift, tilt and traction 2 Seat bar sensor circuit shorted to
functions will not battery voltage'.
U operate. 3 Seat bar sensor circuit shorted to
ground.
,
Valve Control Valve Can Control Valve Lift and tilt functions 1 Valve output circuit is open.
Be Used Cannot Be Used will not operate. 2 Valve output circuit shorted to battery I
~) voltage'.
3 Valve output circuit shorted to ground .
3 Valve output circuit is not grounded. ,
Traction Loader can be Loader cannot be Loader cannot be 1 Traction lock hold coil circuit is open.
® moved forward &

backward.
moved forward and
backward.
moved forward and
backward.
2
3
Traction lock hold coil circuit shorted
to battery voltage'.
to ground.
4 Traction lock pull coil circuit is open.
5 Traction lock pull coil circuit is shorted
to battery voltag_e*.
to ground.
Power BICS Controller BICS Controller is Lift, tilt and traction
+
I
is operating not operating functions will not N/A N/A
correctly. correctly. operate.
- - - - - - -
Normal S ICS 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 Instruction. (See Page 8-1.)
(2) If all five lights flash repeatedly, the voltage supply is greater than 16 volts or less than 9 volts.
(3) Flashin g patterns will repeat every 3.25 seconds.
963 Bobcat Loader

BICSTM (Without Press To Operate Button)
Inspecting The BICSTM Controller (Engine STOPPED
- Key ON)
1. Sit in the operator's seat. Turn key ON, lowerthe seat
bar and disengage the parking brake . All five BICS
System Controller lights should be ON (Items 1,2, 3,
4 & 5) [A].
2. Engage the parking brake and 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 8-6.
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.
Inspecting Deactivation of the Auxiliary Hydraulics
System (Engine STOPPED - Key ON)
5. Sit in the operator's seat. Lower the seat bar. Press
the auxiliary hydraulics mode switch. The mode
switch light will come ON. Raise the seat bar. The
light should be OFF.
Inspecting the Seat and Seat Bar Sensors (Engine
RUNNING)
6. Sit in the operator's seat. Lower the seat bar. Engage
the parking brake. Fasten the seat belt.
7. 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)
8. Fasten the seat belt, disengage the parking brake, Operator
and raise the seat bar fully. Move the steering levers
slowly forward and backward. The traction lock ~seat
should be engaged . Lower the seat bar.
9. Engage the parking brake pedal and move the
traction lock should be engaged.
) Seat
Spring
Inspecting the Lift Arm By-Pass Control
10. Raise the lift arms six feet (2 m) off the ground. Stop
the engine. Turn the Lift Arm By-Pass Control Knob
clockwise 114 turn. Then pull up and hold the Lift Arm
By-Pass Control Knob until the lift arms slowly lower.
Maintenance
Clean any debris, dirt or objects from under or behind the MC-02043
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 under the seat spring (Item 1) [C]

A WARNING
and the seat, 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 (BICSTM)
Inspect seat bar pivot area for tightness of linkage bolts. must deactivate the lift, tilt and traction drive
functions. If it does not, contact your dealer for
Replace parts that are damaged. Use only genuine service. DO NOT modify the syst em.
Bobcat replacement parts. W-2151-{)394
963 B obcat Loader

BICSTM (Without Press To Operate Button) (Cont'd)
lights are off or flashing. Have the service procedure performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL.
Flashing Indicator Means System Problem I

Effect on Operation (See Your Bobcat Dealer for Service)
of loader
Indicator When light Is Number of
Light light ON light OFF OFF Flashes Cause
Seat Operator in Seat No Operator in Seat Lift and tilt functions 2 Seat sensor circuit shorted to battery
6
Seat Bar Seat Bar Down Seat Bar Up
will not operate.
Lift, tilt and traction

3
2
voltage' .
Seat sensor circuit shorted to ground
Seat bar sensor circuit shorted to I
I

U operate. 3 Seat bar sensor circuit shorted to:
ground.
Valve Control Valve Can Control Valve Lift and tilt functions 1 Valve output circuit is open .
Be Used Cannot Be Used will not operate . 2 Valve output circuit shorted to battery
~) voltage' .
3 Valve output circuit shorted to ground .
3 Valve output circuit is not grounded .
Traction Loader can be Loader cannot be Loader cannot be 1 Traction lock hold coil circuit is open .
e moved forward &

backward.
moved forward and
backward .
moved forward and
backward.
2
3
Traction lock hold coil circuit shorted I
to battery voltage'.
'
to ground .
to battery volta~e ·.
to ground.
+ is operating
correctly.
not operating
correctly.
functions will not
operate.
SEAT SENSOR OVERRIDE ONLY (If Equipped)

Indicator light Flashing Effect on loader Operation
light Continuously When light is Flashing Cause
Seat Operator in Seat with Seat Bar Lift , tilt and traction Seat Sensor Override has been
6
- - -
down and Seat Sensor Override
has been activated
- - - - - - - - -
functions will operate. activated . Seat Sensor maintenance
is required.
-
NOTES:
(1) If the seat and/or seat bar sensor circuits are open , the corresponding lights will be OFF. If one of the lights
(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.
• On ly 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.
* Normal BICS operating voltage is less than the electrical system voltage. If voltage is more, the circuit is shorted
to system voltage.
963 Bobcat Loader

Revised Oct. 98 -8--0- Service Manual
BICSTM SYSTEM CONTROLLER
Troubleshooting Guide
The following troubleshooting guide is provided for

assistance in locating and correcting BICS system
A WARNING
problems. It is recommended that these procedures be

done by authorized Bobcat Service Personnel only. Check for correct function after adjustments,
repairs or service. Failure to make correct
death.
W-2004-1285
PROBLEM SOLUTION #
Power indicator light does not come ON. 1,2,3,6
All indicator lights flashing. 4
One of the indicator lights flashing. 5

Intermittent indicator lights. 6, 7,8,9
Key ON , seat bar down, push the Press To Operate Button. The system
activated, valve and traction indicator lights do not come ON. 10
SOLUTION SUGGESTIONS
1. Check that ignition switch is ON.
2. Check BICS 10 amp. fuse.
3. Check wiring and connections. Make sure the connector is securely connected
to the controller. Remove system controller and pull on connector to check.
4. Look at indicator light windows, if they are milky white in appearance , it is most
likely caused by moisture in the system controller. Allow to dry or replace the system
controller.
5. Refer to BICS system controller troubleshooting chart. (See Page 8-4.)
6. Check wire connections to make sure connectors are locked into place.
7. Check pins in connectors for pins pushed back or bent.
8. Move the system wiring back & forth to try to find area that may be causing the
intermittent connection.
9. Use sensor tester (MEL 1428) to isolate problem between sensor and system controller
and wiring.
10. Check the wiring and connections. Remove the left instrument panel and chek the
Press To Operate Button with an ohmmeter at the two-pin connector.
963 Bobcat Load er

BICSTM SYSTEM CONTROLLER (Cont'd)
The system controller mounting bolts are located on the

back of the operator cab [A].
Remove the top mounting bolt (Item 1) [A] from the

system controller.
Loosen the two lower mounting bolts (Item 2) [A] .
NOTE: The operator seat is removed in photo [B] for

clarity purpose only. The seat does not need
to be removed to remove the system
controller.
Slide the system controller (Item 1) [B] up and remove it

from the back of the operator cab .
Disconnect the electrical harness from the system

controller and remove the system controller from the
loader.
NOTE: Install the harness connector (Item 1) [C] into

the system controller (Item 2) [C] before
installing the system controller.
c .n:'
IMPORTANT
"i.
Be sure the connector to the BICS system

controller are correctly engaged in the
controller when installing the controller. An
audible snap can be heard when the
connector is correctly install ed. Try to pull the
connector out of the controller, if it cannot be
removed it has been correctly installed [C].
1-2087-1095
Installation: Tighten the system controller mounting

bolts to 80-90 in .-Ibs. (9 ,0-10,2 Nm) torque.
Reverse the removal procedure to install the system

controller.
963 Bobcat Loader

Revised Mar. 99 -8-8- Service Manua\
SEAT BAR SENSOR

A WARNING

death.
W-2004- 1285
PROBLEM SOLUTION #
Indicator light does not come ON when seat bar is lowered. 1, 2,3,4, 5,6
1. Check controller power indicator light. It must be ON.
2. Check sensor wire connection .
3. Use the BICS sensor tester (MEL 1428) to check sensor and system controller.
4. Check for loose hardware.
5. Check keyed bushing to make sure magnet collar rotates with seat bar.
6. Check magnet collar magnets for contamination such as metal particles.
963 B o bcat Loader

SEAT BAR SENSOR (Cont'd)
Seat Bar Sensor Test
Use Sensor Tester (MEL1428) for the following

procedure :
Disconnect the seat bar sensor connector (Item 1) [A].
P-{)4702
Connect Sensor Tester (Item 1) [B] in-line as shown to

the seat bar sensor connectors. (See Inset [B].)
Turn the key to the ON position. 00 NOT START THE

ENGINE.
The toggle switch (Item 1) [C] can be in either the Absent

or Present position .
The power light (Item 2) [C] on the sensor tester will

c
illuminate.
•
SEt:lSOR TEST
Lower the seat bar. The sensor test light (Item 1) [0]
should illuminate. D
Raise the seat bar. The sensor test light (Item 1) [0]
should go off. SEltSOfl. TEST
O~ = =t
If the above tests fails, there is a problem with the seat bar . . ',:
sensor. CON'mOUER tEST
Disconnect the sensor tester.

POWER
If the above tests pass, do the BICS controller seat bar
circuit test. (See Page 8-12.) Ct:'0
SENSOR TESTER
P-04699
963 Bobcat Loader

SEAT BAR SENSOR (Cont'd)
Disconnect the seat bar sensor connector (Item 1) [A].
P-04702
Remove the mounting bolt (Item 1) [8] from the pivot

bushing.
Installation: Tighten the mounting bolt to 25-28 ft.-Ibs.

(34-38 Nm) torque.
Remove the sensor mounting bolt (Item 2) [8] and nut.
IMPORTANT
Be careful to not overtighten the sensor

mounting bolt and nut to prevent breakage of
the sensor.
1-2088-1095
Installation: Be sure the tabs on the pivot bushing are

positioned in the slotted hole (Item 1) [C] of the operator
cab as shown .
Pull the seat bar back and remove the assembly as

follows :
NOTE: The sensor assembly [0] is shown removed
from the operator cab for clarity purpose
only. The sensor assembly can be removed
without removing the seat bar from the
operator cab.
Remove the pivot bushing mounting bolt (Item 1) [0] and

washer (Item 2) [0] from the pivot bushing (Item 3) [OJ.
Installation: Tighten the pivot bushing mounting bolt to

180-200 in .-Ibs . (21-23 Nm) torque.
D
.Y
.!
Remove the pivot bushing (Item 3) [0] , sensor (Item 4)
[0], magnet (Item 5) [0] and plastic bushing (Item 6) [0]
from the seat bar.
Inspect all parts for damage and wear and replace if

necessary.
Reverse the removal procedure to install the seat bar
~
': '
~ :"'.
sensor. • y
Refer to Page 5-1 for seat bar removal and installation Left Side
procedure. of Seat Bar
4
.... P-03284
963 Bobcat Loader

SEAT BA R SENSOR (Cont'd)
BICSTM Controller Seat Bar Sensor Circuit Test
Sensor Tester (MEL 1428) is necessary for the following

procedure:
Disconnect the seat bar sensor connector (Item 1) [AJ.
Connect the Sensor Tester (Item 1) [B] to the seat bar

sensor connectors (See Inset) [A].
Turn the key to the ON position . DO NOT START THE B

ENGINE .
SENSOR TEST
No power light on the sensor tester, check the tester or
wiring harness .
. Power light illuminated, move the toggle switch (Item 2)

[B] on the tester to the Present position .
NOTE: The sensor test light (Item 3) [B] is activated

by the seat bar. It will be off with the seat bar
up or ON with the seat bar down.
The seat bar light (Item 1) [C] on the BICS controller

should illuminate.
Move the toggle switch (Item 1) [0] on the sensor tester

(Item 2) [0] to the Absent position.
The seat bar light (Item 1) [C] should go OFF.

S€NSO~TEST
If the tests above fail , there is a problem with the BICS
system controller or the wiring harness.
963 Bobcat Loader

SEAT SENSOR

A WARNING
problems It is recommended that these procedures be

death.
W-2004-1285
PROBLEM SOLUTION #
Seat indicator light does not come ON with operator in seat. 1,2,3,4,5,6,7,8,9,10,11 I
Seat indicator light stays ON when operator is out of seat. 2, 3, 6, 10, 11, 12, 13, 14
Intermittent indicator light during operation. 11, 15, 16, 17, 18

J
1. Check to make sure power indicator light is ON.

2. Check for debris under and around seat.
3. Look for any obstruction around seat.
4. Check to make sure seat rail lowers when weight is in seat.
5. Raise cab and check for magnet collar movement when weight is added to seat.
(Magnet collar should extend approximately 3/8 inch (9,53 mm) beyond the
sensor assembly with weight in the seat.)
6. Use sensor tester to check operation of sensor and system controller. Follow
instructions on tester.
7. Check to make sure the magnet guide pin is in place.
8. Check for contamination on magnets such as metal particles or for shipping plate
over magnets.
9. Check to make sure both magnets are in collar.
10. Check for binding of magnet collar or bushing with hex head on other side for
binding.
11. Check for correct mounting. One spring for standard seat. Two springs for
suspension seats. Thick washers should be under front seat mounting rails on
both sides.
12. Check for loose hardware mounting magnet collar. Check to make sure the
magnet collar bushing is threaded on all the way so it is contacting seat rail.
13. Check to make sure seat rail raises when weight is removed from the seat.
14. Raise cab and check for magnet collar movement when weight is removed from
seat. (Magnet collar should extend approximately 1/8 inch (3,18 mm) beyond the
sensor assembly without weight in seat.)
15. With smaller operators that operate with the seat forward some mounting
alterations may be required. (See solution suggestions 16, 17 and 18.)
16. Adjust suspension seat to lightest weight setting.
17. Check to make sure the seat rails move up and down freely when weight is added.
18. Add washer between the bushing and the magnet collar assembly which slides on
and the seat rail. This will reduce the amount of seat travel required to activate
the system. Must check, with seat moved all the way back, that indicator light
does not stay on with operator out of seat. If light does not go out with operator
out of the seat, the washer must be removed.
963 Bobcat Loader

SEAT SENSOR (Cont'd)
Seat Sensor Test
Use Sensor Tester (MEL 1428) for the following

procedure:
NOTE: Clean any debris, dirt or objects from under
or behind the operator seat before starting
the test. The rear of the seat must move up
and down.
Turn the key to the ON position. DO NOT START THE
ENGINE .
Disconnect the seat sensor connector (Item 1) [A].
Connect sensor tester (Item 2) [A] as shown to the seat
sensor.
Move the toggle switch (Item 1) [8] to the Absent

position. B
•
ENGINE. SEHSORTEST
The power light (Item 2) [8] on the sensor tester will

illuminate.
-"
CONTROllER TEST
Sit on the operator seat. The sensor test light (Item 1) [C]
should illuminate.
Get off the operator seat. The sensor test light (Item 1) [C]
should go OFF.
If the above tests fail, there is a problem with the seat
sensor.
Raise the operator cab.
Disconnect the sensor tester.
Replace the seat sensor. (See Page 8-15.)
If the above test pass, do the BICSTM controller seat
sensor circuit test. (See Page 8-16.)
963 Bobcat Loader

Locate the seat sensor (Item 1) [A] beneath the operator

cab.
Remove the sensor connector (Item 1) [B] from the

holder.
Disconnect the sensor connector (Item 1) [B].
Remove the magnet collar mounting bolt (Item 2) [B] ,

washer (Item 1) [C] and magnet (Item 2) [C] from the
sensor (Item 3) [B].
Remove the sensor mounting bolt (Item 4) [B] and nut.
IMPORTANT
DO NOT overtighten the magnet mounting

bolt to prevent damage to the magnet.
1-2089-1095
c ,. 4' ~~
IMPORTANT
Be careful to not overtighten the sensor ,:!:

,.
mounting bolt and nut to prevent breakage of
the sensor. ~
1-2088-1095
Remove the sensor (Item 3) [C].
<:'~ . . P--04041
NOTE: Be sure not to lose the magnet collar
alignment pin (Item 4) [C] which is located in
the sensor (Item 3) [C] when removing the
sensor.
Remove the threaded bushing (Item 5) [C] from the seat
track mounting bolt (Item 1) [0].
Inspect all parts for damage and wear and replace if

necessary.
Reverse the removal procedure to install the seat sensor.
Refer to Page 5-1 for seat removal and installation

procedure .
963 Bobcat Loader

BICSTM Controller Seat Sensor Circuit Test
Use Sensor Tester (M EL 1428) for the following

procedure :
NOTE: Clean any debris, dirt or objects from under
or behind the operator seat before starting
the test. The rear of the seat must move up
and down.

ENGINE.
Disconnect the seat sensor connector (Item 1) [Al
Connect sensor tester (Item 2) [A] as shown to the seat

sensor.

ENGINE. B
The power light (Item 1) [B] on the sensor tester will
illuminate, if the light is not ON , check the tester or wiring
harness. . ...
SENSOR TEST
~
Move the toggle switch (Item 1) [B] to the Present
position.
The sensor test light (Item 3) [B] is activated by the seat

sensor switch.
-
CONTR~TEST
P-04698
The seat light (Item 1) [C] on the controller will be ON .
Move the toggle switch (Item 2) [8] to the Absent

position, the seat light on the controller will go OFF.
If the test above fail, there is a problem with the BICS

system controller or the wiring harness.
963 Bobcat Loader

TRACTION LOCK

A WARNING

death.
W-2004-1285
PROBLEM SOLUTION #
I
Traction lock stays engaged. 1,2,3,4, 5,6, 7
Traction lock will not engage. 6, 8
Intermittent activation of traction lock solenoid. 9, 10
1. Check that the controller power light is ON.
2. Make sure that the brake pedal is not engaged.
3. Measure charge pump pressure, should be above 280 PSI (1930 kPa)
4. Test traction lock solenoid, the coil resistance should be 9 to 11 ohms.
5. Check all hydraulic connections for the brake.
6. Traction lock solenoid valve is defective.
7. Brake discs are locked on pinion.
8. Red by-pass knob on the traction lock solenoid is not in the engaged position .
9. Check wire connections for loose connector body.
10. Check for loose or bent pins in the connectors.
963 Bobcat Loader

BOSS ® DIAG NOSTIC TOOL
Procedure
procedure:
MEL 1400 - Diagnostic Tool
Stop the engine. Lift and block the loader. (See Page
1-1 .)
Remove the dust cap from the diagnostic connector plug.
Connect the diagnostic tool plug (Item 1) [A] into the
loader connector.
Use the instructions from the BOSS Operation &
Maintenance Manual to make service checks of BOSS
system operating unit and other components [A].
SENDER AND SENSOR
Service Checks
Use the following information when checking the senders
and sensor with a volt/ohmmeter:
Components Value
TEMPERATURE SENDER
70 degree F. (21 degree C.) ... ... . . . . .. . 970 ohms
80 degree F. (27 degree C.) .. ...... .. .. 10130hms
ENGINE OIL PRESSURE SENDER
o PSI ................ .... .. . ... .. . . 3 ohms Max.
6 PSI (41 kPa) ........... ..... ... 8-13 ohms Min.
50 PSI (345 kPa) . . . . . . . . . . . . . . . . . . . . 39-53 ohms
70 PSI (483 kPa) . . . . . . . . . . . . . . . . . . .. 70-94 ohms
TRANSMISSION CHARGE PRESSURE SENDER N-1 7553
o PSI .............. . . .... . ... . .. . 0-5 ohms min.
100 PSI ~690 kPa) ..... .. . . .. . . ... ....... 58 ohms
130 PSI 896 kPa) ..... ... . .. ... . ........ 75 ohms
400 PSI 2758 kPa) .... . . ... ....... 90 ohms max.
FUEL SENDER
Full .. ... . ..... . . . . .. . .... . . .. ... ....... 20 ohms
Empty .. . .. . ... . .. .... .. . .. ...... ..... 244 ohms
RPM SENSOR
Continuity Resistance . . . . . . . . . . . . . 3000-3500 ohms
Adjustment
Remove the engine drive belt shield. (See Page 3-1.)
Disconnect the connector (Item 1) [B] from the engine
harness. Loosen the jam nuts (one on top and one below
the flywheel housing) on the RPM sensor [B].
N-1 7552
Turn the RPM sensor (Item 1) [C] in until it makes contact
with the engine flywheel.
Turn the jam nut until it contacts the flywheel housing. The
jam nut should not be tightened , it needs to turn with the
RPM sensor when the sensor is turned back out for
adjustment.
Turn the RPM sensor and the jam nut out from the
flywheel. Set a clearance of 0 .050 inch (1,27 mm)
between the jam nut and the housing with a feeler gauge
(Item 2) [C]. Retighten the jam nuts.
NOTE: The p lastic tip on a NEW RPM SENSOR is
used as a gauge to set the correct clearance.
Turn sensor in until it just touches the
flywheel, the plastic tip is designed to come
off after the engine is started.
963 Bobcat Loader

Revised Mar_99 -8-18- Service Manual
MONITOR SERVICE CODES
Chart
The following list references the defect codes that are

transmitted to the instrument panel display which can
A WARNING
occur. Some service procedures for correcting the

problems can be found in this manual and other Instructions are necessary before operating or
procedures must be performed ONLY BY QUALIFIED servicing machine. Read and understand the
BOBCAT SERVICE PERSONNEL. Operation & Maintenance Manuals, Handb ook
or death. W-2003-0199
SERVICE CODES
-------------------
SUBJECT DISPLAY READS CON DITION
Engine Coolant Temp. EC-1.1 SHUTDOWN, Engine Temperature
1:0 1:0 0:0 0:0 0:0 [ ]
1_o '_0 0=0 0=00 0=0 EC-2.1 WARNING , Engine Temperature
EC 3 Wiring Not Connected
EC4 Wiring Shorted
EC 5 High Sensor Voltage
EC 7 Sensor Out Of Range
Engine Oil Pressure EP 1 SHUTDOWN, Pressure
1-0 I-I 0=0 0=0 0=0
1:0 '':0 0:0 0:0 00:0
[3] EP 2 WARNING , Pressure
EP 3 Wiring Not Connected
EP 4 Wiring Shorted
EP 5 High Sensor Voltage
EP 7 Sensor Out Of Range
Engine Speed ES 1 SHUTDOWN , Engine Speed Too High
Co 1:0 0:0 0:0 D:O
'_0 0_1 0=0 °=00D=O
[3] ES-2.1 WARNII\JG , Engine Speed Slightly High
ES-6 Sensor No Signal
ES-7 Sensor Out Of Range
Air Filter AF 2 WARNING , Restriction Too High
1:1 ':0 0: 0 D: O 0:0
1=1 .=0 0=0 0=°0 0=°
[3] AF 6 Sensor No Signal
Battery b-2.1 WARNING , Bad Battery
1=0 0=0 0=0 0=0 0=0
.:' 0::0 0:0 O:OoD::O
[3] b-2.2 WARNING , Battery Voltage
Fuel Level FUEL2 WARNING, Low Level
':0 1:1 .:0 .:0 0:0 [ ]
'=0 '_I '_0 '_°0= 0
0
FUEL3 Wiring Not Connected
FUEL4 Wiring Shorted
FUEL5 High Sensor Voltage
FUEL7 Sensor Out Of Range
~
963 Bobcat Loader

MONITOR SERVICE CODES (Cont'd)
Chart (Cont'd)
SUBJECT I DISPLAY READS CONDITION

Hydrostatic Charge
Filter Conditions
,"',;::,, '';::0-a 0:00=0 0=00;;:0 00;;:0"'0 [3J
0
Hydrostatic Fluid
lei I-I D=O D=O 0"' 0
,;::, ':'0 0;;:0 0:'0 0:'0 0
0 HP 2 WARNING, Pressure
HP 3 Wiring Not Connected
- 4
HP 5
HP7 Sensor Out Of Range
Hydrostatic Fluid HC1 SHUTDOWf\I, Temperature
Temperature HC2 WARNING . Temoerature
lei '-0 o=a D=O 0=0
.;::_ '':0 0:'0 0;;:0 0: 0
[3J
0
HC 3
HC4
HC5 High Sensor Voltage
HC 7 S
963 Bobcat Loader

TROU BLESHOOTING THE BOSS® & LCD DISPLAY
SUBJECT SYMPTOM INDICATES TO CORRECT SYMPTOM
BOSS Temperature related 112 volt supply and 1. Check stored defects with the BOSS tool.
shutdown codes BOSS failure . *2. If defect list has EC1, HC1, EC2.1, HC2. EP3,
when no heating EP7, HP7, B2.2, low fuel, Fuel 7 and last
occurs. occurrence hr. readings are within a hundredth,
the BOSS is defective and must be replaced.
* NOTE: You may have some or all of the 3. Using a voltmeter, check the alternator output.
codes listed. You will have high
temps, high press, low voltage
and low fuel.
LCD Display Intermittent code of I Sensor No Signal or 1. ES6 will occur if the loader is stalled or shutdown
ES6 while engine No RPM's. during run cycle . The code is generated due to the
running. lack of RPM and the existence of residual
pressure in the system.
Display is dead - No Lack of 5.0 volts

Icons, Bar Graphs, regulated power.
I 1. Check pin A for 5.0 volts. If 5.0 volts is present
replace the display.
Hourmeter. 2. If no power exists at pin A, install BOSS backup
to confirm the BOSS system.
LCD DISPLAY 3. If the problem still exists, check the harness for
continuity.
CONNECTOR
ABC D E
I tf.I
~
"0
~
~
~
1t
0
~
0
_12_Vo_'_t-_B_ac;...k_L-,ig~h_t
1...'
t: - a.
~ -'='G""ro"-"u"'n"'d_ _ __
o :;
{ :; 1...1
Q.
n. I Negative Com..5 to 1.5 Volts

I Positive Com. 3.5 to 4 Volts
5.0 Volts Regulated Power
Power Display Operation
During an active Low voltage (5.0)

WARNING display, triggered reset.
I 1. Turn the ignition switch OFF. Re-starting will
return hourmeter reading.
reset occurs and the 2. If re-starting will not return hourmeter reading,
hourmeter becomes check pins B & C as stated in Step 5 below.
all zero's.
After glow sequence 1. Turn the key OFF and re-start.

or after a WARNING
goes away, the Icon
remains ON.
No Bar Graphs, no Bad display or BOSS

Hours.
I
is not communicating .
1.
2.
Plug in the BOSS tool and start the engine.
If data is being received by the BOSS tool, the
BOSS unit is not the cause of the problem.
3. If. no data is received at the BOSS tool.
disconnect the LCD display.
* NOTE: The display has caused the 1*4. If messages are now received at the tool, the
display is the problem. If problem still exists go to
problem by locking the

Step 5.
communication lines and

5. Check pins B & C for signal.
stopping communications from

6. If there is no signal. install BOSS backup unit.
the BOSS. 7. If the problem still exists, check the harness for
continuity.
963 Bobcat Loader

Revised Mar. 99 -8-21- Service Man ual
BOSS ® UNIT
The sensing system unit is located under the steering

lever control panel on the left fender.
Loosen the nuts from the sensing system unit (Item 1)

[A].
Use a screwdriver and remove the two connectors (Item

2) [A].
Remove the sensing system unit from the mounting

bracket.
Installation: Tighten the mounting nuts to 80-90 in .-Ibs.

(9,0-10,2 Nm) torque.
963 Bobcat Loader

BOSS ® INSTRUMENT PANEL
Pry the rubber light mount free from the operator cab
(both sides) [A].
Lower the light from the operator cab to locate the three
instrument panel mounting bolts (Item 1) [B] (both sides).
Remove the three mounting bolts and pull the left panel
(Item 1) [C] down from the operator cab.
Installation: Be careful to not overtighten the panel

mounting bolts to prevent stripping the threaded holes of
the panels.
Disconnect the wire harness connectors from the panel

and remove the panel.
Remove the three mounting bolts and pull the right panel
(Item 1) [D] down from the operator cab.
Installation: Be careful to not overtighten the panel

mounting bolts to prevent stripping the threaded holes of
the panels.
Disconnect the wire harness connectors from the panel

and remove the panel.
963 Bobcat Loader

PWM MODULE
Description
• Take voltage measurements by probing into wires near

the PWM module shown in figure [A]. All connectors
must remain plugged into their respectful harness. ,-~,,~
0-"-""--0
c-!)C.~J1!IN(~
• Turn the key to the ON position with the engine OFF.
• Turn the switches ON to get their appropriate readings.

(Example: Input from Proportional flow switch - Push
switch full left then full right to get the voltage readings
listed below.)
• Press the auxiliary mode switch (Item 2) [8] twice.

Both Green lights will be ON. Check Items 17, 18, or
19.
<!C-.~--'=*=\,-,,--0
®---~. QlEBV'fB..l.CM-1J E-LT . G15JU!l\l:~
0-- IT . ~-C .-cava ~
NOTE: Item descriptions are listed below as Input to
or Output from the Module. Voltage readings
are approximate. They are affected by battery
condition (system voltage). Voltage readings
for Items 10, 18, and 19 are variable and
correspond to Proportional Flow Switch
travel.
Fig. [A]:
Item Description Volts
1 Input for Attachment 1.0. 11.5

2 Ground 0
3 Input from Key Switch 12.0 MC-02265
4 Input from *Mode Switch 9.5
5 Output to Momentary Light 7.5
6 Output to Aux. Hyd . Switch 11 .0
7 Output to Detent Light 6.5
8 Input from Key Switch (Bleed position) 12.5
9 Output to **High Flow Solenoid (Not Used) 11.5
Non-High Flow Loaders 0
10 Input from Proportional Flow Switch 0.5-1.5
11 Ground to Proportional Flow Switch 0
12 Output to Proportional Flow Switch 2.0
13 Input for Loader Model 1.0. 12.0
14 Input from Detent Switch 12.0
15 Input from Rear Aux. Base Switch 11.0
16 Input from Rear Aux. Rod Switch 11.0
17 Output to Rear Aux. Diverter Solenoid 10.0
18 Output to Aux. Rod Solenoid 0-6.0
19 Output to Aux. Base Solenoid 0-6.0
*Input signal is present only as Auxiliary Hydraulic Switch

is pushed.
**Output signal goes to High Flow dash panel switch, then

to solenoid. Used only on H models. Zero voltage on
non-high flow loaders.
Key Switch Item 1 [8]

Auxiliary Hydraulic Switch Item 2 [8]
Momentary Light Item 3 [8]
Detent Light Item 4 [8]
High Flow Switch item 5 [8] Right
Steering
Proportional Flow Switch Item 1 [C] Lever
Detent Switch Item 2 [C] Control
Rear Aux. Switch (Base & Rod) Item 3 [C]
P-02129
963 Bobcat Loader

Revised Mar. 99 -8-24 Serv ice Manual
PWM MODU LE (Cont'd)
Description (Cont'd)
A

the PWM module. All connectors must remain plugged
into their respectful harness
• Sit in the operator's seat. Turn key to ON position.
Lower the seat bar. Check that the BICSTM controller
lights are on. Check input voltage (Item 1) [A]. Press
the auxiliary hydraulics mode switch. The mode switch
light will come ON. Raise the seat bar. The light should
be OFF Input voltage will drop to less than 1.0 volts.
NOTE: Item descriptions are listed below as Input to
or Output from the Module. Voltage readings
are approximate. They are affected by battery
condition (system voltage).
Fig. [A]:
Item Descrie.tion Volts
1 Input from BICSTM Auxiliary Deactivation 12.0

(~ Gr- "RAY
~ GR AY / ~rO
2 For future use (?L __ GRAY / ~~ ~ 6CK
~
3 For future use
4 For future use
C~ Y[ L'. OW/ DKBIUf
PWM TROU BLESHOOTING TS-D1433
Conditions
• Auxiliary Hydraulic Switch lights will not come ON .

Check the following:
PWM fuse
Wires disconnected, shorted, or cut.
Auxiliary hydraulic switch failure.
Module failure.
Use the voltage tests in the wire identification
section to determine the cause.
• Auxiliary Hydraulic Switch lights are flashing. See

the troubleshooting chart. (See Page 8-25.)
963 Bobcat Loader

Revised Mar. 99 -8-25- Servi ce Manual
PWM TROUBLESHOOTING (Cont'd)
Chart
The PWM module sends a diagnostic code to the
Auxiliary Hydraulic Switch lights when the conditions
listed in the chart below occur.
• When the lights are flashing , the key needs to be

turned OFF and then ON . If the problem still exists they
will continue to flash .
• Proportional flow cannot be engaged if the lights are
blinking.
• Continuous flow (detent) can be engaged if alternate
blinking lights are off after the key switch is turned OFF
and then ON (during a proportional flow switch failure).
Momentary LED Detent LED

(Item 1) [A] (Item 2) [A] PROBLEM AREA PROBLEM CAUSE
Light Blinking Light OFF Base End Solenoid or Wiring • Wires Disconnected
• Wires Shorted
• Wires Cut
• Solenoid failed . Perform solenoid
coil test.
• PWM module failed.
Light Off Light Blinking Rod End Solenoid or Wiring • Wires Disconnected
• Wires Shorted
• Wires Cut
• Solenoid failed. Perform solenoid
coil test.
Light Blinking Light Blinking Diverter Solenoid or Wiring • Wires Disconnected I
• Wires Shorted
• Wires Cut
coil test.
*Blinking/OFF *OFF/Blinking Proportional Flow Switch • Wires Disconnected

(Right Handle) • Wires Shorted
• Wires Cut
• Proportional flow switch failed.
Check voltage to switch.
Perform handle test.
*Alternate Blinking Lights
963 Bobcat Loader

PWM CONTROL HANDLE
Handle Testing
A
The right side steering lever handle switch (Item 1) [A]

controls the proportional flow to front auxiliary. Test the
switch with a Ohm test meter.
Disconnect the handle switch harness from the controls

harness. Use the chart below to test the handle switch .
Handle Switch Position

Test between
handle wires Full Left Center Full Right
White/Black 4.5-5.5 4.5-5.5 4.5-5.5

& White K-Ohms K-Ohms K-Ohms
White/Red 0.5-1.5 2.3-2 .7 3.5-4.5

& White K-Ohms K-Ohms K-Ohms
White/Red & 3.5-4.5 2.3-2.7 0.5-1.5

White/Black K-Ohms K-Ohms K-Ohms
One K-Ohm is equal to 1000 Ohms.
NOTE: Push the switch gradually from center to

either left or right. The Ohm reading must
change gradually. Replace the handle switch
assembly if required.
PWM ELECTRIC SOLENOID N-15704
Solenoid Coil Testing
The front auxiliary solenoid valves (Item 1) [B] are located

in the hydraulic control valve. Test the solenoid coils with
a Ohm test meter.
Disconnect the coil from the controls harness. The correct

reading is 1-5 Ohms.
963 Bobcat Loader

ELECTRICAUHYDRAULIC CONTROLS REFERENCE
Controls Identification Chart
Attachment
Solenoid Harness Attachment
Switch Number Terminal Harness
Number Activated Activated Connector
Left Side Right Side
Control Handle RH Control Handle
Switches Switches
1 1 1 K
2 2 2 K
* 3 1 1 K
~"
4 2 2,3 K,A,D
[i4[[]S m 1 1,3 K,A,C
m2[[]1~
5
1= :::;:_I!l
6 1 1,3 K,E
III
- );). 1
7 1 1,3 K,F
8 1 1,3 K,G Viewed from front

(pin side of connector)
9 1 1,3 K,H of loader.
10,11,12, - K
13,14
RH - Loaders with Rear Hydraulics Option.

* If harness terminals K & L are jumped together, switches 4 thru 9 will function the same as switch 3.
Solenoid Hydraulic Wiring

Number Coupler Color
1 Front Dk. Green/

9 Female Red
6
2 Front Dk. Green/
3 Male Lt. Green
3 (Top) Diverter Yellow
4 (Bottom) Bleed - Rear Dk. Green/

Male & Female Yellow
MC-02314
963 Bobcat Loader

SPECIFICATIONS
Page
Number
DECIMAL & MILLIMETER EQUIVALENTS
Chart ......... '" ................ . ....... .. .................. 9-20
ENGINE SPECIFICATIONS
Camshaft And Thrust Washer ......... . ......................... 9-8
Connecting Rod And Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-6
Crankshaft ............................... . ...... . ...... ... ... 9-6
Crankshaft Re-Grind Data ................ . ............ . ....... 9-7
Cylinder Block ........... .. .......... ... ... . ........ . . . ....... 9-8
Cylinder Head ... . ............... ... ........ . ... . ............. 9-5
Cylinder Liners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-8
Engine Torque ............... . ........ . ... .. .................. 9-11
Exhaust Valves ........... . ............ .. ........ . ........ . ... 9-5
Fuel Lift Pump ......... . .......................... .. .......... 9-8
Fuel Injection Pump .............. .. ........................... 9-8
Flywheel ........ .. ....... . .............................. . .... 9-9
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-8
General ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-5
Intake Valves ......... ... ....................... .. ........ . ... 9-5
Main Bearings ................................................ 9-8
Oil Pump, Gear And Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Piston And Piston Rings .... ... ..... . .................. . ........ 9-6
Rocker Shaft, Rockers And Bushings .. ... ....................... 9-6
Thrust Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-8
Timing Case And Timing Gears ............................. . ... 9-9
Turbocharger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-9
Valve Guides ....................................... . ......... 9-5
Valve Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-5
Water Pump And Thermostat .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-10
HYDRAULIC CONNECTION SPECIFICATIONS
Flare Fitting ............... .. ................................. 9-15
O-ring Face Seal Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-15
O-ring Flare Fitting .......................................... " 9-16
Port Seal Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-18
Straight Thread O-ring Fitting . . ............ . .... . . . ..... . ...... 9-15
Tubelines and Hoses .................. . ........ . .............. 9-15
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATONS
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-19
LOADER SPECIFICATIONS
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-4
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-3
Drive System ........... . .... . ..... . .................... .. .... 9-4

SPECIFICATIONS
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-4
Engine ..... '" ............................................... 9-3
Hydraulic System ....... . .......................... ..... ...... 9-4
Performance ......................... . ..... . ........ . ........ 9-3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-3
Tires ......................................................... 9-4
LOADER TORQUE
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9-12
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General Metric Bolts . . ............ ... ............ . .. 9-14
Torque For General SAE Bolts ............................ . ..... 9-13
U.S. TO METRIC CONVERSION
Chart ..... .. ........ . ........ . ...... .. ....................... 9-20

\BnUBW a3~I\Jas -;::-6
Jape0 1 le:>qo8 E96
LOADE R SPECIFICATIONS • Dimen sions are given for loader equipped with standard tires and dirt bucket and may
vary with other bucket types. All dimensions are shown in inches. Respective metric
dimensions are given in millimeters enclosed by parentheses.
Specifications
·Where applicable, specification conform to SAE or ISO standards and are subject to
change without notice. AO •
83.7
(2126) 166.8
(4235)
128.0
(3252)
89.7 98.7
(2279) (2507)
-4
~
"8"
25° ' I >- <:: \ '- I /. 30°
,
"A" 9.4j -ii
0",
t
(239)
I~ 122.3 ~]; 8.6
(3105) )0 I~ m
0 (219)
6595532
"A" STD . TIRES - 78 .0" (1981) "B" STD . TIRES - 62.6" (1590) " C" 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.
Performance
Rated Operating Capacity (SAE) .. . .. . 3000 Ibs. ~1362 k9~
Tipping Load (SAE Rating) .......... . 6000 Ibs. 2724 kg
Operating Weight .. ... : . ........... . 9900 Ibs. 4495 kg
SAE Breakout Force - Lift .. . .... . ... . 6050 Ibs. (26923 N)
- Tilt .. . ........ . 6300 Ibs. (28035 N)
Axle Torque ........ . ..... ......... . 9200 ft.- Ibs. (12475 Nm)
Travel Speed (Low) ...... ... . ....... . 5.2 MPH (8.3 km/hr.)
(High) ................. . 9.00 MPH (14.5 km/hr.)
Controls
Vehicle Steering ..... . ..... . . ..... . . Direction and Speed controlled by two hand levers.
LE~~~~~I~a~.II~~. ... . . .. . .......... . 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 Hydraulic Disc, foot operated pedal.
Engine
Make/Model ......... . .. . ...... .... . Perkins/1004.40T
Fuel/Cooling . . ..................... . Diesel/Liquid
Horsepower (ISO) . . . .. ........ . .. . . . Gross: 105 (78 kg)
Maximum Governed RPM ........... . 2200 RPM
Torque @ 1600 RPM (ISO) ........ . . . Gross: 308 Ibf. ft. (418 Nm)
Number of Cylinders ... . ...... . ..... . Four
Displacement , . .................... . 243 cu. in. (3,99 L)
Bore/Stroke . .. . ............. . ..... . 3.94/5.00 (100/127)
Lubrication ............ . .. ... . ..... . Pressure System W/Filter
Crankcase Ventilation .. . .... .. . ... . . . Open System
Air Cleaner ..... ...... .... ......... . Dry replaceable cartridge w/safety element
Ignition .. . ... ........ . . ...... . .... . Compression
Low Idle ... . ...... . ..... ... . ...... . 950-1000 RPM
High Idle .. . . , ... .. ..... , ..... ..... . 2335-2400 RPM
963 Bobcat Loader

LOADER SPECIFICATIONS (Cont'd)
H~~~~U.I~~.~~~.t~.~ .................. . Engine Driven, Gear Type

Pump Capacity ........ . .. . ........ . 26.2 GPM (99,2 Umin.) @ 3575 RPM
Tilt Relief Settings ................ . 3500 PSI (24133 kPa)
Lift Relief Settings ................ . 4000 PSI (27580 kPa)
System Relief @ Quick Couplers ... . First Stage 3025 PSI (20857 kPa)
Second Stage 3375 psI (23270 kPa)
Filter Hydraulic ..................... . Replaceable #3 micron element
Hydraulic Cylinders ................. . Doubleacting;
Tilt cylinder has custioning feature on dump & rollback
Bore Diameter:
Lift Cylinder (2) .... . ........... . .. . 3.00 (76,2)
Tilt Cylinder (2) ................... . 3.00 (76,2)
Rod Diameter:
Lift Cylinder (2) ................... . 1.75 (44,5)
Tilt Cylinder (2) ................... . 1.50(38,1)
Stroke:
Lift Cylinder (2) ................... . 31.81 (808,0)
Tilt Cylinder (2) ................... . 21.11 (536,2)
Control Valve ...................... . 3-spool, open center type w/float detent on lift and hydraulic bucket
positioning. Electronically controlled auxiliary spool.
Fluid Lines ........................ . SAE standard tubes, hoses & fittings
Fluid Type ......................... . Bobcat Fluid (P/N 6563328). If fluid is not available, use
1OW-30/1 OW-40 Class SE motor 011 for temperature above OaF (-18°C)
5W-30 Motor Oil for temperatures below OaF (-18° C)
HA~~~~I~i:~~~~O~ ~~.~ ............. . 4.4 Seconds
Lower Lift Arms ................... . 3.0 Seconds
Bucket Dump ..................... . 2.8 Seconds
Bucket Rollback .................. . 2.2 Seconds
Electrical
Alternator ......................... . 50 amp open frame w/integral regulator
Battery ..................... . ..... . 12 volt, 1000 cold cranking amps. @ OaF. (-18°C);
180 minute reserve capacity
Starter ............................ . 12 volt, Gear Reduction Type
Instrumentation .................... . Gauges: Hourmeter, Voltmeter, Fuel, Engine Temperature.
Warning Lights: Engine Oil Pressure, Hydrostatic Charge Pressure,
Hydrostatic Fluid Temperature & Hydrostatic Filter.
Drive System
Main Drive .... . ... . .. . ........... . . Hydrostatic 4 wheel drive
Transmission ...................... . Infinitely variable tandem hydrostatic piston pumps, driving 2 fully
reversing hydrostatic motors. Separate gear type charge pump.
Final Drive ........................ . Double gear reduction & #120 HS endless roller chain & sprockets
in sealed chaincase with oil lubrication
Total Engine to Wheel
Reduction ........................ . N/A
Axle Size .......................... . 2.95 (75)
Wheel Bolts ....................... . (10) 3/4 inch
Capacities
Cooling System .................... . 20 qts. (18,9 L)
Fuel .............................. . 32.5 gals. (123,0 L)
Engine Oil W/Filter ................. . 8 qts. ;7,6 L)
Hydraulic Reservoir ................. . 28 qts. 26,5 L)
Hydraulic/Hydrostatic System ...... . . . NA
Chaincase Reservoir ............... . 20.5 gals. (77,6 L)
Tires
Standard .......................... . 8-19.5,8 ply rating
Flotation .......................... . 14-17.5,10 ply rating
Super Flotation .................... . 38 x 20-16, 8 ply rating
Solid ............................. . 9.00 -16
Recommended Pressure ..... . .... . Inflate tires to MAXIMUM pressure shown on the side wall of
the tire. DO NOT mix brands of tires used on the same loader.
963 Bobcat Loader

Revised MaT. 99 -9-4- Service Manua'
ENGINE SPECIFICATIONS
All dimensions are given in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.
General
Number Of Cylinders .............. . .................................................. . .. . ... . ......... 4
Cylinder Arrangement ............................................ . ..... . ... . ..................... In-line
Cycle .................. . .. . ................................................................... 4 Stroke
Direction Of Rotation ....................................................... . .... Clockwise From The Front
Intake System ............................................................................. Turbocharged
Combustion System ................. . ........... . ... . ... . ... . ... . ..... . ... . .............. Direct Injection
Nominal Bore ............................................................................... 3.937 (100)
Stroke ............................. . ............... . ... . ... . ... . ..... . ... . ... . ............ 5.000 (127)
Compression Ratio ............................................................................. 17.25:1
Displacement .................................................................... . .. . .. 243 C.1. (4 liters)
Firing Order .... . ..... . .. . .. . ................ . ... . ... . ... . ....... . ............................. 1-3-4-2
Cylinder Head
Head Thickness ............................................................. 4.047 - 4.078 (102,8 - 103,6)
Head Thickness After Machining (Minimum) ..... . .. . . ... . ... . ....... . .... . . ................... 4.035 (102,5)
Valve Seat Angle ................................................................................... 46°
Leak Test Pressure ...... . ....... . ....... . ... . .. . . .................... . .... . .. . ... . ..... 29 PSI (200 kPa)
Valve Guides
Inside Diameter ............................................................... 0.3744-0.3764 (9,51-9,56)
Outside Diameter ................ . .. . .... . ...... . .... . ...... . ... . ..... . ..... 0.6260-0.6264 (15,90-15,91)
Valve Guide Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0.6248-0.6256 (15,87-15,89)
Valve Guide Clearance In The Cylinder Head (Interference) .. . ... . ... . ..... . ..... 0.0018-0.0027 (0,047-0,007)
Overall Length:
Intake .................................................................................. 2.281 (57,94)
Exhaust ................ . .. . ......... . ... . .. . . ... . ................ . ..................... 2.406 (61,10)
Protrusion From Bottom ........................................................ 0.585-0.596 (14,85-15,15)
Exhaust Valves
Valve Stem Diameter ............................... . ... . ... . ... . .... . .......... 0.3515-0.3528(8,93-8,96)
Valve Guide Clearance ....................................................... 0.0016-0.0033 (0,040-0,84)
Maximum ............... . ................ . .. . ... .. ...... . ... . .... . . .................... 0.0041 (0,104)
Valve Head Diameter ........................................................... 1.609-1.619 (40,88-41,12)
Valve Face Angle .................................. . ... . ... . ... . .... . .... . .......................... 45°
Overall Length ............................................................. 4.829-4.854 (122,66-123,30)
Seal Type ............................................ . ...... . .... .. .... . ...................... Positive
Valve Seat Angle ................................................................................... 46°
Valve Clearance .......................................... . ... . .... . ........ . ............... 0.018 (0,45)
Exhaust Depth (Production) ....................................................... 0.055-0.067 (1,40-1,70)
Exhaust Depth (Service) ........... . ... . ....... . ............................................. 0.077 (1,95)
Intake Valves
Valve Stem Diameter ......................................... . .......... . ...... 0.3525-0.3535 (8,95-8,98)
Valve Guide Clearance ... . ................ . .................................. 0.0010-0.0027 (0,025-0,069)
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0.005 (0,13)
Valve Head Diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.688-1.698 (42,88-43,12)
Valve Face Angle ................................................................................... 45°
Overall Length ............. . ............ . ... . ... . .......................... 4.829-4.854 (122,66-123,30)
Seal Type ..................................................................................... Positive
Valve Seat Angle ................ . .. . .... . .................... : ..................................... 46°
Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0.008 (0,20)
Intake Depth (Production) ......................................................... 0.050-0.068 (1,27-1,60)
Intake Depth (Service) .............................. . ... . ............ . ...................... 0.077 (1,85)
Valve Springs
Double Valve Springs (Outer)
Installed Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.41 (35,8)
Installed Height Pressure ............................................... . ..... 39.5-43.7Ibs. (176-195 N)
Double Valve Springs (Inner)
Installed Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.34 (34,0)
Installed Height Pressure ......................................................... 20-23 Ibs. (89-104 N)
963 Bobcat Loader

ENGI NE SPECIFICATIONS (Cont'd)
Rocker Shaft, Rockers And Bushings
Shaft Outside Diameter . .. . .......... . . . ... . ... . ... . . . . .. . .... ... . .............. 0.748-0.750(19,01-19,04)
Rocker Arm Bushing Bore Diameter ........................... . .. . .. ............. 0.875-0.876 (22 ,23-22,26 )
Outside Diameter of the Bushing . .... . .. . ... . ............. . .. . . .. .. ........ .. . . 0 .877-0.8783(22,28-22 ,31 )
Rocker Arm Bushing Clearance .. ...... . .. .. . ... . . .... . ........ .. ..... ... . .. . 0.0008-0.0035 (0,020-0 ,089 )
Inside Diameter of Reamed Rocker Bushing . . .......... . ..... . . ... . ... . .. . . ... . . . 0.750-0.752 (19,06-19 ,10)
Clearance Between Rocker Arm Bushing and Shaft ............ . . . .. . . . .. .... . .. .... 0 .001-0.0035 (0 ,03-0 ,09)
Maximum .. . . .. .. . . ...... ..... .... . .. ..................... ... . ... . .. ..... . ............... 0.005 (0,13)
Pistons And Piston Rings
Type .............. . ... ......... . . . ... ....... Fastram combustion bowl inserted top ring groove, graphitie skirt
Piston Pin Bore Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.5001 - 1.5004 (38,103-38,109 )
Piston Projection Above the Block Deck ... .. . ... . .... . ... . ......... ... ... ..... ..... 0.006-0.014 (0,14-0 ,36)
Top Ring Groove Width ... .... . . . .. ... .. ... . . .. . ............ . . . ... .. . . . . . .. . ... . .............. . .. Tapered
Second Ring Groove Width ... . .. .. ... ....... .. ......... . ... ... ... .... . . ..... ... 0.1008-0.1016 (2 ,56-2 ,58)
Third Ring Groove Width .. .. .. .. .. . . ... ..... . .. . . . .. . ... .. ...... . .... ..... . . .. . 0.1591-0.1598 (4,04-4 ,06)
Top Ring . ................ . .. ... . .. ... ... . .. .... .. ... . .... . . . . . ... Barrel Face , Molybdenum insert, Wedge
Second Ring .. . . .. . . . . . . .. . . . . . . ... . .. . .. .. . .. .. .. ... . ... . ..... Taper Face, Cast Iron , Outside Bottom Step
Oil Control Ring . . ....... . . . .. . . . . .... . ... . . ...... . ......... . ..... .. . . . Coil Spring Loaded, Chromium Face
Top Ring Width ........ ... ... . ... . ..... .. . . .. .. . .. .. ... . ... .. ... . . .. . . . . .. . .. .. .. ..... ... . .. . . .. Tapered
Second Ring Width ... . .............. ... ... . .. . ... .. ... . .. . . ...... .. . .. . .. . ... . .. 0 .097-0 .098 (2,48-2,49)
Th ird Ring Width . . ... . ... . ....... . . . .. ....... ... ... ....... . ... . .. . . .... ..... .. 0.1366-0.1374 (3,47-3,49)
Top Ring Side Clearance . . ... . .. . ......... . .. . . .. .. ........ . . . .... ... . . . . ...... . .. ............... Wedge
Second Ring Side Clearance ... .. ... . . .. . .. ....... .. ............ . .... ... . ... . .. ... 0.003-0.004 (0,07-0 ,10)
Third Ring Side Clearance . . . .. ................. ............. . . .. .... ... .. . . . .... . 0.002-0.003 (0,05- 0,07)
Top Ring End Gap .............. ..... .. . .... . . .... . ................... . . . ........ 0.011-0.025 (0,28-0,63)
Top Ring End Gap (With Internal Step) . . ..... . . ..... . ................. ... . .... .... . 0.014-0.028 (0,35-0,70)
Second Ring End Gap .............. ...... ....... . ................ . . .. ... .... .... 0.012-0.030 (0,30-0,76)
Second Ring End Gap (With External Step) ...... . . . . .... . ... . . . . . . . . .. ... . ... .... .. 0.016-0.034 (0,40-0,85)
Third Ring End Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0.010-0.031 (0,25-0,75)
Piston Pin Type ................. ...... ...... . ... . . . ....... .. ... .. ... .. .. . .................. Full Floating
Piston Pin Outside Diameter ......... ...... .... . .. . .. . . ... ........... ...... . 1.5628-1 .5630 (39 ,694-39 ,700)
Piston Boss Clearance .... . ...... ..... . . .. .. ... . . .... .... . . ... ..... .. ..... .. 0.0001-0.0006 (0 ,003-0,015)
Bushing Type ...... . ... . .. . ... ..... ...... . .. . .. . .... . ... . ..... Steel Back, Lead Bronze lin Bearing Material
Bushing Outside Diameter . . .... . ......... . ........ . . .................... . . . . . 1.6972-1 .6988 (43,11-43,15)
Bushing Inside Diameter (Reamed) .... . ....... . ... . . . ...... . .. . . . ... . ...... 1.5638-1 .5645 (39,723-39 ,738)
Piston Pin Bushing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 0 .0009-0.0017 (0 ,023-0,044)
Connecting Rods And Bearings

Connecting Rod Type ........ ... . .. . . . . . . .... . ... . ................ . .... H Section, Wedge Shape Small End
Connecting Rod Cap Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Flat joint face with dowels
Crank Pin End Diameter ......... .... . .. . . ... . ... . .................. ... . .. . . . 2.6460-2.6465 (67,21-67,22 )
Piston Pin End ............ . ... . ... . . .... . . ..... . ................. ..... . .. . .... 1.656-1.657 (42,07-42,09)
Length Between Centers ... . .. . .. ... . .. ........................... . ... . ..... 8.624-8.626 (219,05-219,10)
Bearing Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Steel Back, Lead Bronze Bearing Material with Lead Finish
Bearing Width ..................... . . . . ... .. . . . .... . ...................... . .. . . 1.242-1.255 (31,55-31 ,88)
Bearing Thickness At The Center ...... . . . . . . . . . .... . .. . ................ ...... 0.0723-0.0726 (1,835-1,844)
Bearing Clearance ................. . . ..... . . . . ... . .... . ....... ... . . ...... . .. , 0.0012-0.0032 (0,03-0 ,081)
Bearing Undersize Available ........ . . ... . ... ....... . . ... ... . .. -0.010 (-0 ,25) , -0.020 (-0,51). -0.030 (-0,76)
Cran kshaft
Main Journals . .... . .. ... . . ..... . .. .. ... . ............... .. ... . .. . . ..... . . ...... 2.998-2 .999 (76,16-76,18)
Maximum Wear And Out Of Round Of The Journals And Crank Pins . .. .. .. ..... ... . .. .. ...... . . . 0.0016 (0,04)
Width Of Front Journal . .. .. . . .. .... .. ....... ...... .. . .... . . . . ... . ... ..... . .... 1.454-1.484 (36 ,93-37,69)
Width Of Center Journal .... .. . .. . . . . ... . ... . . ............... . ......... ... . .. . . 1.738-1.741 (44,15-44,22)
Width Of Other Journals ..... .. ... . .. ... . .. .... .... ...... . .... . .... . . . ... . . .. . . 1.545-1.549 (39,24-39 ,35)
Crank Pin Diameters .............. . . . . ..... . .. ..... . ... . .... . ..... . ... . . . . .. . . 2.499-2.500 (63,47-63,49)
Width Of Crank Pins ............ . . . .. .. . ... ........................... . . . . .. . . . 1.589-1.591 (40,35-40,42)
Crankshaft End Play ............. . .. ... . . .. . .. ......... . .... . ........... . . . .. . . .. ........ 0.00075 (0,019)
Thrust Washer Thickness: Std. .. .. .. .. . ... ....................... . ........... . .. 0.090-0.091 (2,26-2,31)
Oversize ... . ... ... .. . .. . .. .......... . . ......... .. . . .. .. . .. 0.096-0.098 (2,24-2,50)
Main Bearing Oil Clearance ......... .... . ... ................................. . 0.0022-0.0046 (0,057-0,117)
963 Bobcat Loader

Revised June 98 -9--6- Service Manual
ENGINE SPECIFICATIONS (Cont'd)
Crankshaft (Cont'd)
Undersize Journals And Crank Pins .... ..... .... .. . . .... ... ..... . . . . ... 0.010 (0,25), 0.020 (0,51) , 0.030 (0,76)
With the crankshaft on V-blocks check the maximum run-out of the journals. They must not exceed these specifications
below and the difference in run-out between journals must not exceed 0.004 (0,10)
Journal #1 ... .. .. . .... .. . . . . ... . .... .... ............ ... ... .. ....... .. . .. .. .. ....... . .. ... . .. Mounting
Journal #2 .. . ... ... . .. .. ... . .... .. . .... . . . . ........ . . ... .. . .. .... ... . .. ..... . ....... . . .. . 0.003 (0,08)
Journal #3 ......... . . ..... . .. . . . ... ..... . . ...... ... . ....... ... . . ... .. .. . ... . .. . .. ........ 0.006 (0,15)
Journal #4 . . . .. . . .... ........ .. . .................. . .... . ..... . ... . .. . . ... ... .. . .. ...... . . 0.003 (0,08)
Journal #5 .. .. .... .. ... .. .... . .. . . .. ........ ..... . . ..... . ...... .... ..... . .. . .. ....... .. .. . . . Mounting
Crankshaft Re--Grind Data
6 6
0.189 .-.I '-
(4,8)
- I I I
8
B-D5594
The finished sizes for crankshaft journals which have been ground undersize are given in the table below:
Item 0.010 (0,25) 0.020 (0,51) 0.030 (0,76)
1 2.9884-2.9892 2.9784-2.9792 2.9684-2 .9692

(75,905-75,926) (75,651-75,672) (75,397-75,418)
2 2.4888-2.4896 2.4788-2.4796 2.4688-2.4696
(63,216-63,236) (62,962-62,982) (62,708-62,728)
3 1.554 (39,47) maximum - -
4 1.489 (37,82) maximum - -
5 1.759 (44,68) maximum - -
6 1.596 (40,55) maximum - -
7 5.243 (133,17) maximum - -
8 Do not machine this diameter - -
9 0.145-0.156 (3,68-3,96) - -
Crankshaft Heat Treatment: 60 Hour Nitride
NOTE: Crankshafts that have been nitrided for 60 hours can be machined 0.010 (0,25) without the need to harden
again. Check the crankshaft for cracks before and after machining. Demagnetize the crankshaft after it
has been checked for cracks. Remove any sharp corners from the oil holes. Surface finish and fillet radii
must be maintained.
963 Bobcat Loader

Main Bearings
Type .... .... ... ....... ... ..... . ... ... . . ....... . . ..... ... .. ..... .. . .. . . ... Steel Back, 20% Tin Aluminium
Center Bearing Width . . ..... .... . .... ... . . ............. .. ... . ............ . ..... 1.430-1.445 (36,32-36,70)
All Others . . . . ...... . ...... . .......... . . . . . ........ . . . .. .. ..... .... .... ...... 1.245-1 .255 (31,62-31,88)
Bearing Thickness (center) .. . . ... .. . ....... . . . . . ... . .. . .. . ... ... . . ....... .. . 0.0820-0.0823 (2 ,083-2,089)
Bearing Clearance . ... ...... .... ........ .. .. . . ... .. ... ...... ........ . . . .. , . . 0.0022-0.0046 (0,057-0,117)
Thrust Washers
Type .... ..... ...... . ..... . ..... . ... ...... . ...... , .. . ... ... ... . .... ...... . . .. .. , Steel back, Lead Bronze
Position .... . . . . . ....... .. . .. .... ... ....... ... . .. ..... ... . .. ...... .. ... Each Side Of Center Main Bearing
Standard . . . . . .. ..... .. . . .... . .. .. .. . . , ... . . .... .... . . ... ... . .. .. .. . .... . . ... . . . 0.089-0.091 (2 ,26-2 ,31 )
Oversize ........ . . . . ....... . . .. . . ... . .. . . . ... .. .... . . .. . , ..... .... . . .. .. . .. .... 0.096-0.098 (2 ,45-2 ,50 )
Camshaft And Thrust Washer
Journal #1 Diameter ....................... .... ... . ..... . . . .... . ........ ... . . .. 1.997-1.998 (50,71-50,74)
Journal #2 Diameter ........................ ..... . . ............ .. .... . ..... ... . 1.987-1.988 (50,46-50,48)
Journal #3 Diameter . .............. .. .. . ..... . . . .. ... ... ,...... .... .......... . . 1.967-1.968 (49,95-49 ,98)
Clearance On All Journals ............ . . . . ... . ... ... ...... ......... . ... . ........ 0.0024-0.0055 (0,06-0,14)
Cam Lift (Intake) ... . ........... . ..... ... .. . . . ......... ... ...... . ....... .. ..... 0.2999-0.3027 (7,62-7,69)
Cam Lift (Exhaust) ...................... .... . . ..... .. .... .. ... .. ........ .. . . . .. 0.3035-0.3066 (7,71-7,79)
Maximum Wear And Out Of Round ... . .. ... .. .. . ... .. . . ....... . .. . ...... .. .. ... .... .. . . ... . .. 0.002 (0,05)
Camshaft End Play ....... .... ..... . . .... ... .. ... . . . . . ...... .. . .... ... .... ... . ... 0.004-0.016 (0,10-0,41)
Service Limits ..... . .............. . . .. .... . . ... .. . . . ...... ..... .. . ... ........ ... ... . ...... 0.021 (0 ,53)
Thrust Washer Type .... . ............ . . .. . . ... . ..... ..... ............. . ....... . ........... . ........ 3600
Thrust Washer Thickness . .. . .. . ... . ..... . .. . ......... . ... . ........ . ...... . .. . .... 0.216-0 .218 (5,49-5,54)
Thrust Washer Recess Depth .. . . .. .. . .... " ... .... . . . . .. . .... . . . ... ...... . . .. .. .. 0.215-0.218 (5,46-5,54)
Bore #1 . ...... .. . ... ....... .. . . ... ... .. . . . . .... .... . . .... . .. ... ........ ...... 2.187-2.189 (55,56-55,59)
Bore #2 . ........ .... . . .... . . .. .. .. . . .. . ...... . .. . . . ......... . .. ..... . . , . . . ... 1.990-1.992 (50,55-50,60)
Bore #3 .. . . .. . . . .... . . .. . .. ... . ...... .. ...... . . . .. .. . ............. ... . . ...... 1.970-1.972 (50,04-50,09)
Cyli nder Block

Cylinder Bore Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4.103-4.104 (104,20-104,23 )
Cylinder Liner Flange Recess ... . . . . .. .... ..... .. ........ ........ . . . .. ...... ... . . 0.150-0 .154 (3.81-3.91)
Cylinder Liner Flange Recess Diameter .. . ... .. ....... .... .... . ... . . . .. ... ..... 4.245-4.250 (107,82-107,95)
Main Bearing Bore Diameter . . ... ....... .. . .. ...... ... ... . . .. .. .. . . ... .... . . . 3.166-3.167 (80 ,416-80,442)
Cylinder Liners
Production .. ... . ..... . .. . .. ... . . ..... . . ..... . . .... ..... . . . .. Dry, Interference Fit, Flanged, With Flame Ring
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Dry, Interference Fit, Flanged, With Flame Ring
Production Liner Outside Diameter ... . ..... . .... . .......... . .......... ... . . ... 4.105-4.106 (104,25-104,28)
Production Liner Clearance . . ... . . ........ .. ...... . .. . ... ..... . . ... . .... ... . . .. . .. 0.001-0.003 (0,03-0,08)
Production Liner Inside Diameter .. ........ . ... . . . .. . . . ........ ... ....... .... . 3.937-3.938 (100,00-100,03)
Service Liner Clearance ..... . .. ... .... .... .... ...... ....... .. . . ........ .... .... ... . . ...... ±0.001 (±0,03)
Inside Diameter Of Service Liner With Flame Ring (Installed) . .. . .. .... ....... ..... 3.937-3.961 (100,0-100,63)
Maximum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.010 (0,25)
Flange Thickness ....... ..... ..... .... . .. . . ... .. ....... ..... ...... ... . .. . . . . .. . . . 0.150-0.152 (3,81-3,86)
Liner Projection From Deck Surface . . . .... . ... ... ...... ..... . ... ... .. 0.004 (0,10) Above or 0.004 (0,10) Below
Hose Angle . .. . . .. .. ... ....... . . .. ...... ... . ..... .... . ......... . .. ....... .. ........ .... .... . . . .. 30/35 0
Piston Cooling Jets ... ........ ...... ...... .. ..... ..... .... . .. ... . . . .. ... . . .. . .. ....... .. 20 ft.lbs. (27 Nm)
Fuel Injection Pump

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Stanadyne DB4, Pin Timed
Number 1 Cylinder Outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 O'clock Position Viewed From The Rear
Rotation From Drive End .. . . ... . .. .. ........ ... . .. .. . . .... .... .. . . ... . ....... .. ...... . .. . ..... Clockwise
Fuel System ......... . ... . ..... . . . .. .. . .. .. . ...... .. .... . ......... . ....... . ....... ..... ....... Self Vent
Fuel Injectors
Working Pressure . .. . ..... . . .... ..... . .... .. ..... . ......... .... .. . .... . .. .. . .. .. .. 4263 PSI (29393 kPa)
Fuel Lift Pump

Type .... ..... . .... ...... ............ .. . . ... . .... . . .. .. .. ........... .... .... . .. . . ... A.C. Delco, Type XD
Method of Drive ...... .. .. .... ... . . .. .... . . . ...... . ...... ... ..... . .... . . ..... ......... .. . .. ... Camshaft
Standard Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-10 PSI (42-70 kPa)
Minimum Pressure ........... . .. . ........ . .................... . .......... . . . .. . ... . . .. . 3.75 PSI (25 kPa)
963 Bobcat Loader

Timing Case And Timing Gears
Camshaft Gear Number Of Teeth ...................................................................... 56
Camshaft Gear Bore Diameter .... . .. . ....... . ...... . ... . ....................... 1.375-1.376 (34,93-34,95)
Camshaft Hub Outside Diameter ................................................ 1.374-1.375 (34,90-34,92)
Camshaft Gear Hub Gear Clearance . . ....... . .................. . ... . ........ 0.0003-0.0019 (0,008-0,048)
Fuel Pump Gear Number Of Teeth ..................................................................... 56
Fuel Pump Gear Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 1.417-1.420 (36,00-36,06)
Crankshaft Gear !\lumber Of Teeth ................................... . ................................. 28
Crankshaft Gear Bore Diameter ...... . .... . .. . .. . ... . ........... . ........... 1.875-1.8760 (47,625-47,650)
Crankshaft Gear Hub Diameter .............................................. 1.875-1.8758 (47,625-47,645)
Crankshaft Gear Clearance .......... . .... . ..... . ... . .. . ... . .... . .. . . -0.0008 - +0.0010 (-0,020 - +0,048)
Idler Gear Number Of Teeth ........................................................................... 63
Idler Gear Bore Diameter ............ . .... . ..... . ...... . ... . ... . ... . .... . ....... 2.250-2.251 (57,14-57,18)
(With Needle Bearings) ....................................................... 2.717-2.718 (69,01-69,03)
Width Of Idler Gear And Bushing Assembly .......... . ... . ... . ....... . .... . ....... 1.186-1.187 (30,14-30,16)
Flanged Bushing Inside Diameter ................................................ 1.999-2.000 (50,78-50,80)
Idler Gear Hub Outside Diameter ................................................ 1.996-1.998 (50,70-50,74)
(With Needle Bearings) ........... . .. . .... . .. . .......... . .... . ....... . .... . ... 2.164-2.165 (54,99-55,00)
Idler Gear Hub Bushing Clearance ............................................... 0.0016-0.0039 (0,04-0,10)
Gear End Play .......................................... . ... . ................... 0.004-0.008 (0,10-0,20)
(With Needle Bearings) ......................................................... 0.009-0.013 (0,24-0,33)
Service Limit ............................................................................. 0.015 (0,38)
Backlash For All Gears .............................................................. 0.003 (0,08) Minimum
Oil Pump, Gear And Relief Valve
Type of Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Gear Driven, Differential Rotor
Number Of Lobes ........................................................................ Inner 6, Outer 7
Clearance Of Outer Rotor To Body ..... . .. . .... . ... . ................... . .... . ...... 0.006-0.013 (0,15-0,34)
Inner To Outer Rotor Clearance ................................................ 0.0015-0.0050 (0,04-0,13)
End Play ........................... . .............. . ... . ........................ 0.001-0.004 (0,03-0,10)
Oil Pump Idler Gear Bushing 1.0 . ............................................... 0.875-0.876 (22,23-22,26)
Idler Shaft 0.0. . ................................... . ......................... 0.873-0.874 (22,19-22,21)
Idler Gear Shaft Bushing Clearance .................................. . ..... . .. 0.0008-0.0026 (0,020-0,066)
Oil Pump Idler Gear End Play ................................................ 0.0005-0.0253 (0,012-0,643)
Relief Valve Plunger Bore Diameter .............................................. 0.718-0.719 (18,24-18,27)
Relief Valve Plunger Outside Diameter ... . .... . .. . ... . ... . ....................... 0.715-0.716 (18,16-18,18)
Clearance ..................................................................... 0.002-0.004 (0,06-0,11)
Length Of The Spring (Installed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2.35 (59,8)
Load On The Spring (Installed) ................................................. 3.6-5.2 PSI (15,9-23,1 Nm)
Pressure To Open Pressure Relief Valve ........................................... 60-68 PSI (415-470 kPa)
Oil Filter Type ........................................ . ... . ........... . .. Full Flow Screw-on Type Canister
Pressure To Open By-pass Valve In Oil Filter ......................................... 8-12 PSI (55-83 kPa)
Pressure To Open By-pass Valve In Oil Cooler .............. . ... . ....... . . .... . ... . ........ 25 PSI (172 kPa)
Minimum Engine Oil Pressure At Maximum Speed .......................................... 40 PSI (280 kPa)
Oil Pump Gear and Idler Gear Backlash ........................ . ... . ... . ......... . ... . ....... 0.003 (0,076)
Turbocharger
Type ....................................................................................... Garrett T20
Flywheel
Run-Out .................................................. . ....... . .... . . ... . .... Less than 0.012 (0,30)
Misalignment ... . ... . .. . .......................................................... 0.008 (0,203) @ 8 (203)
963 Bobcat Loader

Revised June 98 -9-9- Service Man ual
Water Pump And Thermostat

Type . .. .. ... ... . . . .... . ... ... . . ........ . . . .......... .. . ..... ........ . . .. ......... Centrifugal , Gear Drive
Shaft Outside Diameter ...... ..... ............ ..... ... .. . .. . .. . .. ... ... .. . ...... . 0.746-0.747 (18 ,95-18 ,96)
Drive Gear Bore Diameter . .. . ... . . .... ... . . .. .. . ... ...... . ... .. . ............. . 0.744-0.750 (18 ,90-18,92)
Drive Gear Shaft Clearance .. .. . . ... . . . .... .... . .. . .... ....... . ... . . . .... . . ... . . 0.0012-0 .0024 (0,03-0,06)
Impeller Bore Diameter ..... ..... . .. . .. .. ...... . .. ... ..... . ... . ...... .. ..... . .. 0.625-0 .626 (15 ,87-15,89)
Impeller Shaft Outside Diameter .. .. . . .. . . . .. . . .. ........ . . . .. .. ....... ..... ..... 0.626-0 .627 (15 ,91-15,92)
Impeller Clearance On Shaft . ... .. . .. . ...... . ............. . . .... ........ . . . ...... 0.0007-0.002 (0 ,02-0,05)
Bearing Bore Diameter ..... ..... ............ ... . . ... . .. . . ..... ...... . ......... 1.498-1.499 (38 ,06-38,08)
Bearing Diameter . ............. ..... . . .... . ... . . . .. ..... ... .. ... ... . . . ........ 1.499-1.500 (38 ,09-38,10)
Bearing Clearance In Pump Body . .. . . ... . . . ...... ..... . . ... . ..... .. .. . ... . .. .... 0.0004-0.0016 (0,01-0,04)
Thermostat Type .... ... . . . . ...... ..... . .. . ..... ....... ...... .. . . . . . . . .... . . . Wax Pellet, By-pass Blanking
Nominal temperature Start to open Fully open Minimum valve

stamped on thermostat temperature temperature lift, fully open
by-pass valve
180° F 170°/185° F 198°/208° F 0 .35

(82 ° C) (77°/85 ° C) (92 °/98° C) (9,0)
160° F 153°/16]0 F 185°/190° F 0.35

(71 ° C) (6 ]0175° C) (85 °/88° C) (9 ,0)
- - - --
963 Bobcat Loader

Engine Torque
Component ft.-Ibs. (Nm)
Bridge Piece To Block . ... .. . . .. ..... . .... ... ..... ... ... .. . . . . . . ... .. . .. . ..... .. ... ...... .. ... .... .. 12 (16)
Camshaft Gear Bolt . .... . . .. ... ... . . . ... . . . . . .... . . . . .. .. ..... ... . . . . . . . . .. . . . .... . . .. .. ... . . . .... 58 (78)
Camshaft Gear Bolts (45 mm long) ... . .. .... ..... . ...... . ... ... ...... . .... . . . . ... .. ..... ... .... ... . 74 (100)
Connecting Rod Nuts
Step 1 ... . ............. .. . . ... . . ...... .. ...... .. ...... .. .... ...... . ..... .. . . ... . .. . . . .... . .. . .. . 45 (61)
Final .. ... . . .. ........ . .... . .... .... ..... . .. . .. ... ..... ... ..... . .. ..... .. . .. .. .. . . .. . . .. .. . .. . .. 92 (125)
Crank Pulley Bolts . ... .... . . . ... . . .. .. . .. . ..... .. . .... . . . ..... . .... .. . . . . . .. .... ... . . .. . . . ..... . . . 85 (115)
Cylinder Head Bolts
Step One .... ... .. .... . . ... ... .. .. . .. . . . . .. . ... . . .. ... . . . . .. .. ...... ... ..... .. . .. .... ... . . ... . . 80 (108)
Step Two - Short Bolts ... .... . . .. . .. .. ...... . .... .. .. . . ..... ..... .... .... .. .. . . .... ... .... ..... .. ... 150°
Step Two - Medium Bolts ..... .. . . .. ... .. . . .. . .. . .... . . . . . . . . . .... .... . . . ... ...... . ..... . . . .. .. ..... 180°
Step Two - Large Bolts ... . . ... . . ... .. . . .. ... .... ... . .. ....... ... . . . . ... . .. .. . .. . ... . . . .... .. .... ... 210°
Engine Lift Bracket Bolts . . ... . ....... . .. ... ......... . ..... .. .. . .. .... .. ... ... ..... .. .... .. . . ..... . . 33 (44)
Exhaust Manifold Nuts ..... ... .... .. ..... ... ............ . .... .. ....... ... . . ... .... ... ... ... .... .... 37 (50)
Flywheel Housing To Cylinder Block .... . . .... .... .. ...... .... . .. . .. ... ...... ...... . .... . ... . ...... . . 52 (70)
Flywheel To Crankshaft Bolts . .. .... . . . ... ... ... . . . . .... ... ... ... . ... .... .... . .... . ... . . . . .. .. . . ... 77 (105)
Fuel Injector Nut . ... ... .... .. . . .. .. . . ... .... ... .. . . ... .. . . .. . . . ..... . .. ... .... . .. .... .. ... .. . . .... 23 (30)
Fuel Injection Pump Gear Mounting Bolts .... ... ... ......... . .. .. ... . . ..... .. . . ... .. ... . . . .... .. . . .. .. 20 (28)
Fuel Injection Pump Gear Nut .... .. ....... . . .. ... ... .... .. . . .... . ........... . . .. ..... . . . .... . . .. ... . 59 (80)
Fuel Injection Pump Flange Nuts ..... ... ... ... ..... .. . . . .. . . .. ...... . .. .. . ..... . . . .... .. .... ... . . ... 16 (22)
Fuel Lift Pump Bolts . .... .. ..... .. . ..... . . . . ...... .. .. ..... ... .... ... .... .... ... . .. . . ... . . . . . .. ... . 16 (22)
High Pressure Fuel Lines Fittings .. . .. .. .. ..... .. .. . . . .... ... .... .... .. ... .. . . . . .. .. . .. .. .. ..... . . . .. 16 (22)
Idler Gear Hub Bolts . .. . . .. .. .. ... . . . . . .. ... . . .. ...... .. ..... . .... ..... .. . . . . .... . . . ... . ... . . ... . .. 33 (44)
Intake Manifold Bolts .. ..... .. ..... . ...... .. . . ....... . .. . ....... ... ... ... ...... . ...... . .... . . . .... . . 33 (44)
Main Bearing Bolts

Step 1 .. ..... .... .. .... . . . . ... .... .. . . .. ... .... ... . . . . . .. .. ... .. . . ..... .... .. ... ... .... ... .... . . 65 (88)
Step 2 ..... .. ... . . . . . .. .. . . . .... . ...... .. . . ... . .. .... ... .... .. . . .. ... . .. ........ . ... .. . . ... . .. 125 (170)
Step 3 .... .... . .... . . .. .. . ........ ...... . .... .. .. .... .. ... .... .. .. . . ... ... .. . . . . . . . ... .. .. . . .. 185 (250)
Oil Cooler Cover Bolts .... . . ..... .. ... .. ....... . ... . .. . .. .. . . ... ... ... ... .... . . .. . . . . . .. . 96 in-Ibs. (11 Nm)
Oil Cooler Mounting Bolts . . .. ... .. . . .. . ...... . . ........ . .......... ..... .. ... .... .. . . .... . ...... .. .. 16 (22)
Oil Cooler To Back Plate .. . . .. ... ... .... ... ..... . ...... . ..... ... ... .. ...... .. .. . ... . ... . .... .. .. . .. 42 (58)
Oil Pan Bolts ... ... . ...... . . . ... ... .... ..... .. . . . . . . .. . . . .. .. . ...... .. . . . . .... .. ... .... .. .... ... . . 16 (22)
Oil Pan Plug . . .. ... . .... . ... .. . .. ... ... . . . .. .. ..... .. .... ... .... . ....... ...... . .. . . ... .. . . ... . . .. . 25 (34)
Oil Pump Cover . .. .... ... .... ... .... ... .. ... . ... . . . .. . . . .. . ... ...... . ..... .. ..... . ..... . .... .. .... 21 (28)
Oil Pump To Front Main Cap .. . ..... . .... .... .. ... .. . .. ... ... ... ..... . .. . . ... . .. . .. .. . .. . ... ... ... .. 16 (22)
Oil Transfer Plate Bolts .... ..... . . .. ... . .. . . . .. ...... . .. .... .. ... .. . . .......... ... ... .... . . .. .... . . . 22 (30)
Piston Cooling Jets . ... . .. . ...... .. . .. .. . . .. .... . . . ... ... .... . ... .. .. . .. ... .... . ... . .. . .. . ..... .. . . 15 (20)
Rear Oil Seal Housing Bolts ... . .... . .... ..... . ... .. . ..... ... . . . . . . . ........... .. .... .. . ..... .. ... .. 16 (22)
Rear Oil Seal Housing Bolts (Torx) .. .... .. ..... .. ...... . ...... .. .... . . . .... . . . . . .... . ..... .. ..... ... . 16 (22)
Rear Oil Seal Housing To Bridge Piece (Torx also) . . ... ... ... ...... . .. . . . . . .... .... .. . . ... . . . .... .. . . .. 13 (18)
Rear Oil Seal Housing To Bridge Piece (Thread Size M6) .. . . ..... .. . ..... ..... . ... .... .... .. ... . . . ..... 10 (13)
Rocker Cover Nuts (With Shim Washer) .. . .. ... .. ..... .. ..... ... . .. . . .. .. . . ... ..... ... .. . ... . . .. . . ... 22 (30)
Rocker Cover Nuts . ..... .. ..... . .. .. .... .... . . . .... . ........ .. ... . . .. ..... .. ...... .. ............ .. 15 (20)
Rocker Shaft Bracket Nuts . .. . . ... ..... ... .... ... . . ...... . ...... . . .... ... .... . ............... . . ... . 55 (75)
Timing Case To Block (M8 Bolts) .... .... . . .... .. .. . ... .. ... .. . .. . . .. .... .. . . . .... .. ... ..... . ..... .. . 16 (22)
Timing Case To Block (M1 0 Bolts) ... .. .. .. . . ... .. . . . .... .. ....... . ..... . . .. . .... . .. . ... . .... .. .. . ... 33 (44)
Timing Case Cover To Timing Case Bolts .... .. . . ... .. ....... .. .. . ....... . .. . ..... . . . ..... .. ..... . .... 16 (22)
Timing Case Cover To Timing Case Nuts ....... ..... .. ... ... . . . ..... . . . .. ... . .. . . .. . . . . .... . . . . . .. ... 16 (22)
Turbocharger To Manifold Nuts .. .. . .. .. .. . . .. . .. .. . . . . . . .... .... .. .... .. ...... .. ..... .. .... ... ...... 33 (44)
Water Pump To Timing Case Bolts & Nuts .. ... . .. . . ... .. ...... . ....... . ..... . .... . .......... . ........ 16 (22)
963 Bobcat Loader

LOADER TORQUE
Specifications
Component ft.-Ibs. (Nm)
Axle Hub End Plate Bolts . ...... . .. . . ... . . .... ..... . ...... .. ............. ..... ... .. .... .. 210-230 (285-311)
Axle Sprocket End Plate Bolts ... .. . . ...... .. . . .. . .. . .... .... ......... ..... ... . .. . . . ...... 210-230 (285-311 )
Bob-Tach Lever Mounting Nut ... ... . .. ............ . .. . ........ . .......... . . . . . ... . . . . .. ..... 25-28 (34-38)
Bob-Tach Pivot Pin Bolt (Tilt Cylinder Rod End) ... .... .......... ...... ... . ... . .. . . . ...... .. 125-140 (170-190)
Bob-Tach Pivot Pin Retainer Bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-20 (21-27)
Bucket Position Valve Mounting Bolts ....... ..... .......... ... ......... . .. . . .. . ... ....... . . .. ........ 15 (20)
Control Pedal Linkage Bolt and Nut . .... . .. . ..... . . ... ... . .. .. . . . ... . . . . .. . . ..... .... . . ..... . . 21-25 (28-43)
Hydraulic Control Valve Mounting Bolts . . ......... .... ....... . . .. .... .. . . . . . ...... . ... . . .. ..... .. . .. .. 25 (34)
Hydraulic/Hydrostatic Filter Housing Mounting Bolts . .. . .......... . .............. ... .... ... . ... ... . . . . . . 25 (34)
Hydraulic Pump Mounting Bolts . ........ . .. .. . .. ..... ... .... . . ..... .... . .. ... ........... .. ......... . 30 (40)
Hydraulic Pump Mounting Bracket Nuts ... . . . . . ..... . . . .. . . .. ... . .. . .... .. . .. . ... ....... .. . ... ....... 70 (95)
Hydrostatic Motor Cover Mounting Bolts ...... ......... .... ......... . .. ..... .... .. . .... . . .. 220-245 (298-332)
Hydrostatic Motor Mounting Bolts ......... .... . ... .... . . . ... .... . .... . . .. ......... ... ......... 65- 70 (88-95)
Hydrostatic Pump Mounting Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 65-70 (88-95)
Hydrostatic Pump Pulley Nut .... ... . . .. ....... .. . . ...... . ..... ..... ... . . .... .. ... . .. . . .. . 175-200 (237-271)
Lift Arm Pivot Pin Retainer Bolt. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 16- 20 (21-27)

Lift Cylinder Pivot Pin Retainer Bolt .. .. ... ... ........ . . . . ... ... . . .. . .. .. . . ... ... . . .... ....... . 16-20 (21-27)
Operator Cab Pivot Bolt and Nut . ........... ... . . .. .... . . . .... ......... .. . .. . ... . . .. .... . .... 25-35 (34-47)
Parking Brake Mounting Bolts .. . . . .. . .. .... . . . . .... ...... ....... .. . .... .... . ... . . .. .. . .. .. .. . ....... 70 (95)
Pedal Interlock Mounting Nuts . ..... .... .. . .... . . .. . . .. ....... . . .. . .. . .. . .. . ........ 84-95 in.-Ibs. (9 ,5-10,8)
Pedal Interlock Linkage Shield Mounting Nuts . ...... ..... . . . . . . .. .... .. . .. .. . .. ......... . . .... . 25-28 (34-38)
Rear Door Latch Nut .. . ................... . ... . .. ....... ...... . . . .. .. ......... . . .. ....... ... 65-70 (88-95)
Reduction Gearcase Mounting Bolts ......... .. ... ... ... .... ... ..... . .... ..... . .. .. ....... 220-245 (298-332)
Steering Cross Shaft Mounting Bolts . . .. ... . .. . .. ........... ...... ........... . . .. . .... ..... . . . 15-17 (21-23)
Tilt Cylinder Base End Pivot Pin Bolt .. . .. ... .... . . ..... . .. . ...... ..... . ............ . ... . . . 220-245 (298-332)
Wheel Nuts .... . ... . . . ..... . ... ... .... .. .... . .. ... . . . . . . . .. . . .. . .. .... . ... .. ... .... .. .. 320-350 (434-475)
963 Bobcat Loader

TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
The following table shows standard torque specifications for bolts with zinc
phosphate coating. Bolts purchased from Melroe that have zinc phosphate
coating are specified by the letter "H" following the part number.
THREAD
SIZE SAE GRADE 5 SAE GRADE 8
INCH. .250 80-90 110-120

LBS. (9-10) (13-14)
(Nm)
.3125 180-200 215-240
(21-23) (24-27)
.375 25-28 35-40

(34-38) (48-54)
.4375 40-45 60-65

(54-61 ) (82-88)
.500 65-70 90-100

(88-95) (125-135)
.5625 90-100 125-140

(125-135) (170-190)
.625 125-140 175-190

(170-190) (240-260)
FOOT .750 220-245 300-330

LBS. (300-330) (410-450)
(Nm)
.875 330-360 475-525
(450-490) (645-710)
1.000 475-525 725-800

(645-710) (985-1085)
1.125 650-720 1050-1175

(880-975) (1425-1600)
1.250 900-1000 1475-1625

(1200-1360) (2000-2200)
1.375 1200-1350 2000-2200

(1630-1830) (2720-2980)
1.500 1500-1650 2600-2850

(2040-2240) (3530-3870)
1.625 2000-2800 3450-3800

(2720-2980) (4680-5150)
1.750 2500-2750 4300-4800

(3390-3730) (5830--6500)
1.875 3150-3500 5500--6100

(4270-4750) (7450-8300)
2.000 3800-4200 6500-7200

(5150-5700) (8800-9800)
963 Bobcat Loader

TORQUE SPECIFICATIONS FOR BOLTS (Cont'd)
Torque For General Metric Bolts
Material
Thread Size
(Dia. x Pitch) Head Mark 4 Head Mark 7 Head Mark 10
M 5 x 0.8 3-4 ft.-Ibs.
(4-5 Nm)
M 6 x 1.0 6-7 ft.-Ibs. 6-9 ft.-Ibs.

(8-9 Nm) (8-12 Nm)
M 8 x 1 .25 6-9 ft.-Ibs. 11-16 ft.-Ibs. 18-25 ft.-Ibs.

(8-12 f\lm) (15-22 Nm) (24-34 Nm)
M 10 x 1.25 13-18 ft. -Ibs. 22-30 ft.-Ibs. 36-50 ft.-Ibs.

(18-24 Nm) (30-41 Nm) (49-68 Nm)
M 12 x 1.25 22-30 ft.-Ibs. 40-54 ft.-Ibs. 69-87 ft.-Ibs.

(30-41 Nm) (54-73 Nm) (94-118 Nm)
M 14x 1.5 36-50 ft.-Ibs. 58-80 ft.-Ibs. 116-137 ft.-Ibs.

(49-68 Nm) (79-108 Nm) (157-186 Nm)
963 Bobcat Loader

Revised June 98 -9-14- Service Manua\
A
IMPORTANT

o

the system.
1-2003-0888
O-ring Face Seal Connection
When the fitting is tightened, you can fee/when the fitting I B

is tight to eliminate leakage caused by under or over
torqued fittings. Use vaseline petroleum jelly to hold the
O-ring in position until the fittings are assembled [A].
Straight Thread O-ring Fitting
Lubricate the O-ring before installing the fitting. Loosen

the jam nut and install the fitting. Tighten the jam nut until
the washer is tight against the surface [B].
Tubelines And Hoses
Replace any tubelines that are bent or flattened. They will

restrict flow, which will slow hydraulic action and cause
heat. A--D1852
Replace hoses which show signs of wear, damage or

weather cracked rubber. c
~il ~
Always use two wrenches when loosening and tightening
r--
hose or tubeline fittings.
Flare Fitting
~
Use the following procedure to tighten the flare fitting:
Tighten the nut until it makes contact with the seat. Make
a mark across the flats of both the male and female parts
@+il
of the connection (Item 1) [C].
Use the chart below to find the correct tightness needed

(Item 2) [C). If the fitting leaks after tightening, disconnect
it and inspect the seat area for damage. I
TS--D1619
Flare Fitting Tightening Torque

Tubeline TORQUE NEW RE-ASSEMBLY
Outside Ft.-Ibs. Rotate No. Rotate No.
Wrench Size Diameter Thread Size (Nm) of Hex Flats of Hex Flats
5/8" 5/16" 1/2" 20 17 (23) 2-1/2 1
11/16" 3/8" 9/16" 18 22 (30) 2 1
7/8" 1/2" 3/4" -16 40 (54) 2 1
1" 5/8" 7/8" 14 60 (81) 1-1/2 1
1-1/4" 3/4" 1-1/16"-12 84 (114) 1 3/4
1-3/8" 1" 1-5/16" 12 118 (160) 3/4 3/4

(Cont'd) A O-ring Flar~
O-ring Flare Fitting
The flare is the primary seal, the O-ring is the secondary

seal and helps absorb vibration and pressure pulses at
the connection [A) .
If necessary, the O-ring-flare fitting can be used without

an O-ring .
Use the following procedure to tighten the O-ring flare jI

fitting. Secondary
Seal
Tighten the nut until it contacts with the seat. Make a mark
P-13009
across the flats of both the male and female parts of the
connection (Item 1) [B).
Use the chart below to find the correct tightness needed BI Hex Flat Tightening Method
(Item 2) [B). If the fitting leaks after tightening, disconnect
~~/) ~
it and inspect the seat area for damage.

~/) rt=D
ITS-01619
O-ring Flare Fitting Tightening Torque

* ** ***
Tubeline TORQUE NEW RE-ASSEMBLY

Outside Ft.-Ibs. Rotate No. Rotate No.
Wrench Size Diameter Thread Size (Nm) of Hex Flats of Hex Flats
SIS" 5/16" 1/2" 20 17 (23) 2-1/2 1
11/16" 3/S" 9/16" -1S 22 (30) 2 1
7/S" 1/2" 3/4" -16 40 (54) 2 1
1" SIS" 7/S" 14 60 (S1) 1-1/2 1
1-1/4" 3/4" 1-1/16" -12 S4 (114) 1 3/4
1-3/S" 1" 1-5/16"-12 11S (160) 3/4 3/4
* If a torque wrench is used to tighten a new fitting to a ** If using the hex flat tightening method to tighten a new
used hose/tubeline. fitting to a new hose/tubeline.
* If a torque wrench is used to tighten a used fitting to a ** If using the hex flat tightening method to tighten a new
new hose/tubeline. fitting to a used hose/tubeline.
* If a torque wrench is used to tighten a new fitting to a *** If using the hex flat tightening method to tighten a used
new hose/tubeline. fitting to a new hose/tubeline.
963 Bobcat Loader

Added June 98 -9-16- Service Manual
(Cont'd) A Copper Bonnet Orifice
O-ring Flare Fitting (Cont'd)
NOTE: O-ring flare fittings are not recommended in

\. "
all applications. Use the standard flare

fittings in these applications.
Do not use a O-ring flare fitting when a copper bonnet

orifice is used . When tightened the connection at the
bonnet may distort the flare face and prevent it from
sealing.
P-13572
Use a standard flare fitting (Item 1) [A] as shown.
When a O-ring flare fitting is used as a straight thread port B .~.~~-

adapter the O-ring flare face is not used to seal. The "
O-ring may come off the fitting and enter the system.
Always remove the O-ring (Item 1) [B] from the flare

face as shown.
An O-ring (Item 2) [B] is added to the flat boss of the

fitting to seal the connection in this application.
i'
0 "
01 , P-13573
963 Bobcat Loader

(Cont'd) A
Port Seal Fitting
The nut is the primary seal, the O-ring is the secondary

seal and helps absorb vibration and pressure pulses at
the connection [A].
The hex portion of the nut does not contact the surface of
the component when the nut is tight.
Use the following procedure to tighten the port seal fitting:
Port seal and nut, washer and O-ring (O-ring Boss)

fittings use the same tightening torque valve chart.
Nut Seals
If a torque wrench cannot be used, use the following to Fitting
method .
Tighten the nut until it just makes metal to metal contact,

you can feel the resistance . Nut Seals
to Port
Tighten the nut with a wrench no more than one hex flat
maximum.
Do not over tighten the port seal fitting.
Secondary a-ring Seal

NOTE: If a torque wrench cannot be used, use the
hex flat tightening method as an approximate
guideline. P-13008
NOTE: Port seal fittings are not recommended in all

applications. Use O-ring boss fittings in Port Seal and O-ring Boss
these applications. Tightening Torque
Fitting TORQUE
Nut Ft.-Ibs.
Wrench Size Thread Size (Nm)
11/16" 9/16" -18 22 (30)
15/16" 3/4 " -16 40 (54)
1-1/8" 7/8" - 14 60 (81)
1-1/4" 1-1/16" -12 84 (114)
1-1 /2" 1-5/16"-12 118(160)
Do not use port seal fittings when a thread in orifice (Item

1) [B] is used in the port. The orifice may interfere with the
fitting and prevent it from sealing.
Use an O-ring boss fitting (Item 1) [B] as shown.
963 Bobcat Loader

Revised May 98 -9-18- Service Manual
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
Specifications
Use Melroe hydraulic/hydrostatic transmission fluid (P/N 6563328). If this fluid is not
available, use 10W-30 or 10W--40 SAE Motor Oil (5W-30 for OaF [-18°C] and
Below) .
DO NOT use automatic transmission fluids in the loader or permanent damage to the
transmission will result.
Diesel fuel or hydraulic fluid under

pressure can penetrate skin or eyes
causing serious injury. Fluid leaks
under pressure may not be visible.
Use a piece of 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.
W-2074-1285
When temperatures below zero degree F (-18°C) are common , the loader must be
kept in a warm building. Extra warm-up time must be used each time the loader is
started during cold temperature conditions. Cold fluid will not flow easily and it makes
action of the hydraulic function slower. Loss of fluid flow to the hydrostatic
transmission pump (indicated by TRANS light ON) can cause transmission damage
in less than 60 seconds.
During cold weather 32°F (O°C) and

below, do not operate machine until
the engine has run for at least five (5)
minutes at less than half throttle.
This warm-up period is necessary
for foot pedal operation and safe
stopping. Do not operate controls
during warm-up period. When
temperatures are below -20°F
(30°C), the hydrostatic oil must be
heated or kept warm. The
hydrostatic system will not get
enough oil at low temperatures. Park
the machine in an area where the
temperature will be above OaF
(-18°C), if possible.
W-2027-1285
963 Bobcat Loader

DECIMAL AND MILLIMETER EQUIVALENTS
FRACTIONS DECIMALS MM FRACTIONS DECIMALS MM

1/64 - 0.015625 - 0.397 33/64 - 0 .515625 - 13.097
1/32 0.03125 - 0.794 17/32 0.53125 - 13.494
3/64 - 0.046875 - 1.191 35/64 -0.546875 - 13.891
1/ 16 0.0625 1.588 9/16 0.5625 14.288
5/64 - 0.078125 - 1.984 37/64 - 0 .578125 - 14.684
3/32 0.09375 - 2 .381 19/32 0.59375 - 15.081
7/64 - 0.109375 - 2 .778 39/64 - 0 .609375 - 15.478
118 0 .1250 3.175 5/8 0.6250 15.875
9/64 - 0.140625 - 3.572 41/64 -0.640625 - 16.272
5/32 0.15625 - 3.969 21/32 0.65625 - 16.669
11 /64 - 0.171875 - 4.366 43/64 -0.671875 - 17.066
3/16 0.1876 4 .762 11/16 0.6875 17.462
13/64 - 0.203125 - 5.159 45/64 -0.703125 - 17.859
7/32 0.21875 - 5.556 23/32 0.71875 - 18.256
15/64 - 0.234375 - 5.953 47/64 - 0 .734375 - 18.653
1/4 0.2500 6 .350 3/4 0 .7500 19.050
17/64 0 .265625 - 6 .747 49/64 - 0 .765625 - 19.447
9/32 0 .28125 - 7.144 25/32 0.78125 - 19.844
19/64 - 0.296875 - 7 .541 51 /64 -0.796875 - 20.241
5/ 16 0.3125 7.938 13/16 0.8125 20.638
21 /64 - 0 .328125 - 8.334 53/64 -0.828125 - 21.034
11/32 0.34375 - 8.731 27/32 0.84375 - 21.431
23/64 - 0.359375 - 9.128 55/64 -0.859375 - 21.828
3/8 0.3750 9.525 7/8 0.8750 22.225
25/64 - 0.390625 - 9.922 57/64 -0.890625 - 22 .622
13/32 0.40625 - 10.319 29/32 0.90625 - 23.019
27/64 - 0.421875 - 10.716 59/64 - 0 .921875 - 23.416
7/ 16 0.4375 11 .112 15/16 0.9375 23.812
29/64 - 0.453125 - 11.509 61 /64 -0.953125 - 24.209
15/32 0.46875 - 11.906 31 /32 0.96875 - 24.606
31 /64 - 0.484375 - 12.303 63/64 -0.984375 - 25.003
1/2 0.5000 12.700 1 1.000 25.400
1 mm = 0.03937" 0.001" = 0.0254 mm

U.S. TO METRIC CONVERSION
TO CONVERT INTO MULTIPLY BY
LINEAR Miles Kilometers 1.609
MEASUREMENT Yards Meters 0.9144
Feet Meters 0.3048
Feet Centimeters 30.48
Inches Meters 0.0254
Inches Centimeters 2 .54
Inches Millimeters 25.4
AREA Square Miles Square Kilometers 2 .59
Square Feet Square Meters 0.0929
Square Inches Square Centimeters 6.452
Acre Hectare 0.4047
VOLUME Cubic Yards Cubic Meters 0.7646
Cubic Feet Cubic Meters 0.02832
Cubic Inches Cubic Centimeters 16.39
WE IGHT Tons (Short) Metric Tons 0.9078
Pounds Kilograms 0.4536
Ounces (Avdp.) Grams 28.3495
PRESSURE Pounds/Sq . In. Kilopascal 6 .895
WORK Foot-Pounds Newton-Metre 1.356
LIQUID VOLUME Quarts Liters 0.9463
Gallons Liters 3.785
LIQUID FLOW Gallons/Minute Liters/Minute 3.785
TEMPE RATURE Fahrenheit Celsius 1.Subtract 32°
2. Multiply by 5/9
963 Bobcat Loader

ADVANCE HAND CONTROL SYSTEM (A.H.C)
Page
Number
ACTUATORS
Disassembly and Assembly ................................. . 10-28
Removal and Installation .......... .. ........................ . 10-27
ACTUATOR VOLTAGE TEST
Procedure ........................... . ........... .. ........ . 10-6
A.H.C. COMPONENTS
Identification ...... . ......................... . ............. . . 10-3
A.H.C'/PWM CONTROLLER
Conditions ................................................. . 10-15
Description ........... . .................................... . 10-14
Handle Testing ........... . ....... . ....... . ................. . 10-16
Removal and Tnstallation ..... . ............. . ............. . .. . 10-13
Solenoid Coil Testing ...... . ................................ . 10-16
Test ................................ . ..................... . 10-13
A:H~C~I~~hN8t~ Chart ........................ . ............. . 10-15
Disassembly and Assembly .............. ... ........... . .... . 10-25
Removal and Installation ......................... . ...... . ... . 10-24
A.H.C. STEERING LEVER
Removal and Installation .................................. . . . 10-26
B§~~~~ l~o/~~~8~K' tONT"ROL S"YST'EM' (S(CSTM) ......... . .. .

10-26
Troubleshooting Chart ...................................... . 10-12
BICSTM VALVE
BICSTM Valve Solenoid ....... . ... . .......................... . 10-31
Check Valve ............................................... . 10-30
Lift Arm By-Pass Orifice ........................... . ........ . 10-29
Lock Valve ................................................ . 10-30
Removal and Installation .................................... . 10-32
HANDLE CONTROL UNIT
Control Unit Connector ................................ . ..... . 10-20
HANDLE CONTROL UNIT TEST
Procedure ........................ . ....... . ................ . 10-9
Anti-Cavitation Valve .. . ............. . ..................... . . 10-40
Anti-Cavitation/Port Relief Valve ............................. . 10-39
Auxiliary Electrical Solenoid ..... . ........................ .. . . 10-46
Auxiliary Sp'ool ......................... . ................... . 10-45
Disassembly' and Ass.embly ............................. . ... . 10-37
H-Port Auxiliary Section .................................... . 10-47
Identification Chart ......................................... . 10-36
Inspection .... . ............................................ . 10-44
Lift and Tilt Spool .................................... . ...... . 10-42
Load Check Valve .......................................... . 10-37
Main Relief Valve . .. .. ......................... . ............ . 10-38
Mounting Plate ............... . ........................ . .... . 10-35
Port Relief Valve (Lift) ...... . ................................ . 10-39
Port Relief Valve (Tilt) ... . .......... . ..................... . .. . 10-40
Rubber Boot ............................................... . 10-41
S~I~~~~a~~6~~ation ...................................... . 10-48
ADVANCED
Removal and Installation ........................ .. .......... . 10-21
HAND CONTROL
TROUBLESHOOTING (A.H.C.)
Chart ......... . ............. , .......................... . .. . 10-4

SYSTEM
963 Bobcat Loader

l,muoW aO!j\Jas -<:-o~-
Jap oo l lo ~qo 8 £96
A.H.C. COMPONENTS
Identification
Steering Lever/Handle Control (Item1) [A].
Handle Control Unit (Item 2) [A].
Control Valve Actuators (Item 1) [B].
A.H.C'/PWM Controller (Item 1) [C].
B.I.C.S . Controller (Item 1) [0].
963 Bobcat Loader

TROUBLESHOOTING (A.H.C.)
Chart
The Advance Hand Control System (A.H.C .) has a built-in diagnostic function which uses the two lights on the left handle
to indicate the condition of the A.H.C. System. The left light is lift and the right light is tilt.
The control module continually checks the system in the order listed. The checks start with the lift handle controller and
then the lift actuator. If no problems are present, it will then check the tilt handle controller and the tilt actuator. The system
will stop its check at the first problem and then flash the code. If the problem is in the tilt controller or actuator, the lift indicator
light will be ON and the tilt light flashing a code .
The system starts its diagnostics and calibration when the ignition key is turned ON. The left light will be ON for 0.5 second
and remain ON, then both lights will be ON for another 0.5 second . (This indicates the handles are wired properly and both
lights are working .)
LOADERS PRIOR TO PRESS TO OPERATE BUTTON-At this time one of the following will happen :
1. Both lights will continue to stay ON . (Normal Operation .)
2. Both lights go out, with no flashing code. (No BICS Signal, BICS Controller Not Satisfied.)
3. The System goes into a flashing code. (See chart below for the problem.)
LOADER WITH PRESS TO OPERATE BUTTO~At this time one of the following will happen:
1. Both lights will be OFF until the PRESS TO OPERATE BUTTON is engaged . (Normal Operation .)
2. The System goes into a flashing code . (See chart below for the problem .)
The following list shows the probable causes and troubleshooting procedures when the lights are flashing.
The system will continually flash the code Signal with the key in the RUN position.
NUMBER PROBLEM CAUSE SOLUTION

OF FLASHES (Page 10-5 )
1 Handle not calibrated Handle controller not in neutral durinq start-up. 1

Mechanical handle controller malfunction . 4
Electrical handle controller problem. 6
2 Actuator not calibrated Control valve spool sticking or not centered during 5
shutdown.
Faulty actuator. S
3 Handle Control Wiring Fault Disconnected connector or wire . 2
Broken wire. 3
Electrical handle controller jHoblem. 6
4 Actuator Wiring Fault Disconnected connector or wire. 2
Broken wire . 3
Faulty actuator. 247
*5 Actuator Fault Faulty actuator. -
*Actuator fault (5 flashes) will only occur while the loader is in operation. The controller sensed the actuator was out of
sync with the hand controller unit. Normally this is caused from dust build up in the actuator motor, which causes a poor
connection at the motor brush . This fault will cause a loss of power to the actuators. When the loader control unit is reset
(The loader key is turned to the OFF position then back to the ON position) you will not get an actuator fault (5 flashes),
the system will reset and say the system is OK or signal an alarm (2 or 4 flashes). When actuator faults (5 flashes) alarm
becomes more frequent replace the actuator.
963 Bobcat Loader

Revjsed Mar. 99 -10-4- Service Manual
TROUBLESHOOTING (A.H.C.) (Cont'd)
Chart (Cont'd)
SOLUTION
1. Turn the key OFF, put the hand controller in neutral position, turn the key 0[\1. (The engine
does not have to be runninQ for system recalibration or diaQnostics).
2. Check wire connections for loose connector body, loose or bent pins in connectors.
3. Check for broken or damaged wire.
4. Check for stuck or sticky handle controller mechanism.
5. Turn the ke~ OFF check to ensure s(2ool moves freel~, returns to neutral, turn the ke~ ON .
6. Check the siQnal voltaQe from the handle controller unit. (See PaQe 10-8)
7. Check the Signal voltage from the lift or tilt spool actuator. (See Page 10-6)
8. Check to insure the actuator moves freely on the actuator mounting bolt.
NOTE: If during operation one or both indicator light(s) goes out, this represents a reduced performance state.
This is caused by the actuator not being able to reach (full stoke) as commanded by the handle controller.
When the handle controller is returned to neutral and the actuator reaches neutral, the condition wi ll clear
itself and the light will come back ON. Reduced speed in the lift or tilt circuits may be noticed. This will
not disable the loader, but may be an indication that an actuator is going bad.
When the wrong BICSTMcontroller, (Black face instead of Green face) is installed in an Advanced Hand
Control loader, and the key is turned to the ON position, the left light will come on for 0.5 seconds and
remain ON, then both lights will stay ON for an additional 0.5 seconds, then both lights will g o out with
n o flashing code, because there is no signal from the BICS to the control module. The BICSTM c o ntroller
light s will be ON , but the Advanced Hand Controller will not allow the loader hydraulics to function.
963 B obcat Load er

ACTUATOR VOLTAGE TEST " ~'
A
--IV!
4 '"
\ . ..
. *', .......,"[..'\f. •. ~.- ..
"........... ~ --",,~..
Procedure
.; '. 'r'-" . ." -::"'-'~.' . ' .~ '-/
.I .. , .j . .,...
P
11'_.
I~I
, , 4"
~. ~ --•....;.
With Test Harness; ! /'."f - is, -.
• . 'r 1 ..'
fL· i.,. '"
l~ ~
I \ 'iril!lt.
Raise the operator cab. (See Page 1-1 .) .

.'Ao
.~ 'if -, tk., / .' )~
, . T\1 ;:.r·· =-,. 'I'" J"
:~
. ~ i~..
Connect the remote start switch (MEL 1429A). (See Page
- ,1(1 ,
1-1.)
:fP\J'
~ ,-_"b;L_
The test harness (MEL 1554) and a digital multimeter are I
necessary to complete the following procedure. ~~
Disconnect the actuator wire connector (Item 1) [A] for
,'.
...... ':'"it"
.... ,
"_:'" \1':
., "-'"
,
•...
1 '
the tilt or (Item 2) [A] for the lift circuit from the controls
harness. \ ; II' __
NOTE: Each actuator has to be checked separately.
Install the test harness (Item 1) [8].
Turn the key to the ON position with engine OFF.
With a digital multi meter, take a voltage reading at the four

prong terminal connector (Item 2) [8].
The sensor supply voltage between terminal 1 (ground)

and terminal 3 [C] should be 4.3 ± 0.1 volts.
The signal voltage reading between terminal 1 (ground)

and terminal 2 [C] should be from 1.55 to 1.85 volts.
NOTE: Terminal 4 [C] is an open terminal not used at
this time.
Without Test Harness;
A digital multi meter is necessary to complete this test.
The wiring harness connectors must remain connected to

complete this test.
If the test harness (M EL 1554) is not available the sensor

supply voltage test (4.3 ± 0.1 volts) can be taken
between terminal 1 and terminal 3 on the tilt control
harness (Item 1) [0] and the lift control harness (Item 2)
[0].
The signal voltage reading (1 .72 volts) can be taken

between terminal 1 and terminal 2 on the tilt control
harness (Item 1) [0] and the lift control harness (Item 2)
[0].
Wire Code For Tilt Control Harness: (Item 1) [0] P-13754

Terminal 1 ... Light BluelYeliow
Terminal 2 ... Light Blue/White
Terminal 3 ... Light Blue
Terminal 4 ' " Open
Terminal 5 .. , PinkiWhite
Terminal 6 . .. Light Blue/Orange
Terminal 7 ... Black
Terminal 8 ., . PinklYeliow
Wire Code For Lift Control Harness: (Item 2) [A]

Terminal 1 '" Light GreenlYeliow
Terminal 2 .. . Light Green/White
Terminal 3 . . . Light Green
Terminal 4 ... Open
Terminal 5 . . , BrownlWhite
Terminal 6 ... Light Green/Orange
Terminal 7 . . , Black
TNminal 8 ... BrownlYeliow
963 Bob cat Loader

Revised Mar. 99 -1Q-..6- Service Manual
ACTUATOR VOLTAGE TEST (Cont'd)
Procedure (Cont'd)
Diagnosis Results For Tilt Actuator (top) Sensor Supply Voltage Test;
If the sensor supply voltage is 4.3 ± 0.1 volts, continue on and check the signal voltage.
If the sensor supply voltage is less than 4.3 ± 0.1 volts or 0 volts, check the PWM fuse , check for shorts or opens in the
wiring harness. If there are no apparent shorts or opens change the AHC/PWM controller. (See Page 10-13.)
If the sensor supply voltage is more than 4.3 ±0.1 volts check for a short of the power wires in the wiring harness. If there
are no apparent shorts change the AHC/PWM controller. (See Page 10-13.)
Diagnosis Results For Tilt Actuator Signal Voltage Test;
If the signal voltage is in the range of 1.55 to 1.85 volts, the system is functioning properly. The nominal voltage reading
is 1 .72 volts.
If the signal voltage is not in the range of 1 .55 to 1.85 volts check the hydraulic control valve spools for a centering problem
or replace the actuators. (See Page 10-27.)
Handle Out (Toward Side Screen):
1. Stop engine. Raise operator cab.
2. Connect the remote start switch (MEL 1429A) to the loader.

3. Turn key to ON position with engine OFF to get a code indication from the indicator lights on the left control handle.
4. Check the sensor supply voltage. (See Page 10--6.)

5. Check the system to make sure it is functional, with no blinking indicator lights.
6. Move right AHC handle toward the side screen to full stroke. Hold in position and and take a voltage reading.
The voltage reading must be 0.13 volts or greater.
If the voltage reading is less than 0.13 volts, replace the actuator. (See Page 10-27.)
While holding the handle toward the side screen turn the key to OFF position and wait five seconds ..
7. Continue to hold the handle toward the side screen and turn the key to the ON position. Take a voltage reading .
(You will have a one blink alarm on the right indicator light.)
The voltage reading should be between 1.55 to 1.85 volts.
If the voltage is above 1.85 volts, repeat steps 5 thru 7, if the voltage is still above 1.85 volts change the actuator.
If the voltage is below 1.55 volts complete the following tests: (See Step 11 Below; Tests a & b .)
Handle In (Toward Center Of Cab):

8. Turn the key to OFF position and wait five seconds, then turn key to ON position. Check the system to make sure
it is functional, with no blinking indicator lights.
9. Move right AHC handle toward the center of the cab to full stroke . Hold in position and take a voltage reading.
The voltage reading must be 3.2 volts or less.
If the voltage reading is more than 3.2 volts, check for shorts in the electrical connections, or replace the actuator.
(See Page 10-27.)
10. While the handle is held toward the center of the cab, turn the key to OFF position and wait five seconds.
11. Continue to hold the handle toward the center of the cab and turn the key to the ON position . Take a voltage reading.
(You will have a one blink alarm on the right indicator light.)
If the voltage is below 1.55 volts, repeat steps 8 thru 11 if the voltage is still below 1.55 volts change the actuator.
If the voltage is above 1.85 volts complete the following tests:
a. Remove the pin from the actuator to the control spool. Watch the spool, if the spool continues to move toward
neutral after the pin is removed, replace the actuator. Also check the mounting hardware on the actuators and
control valve for wear and correct torque.
b. If the spool does not move, check the control valve for a sticky spool or sticky centering mechanism. Also check
the mounting hardware on the actuators and control valve for wear and correct torque.
963 Bobcat Loader

ACTUATOR VOLTAGE TEST (Cont'd)
Procedure (Cont'd)
Diag nosis Results For Lift Actuator (bottom) Sensor Supply Voltage Test;
If the sensor supply voltage is 4.3 ± 0.1 volts, continue on and check the signal voltage.
If the sensor supPly voltage is less than 4.3 ± 0.1 volts or 0 volts, check the PWM fuse, check for shorts or opens in the
wiring harness. I there are no apparent shorts or opens change the AHC/PWM controller. (See Page 10-13.)
If the sensor supply voltage is more than 4.3 ± 0.1 volts check for a short of the power wires in the wiring harness. If there
are no apparent shorts change the AHC/PWM controller. (See Page 10-13.)
Diagnosis Results For Lift Actuator Signal Voltage Test;
!f the signal voltage is in the range of 1.55 to 1.85 volts, the system is functioning properly. The nominal voltage reading
IS 1.72 volts.
If the signal voltage is not in the range of 1 .55 to 1.85 volts check the hydraulic control valve spools for a centering problem
or replace the actuators. (See Page 10-27.)
Handle Out (Toward Side Screen):
1. Stop engine. Raise operator cab.
2. Connect the remote start switch (MEL1429A) to the loader.
3. Turn key to ON position with engine OFF to get a code indication from the indicator lights on the left control handle.
(See Page 10-4.)
4. Check the sensor supply voltage. (See Page 10-6.)

5. Check the system to make sure it is functional, with no blinking indicator lights.
6. Move left AHC handle toward the side screen to full stroke. Hold in position and take a voltage reading.
The voltage reading must be 0.13 volts or greater.
If the voltage reading is less than 0.13 volts, replace the actuator. (See Page 10-27.)
7. While holding the handle toward the side screen turn the key to OFF position.
8. Wait five seconds, then put the handle to the float position. Turn the key to ON position and take a voltage reading .
(You will have a one blink alarm on the left indicator light.)
If the voltage is above 1.85 volts , repeat steps 5 thru 8, if still above 1.85 volts , change the actuator.
If the voltage is below 1.55 volts complete the following tests: (See Step 12 Below; Tests a & b.)
Handle In (Toward Center Of Cab):

9. Turn the key to OFF position and wait five seconds , then turn key to ON position. Check the system to make sure
it is functional, with no blinking indicator lights.
10. Move left AHC handle toward the center of the cab to full stroke, in float position. Take a voltage reading.
The voltage reading must be 4.17 volts or less.
If the voltage reading is more than 4.17 volts, check for shorts in the electrical connections, or replace the actuator.
(See Page 10-27.)
11. While the handle is in float position, turn the key to OFF position. Wait for five seconds.
12. Continue to keep the handle in the float position. Turn the key to ON position. Take a voltage reading.
(You will have a one blink alarm on the left indicator light.)
If the voltage is below 1.55 volts, repeat steps 9 thru 12, if the voltage is still below 1.55 volts change the actuator.
If the voltage is above 1.85 volts complete the following tests:
a. Remove the pin from the actuator to the control spool. Watch the spool, if the spool continues to move toward
neutral after the pin is removed, replace the actuator. Also check the mounting hardware on the actuators and
control valve for wear and correct torque.
b. If the spool does not move, check the control valve for a sticky spool or sticky centering mechanism. Also check
the mounting hardware on the actuators and control valve for wear and correct torque.
963 Bobcat Loader

HANDLE CONTROL UNIT TEST
Procedure
Right Handle Test With Test Harness;
The test harness (MEL 1555) and a digital multi meter are
necessary to complete the following procedure.
Disconnect the handle control harness (Item 1) [A].
Move handle to the neutral position.
Turn the key to the ON position with the engine OFF.
With a digital multi meter take a voltage reading at the four

The sensor supply voltage between ground, terminal 1

The signal voltage reading between the ground , terminal

1 and terminal 2 [C] should be 1.7 to 2.1 volts.
this time.
Right Handle Test Without Test Harness;
A digital multimeter is necessary to complete this test.
For the switch handle harness connector color code. (See

Page 10-22.)
The test must be run at the eight pin switch handle

connector (Item 1) [A]. The wiring harness connectors
must remain connected to complete this test.
Check the sensor supply voltage (4.3 ± 0.1 volts)

between terminal G (Pink/Black) and terminal F
(Pink/Red).
Check the Signal voltage between terminal G (Pink/Black)

and terminal H (Pink/Green) . The voltage should be
between 1.7 to 2.1 volts. 4 3 2
Diagnosis Results for both Tests;
P-13754
If the sensor supply voltage is 4.3 ± 0.1 volts, continue
on and check the signal voltage.
If the sensor supply voltage is less than 4.3 ± 0.1 volts

or 0 volts, check the PWM fuse, check for shorts or opens
in the wiring harness. If there are no apparent shorts or
opens change the AHC/ PWM controller. (See Page
10-13.)
If the sensor supply voltage is more than 4.3 ± 0.1 volts

check for a short to a power wire in the wiring harness. If
there are no apparent shorts, change the AHC/PWM
controller. (See Page 10-13.)
If the signal voltage is in the range of 1.7 to 2.1 volts the

system is functioning properly. The nominal voltage
reading is 1.89 volts . If the signal voltage is not in the
range of 1.7 to 2.1 volts change the handle controller.
963 Bobcat Loader
-10-9- Service Man ual
HANDLE CONTROL UNIT TEST (Cont'd)
Procedure (Cont'd)
Left Handle Test With Test Harness;
The test harness (MEL1555) and a digital multimeter are
necessary to complete the following procedure.
Disconnect the handle control harness (Item 1) [A].
Move handle to the neutral position .
Turn the key to the ON position with the engine OFF.
With a digital multi meter take a voltage reading at the four

The sensor supply voltage between ground , terminal 1

The signal voltage reading between the ground , terminal

1 and terminal 2 [C] should be 1.7 to 2 .1 volts.
this time.
Left Handle Test Without Test Harness;
A digital multimeter is necessary to complete this test.
For the switch handle harness connector color code. (See

Page 10-22.)
The test must be run at the eight pin switch handle

connector (Item 1) [A]. The wiring harness connectors
must remain connected to complete this test.
Check the sensor supply voltage (4.3 ± 0.1 volts)

between terminal G (Brown/Black) and terminal F
(Brown/Red).
Check the Signal voltage between terminal G

(Brown/Black) and terminal H (Brown/Green). The 2
4 3
voltage should be between 1.7 to 2.1 volts.
Diagnosis Results for both Tests;
P-13754
If the sensor supply voltage is 4.3 ± 0.1 volts, continue
on and check the signal voltage.
If the sensor supply voltage is less than 4.3 ± 0.1 volts

or 0 volts, check the PWM fuse, check for shorts or opens
in the wiring harness. If there are no apparent shorts or
opens change the AHC/ PWM controller. (See Page
10-13.)
If the sensor supply voltage is more than 4.3 ± 0.1 volts

check for a short to a power wire in the wiring harness . If
there are no apparent shorts, change the AHC/PWM
controller. (See Page 10-13.)
If the signal voltage is in the range of 1.7 to 2.1 volts the

system is functioning properly. The nominal voltage
reading is 1.89 volts. If the signal voltage is not in the
range of 1.7 to 2.1 volts change the handle controller.
963 Bobcat Loader
HANDLE CONTROL UNIT TEST (Cont'd)
Procedure (Cont'd)
Right Handle (Tilt) Full Stroke Voltage Test
1. Turn the key to the ON position with engine OFF.
2. Check the Sensor Supply Voltage. (See Page 10-6.)
3. Move right AHC handle out or toward the side screen, hold and take a voltage reading. The voltage should be 0.13
or greater. If the voltage is less than 0.13 volts change the handle controller.
4. Allow the handle to go to neutral. Take a voltage reading. The voltage should be 1.7 to 2.1 volts. If the voltage reading
is either higher or lower, check for loose mounting hardware, or a bad handle controller.
5. Move the right AHC handle in toward the center of the cab to full stroke. Hold in position and take a voltage reading .
The voltage reading should be 4.17 volts or less. If the voltage reading is higher, change the handle controller unit.
(See Page 10-17.)
6. Release the handle and allow it to go to neutral. Take a voltage reading. The voltage should be 1.7 to 2.1 volts.
If the voltage is either higher or lower, check for loose mounting hardware, or a bad handle controller.
Leh Handle (Lih) Full Stroke Voltage Test
1. Turn the key to the ON position with engine OFF.
2. Check the Sensor Supply Voltage. (See Page 10-6.)
3. Move left AHC handle out or toward the side screen, hold and take a voltage reading. The voltage should be 0.13
or greater. If the voltage is less than 0.13 volts change the handle controller.
4. Allow the handle to go to neutral. Take a voltage reading. The voltage should be 1.7 to 2.1 volts. If the voltage reading
is either higher or lower, check for loose mounting hardware, or a bad handle controller.
5. Move the left AHC handle in toward the center of the cab to float and take a voltage reading. The voltage reading
should be 3.2 volts or less. If the voltage reading is higher, change the handle controller unit. (See Page 10-17.)
6. Release the control handle and allow it to go to neutral from the float position. Take a voltage reading . The voltage
should be 1.7 to 2.1 volts. If the voltage is either higher or lower, check for loose mounting hardware, or a bad handle
controller.
963 Bobcat Loader

BOBCAT INTERLOCK CONTROL SYSTEM (BICSTM)
lights are off or flashing.
Flashing Indicator Means System Problem

Effect on Operation (See Your Bobcat Dealer for Service)
of Loader
Indicator When Light Is Number of
Light Light ON Light OFF OFF Flashes Cause
Seat Operator in Seat No Operator in Seat Lift and tilt functions 2 Seat sensor circuit shorted to battery
6
Seat Bar Seat Bar Down Seat Bar Up
will not operate.
Lift, tilt and traction

3
2
voltage'.
Seat sensor circuit shorted to ground
Seat bar sensor circuit shorted to
U operate. 3 Seat bar sensor circuit shorted to
ground.
Valve Control Valve Can Control Valve Lift and tilt functions 1 Valve output circuit is open.
Be Used Cannot Be Used will not operate. 2 Valve output circuit shorted to battery
~) voltage'.
3 Valve output circuit shorted to ground.
3 Valve output circuit is not grounded.
Traction Loader can be Loader cannot be Loader cannot be 1 Traction lock hold coil circuit is open.
e moved forward &

backward.
moved forward and
backward.
moved forward and
backward.
2
3
to battery voltage' .
to ground .
to battery voltage*.
to ground.
+ is operating
correctly.
not operating
correctly.
functions will not
operate.
-
SEAT SENSOR OVERRI DE ONLY

Indicator Light Flashing Effect on Loader Operation
Light Continuously When Light is Flashing Cause
Seat Operator in Seat with Seat Bar Lift , tilt and traction Seat Sensor Override has been
6 down and Seat Sensor Override

has been activated
functions will operate .
-
activated. Seat Sensor maintenance
is required .
- -
ADVANCED HAND CONTROLS (AHC)

Indicator Effect on Loader Operation
Light Light OFF When Light is OFF Cause
Valve Control Valve cannot be used . Lift, tilt and traction AHC has detected a diagnostic
~)
- - - - - -- - -
functions will not operate.
-- -
condition OR Hand Controls not in
neutral when engine was started .
NOTES:
(1) If the seat and/or seat bar sensor circuits are open, the corresponding lights will be OFF. If one of the lights
(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.
* Normal SICS operating voltage is less than the electrical system voltage. If voltage is more, the circuit is shorted
to system voltage.
963 Bobcat Loader
A.H.C'/PWM CONTROLLER
At the left fender, remove the four mounting bolts (Item 1)

'0=r,
[A] from the controller.
Disconnect the wiring harness connectors from the

controller (Item 1) [B].
Remove the controller from the loader.
Test
• The wiring harness connectors must be connected to
the controller [B].

the controller shown in figure [B]. All connectors must
remain plugged into their respectful harness.
• Turn the key to the ON position (Item 1) [C] with the

engine OFF.
• Turn the switches ON to get their appropriate readings.

(See chart listed below for switch locations.)
• Press the auxiliary hydraulic switch (Item 2) [C] twice.

II
•.... ~"'"p:-~
r,
'f'~r: ~
Both Green lights will be ON .
.
""t ::~.; .~:.;:". ".' .~'" ..'·~.
' ... ~ cOI)O ~J, . ii - ;·<l>"~'·'
"ii.jJ·""'i .' I • ~;-'
~ ~
~ 0" ,
~ .• ,'l.."'-.!-'
• For individual voltage readings see Page 10-14.
. ,. . . . . . <;: """ ,
I
Key Switch Item 1 [C]
'~.,! I\..~'
nt'
~.
I' ~
~ ~.:.'< F,
' '~'
I , ' f./!
e . :,· ;.:
> ~.~
",
."'.'. '.~~ .~;~eL'WJ::'-JI
I
...."'::':.·
, . ,,'
'""';8';~.~
0....,.". •. •. •., . . . .
.6
::::.
,"!¥
Auxiliary Hydraulic Switch
Momentary Light
Detent Light
Item
Item
Item
2
3
4
[C]
[C]
[C]
' . "':':::::-
_ .' .;i· .' f
_ t
. . . I
"t.'...'
. . . J....i.•·
.8
--<",!¥..
.t;. . .
,-a~
.-.- - ;
~,-,". - .~.• .• ~~.rg-
, .'
,'",_ -, 0 'f~ -~rr,''', i
' Ii.:.··
. . ;;;......
High Flow Switch Item 5 [C]
. . . . . . .
Proportional Flow Switch Item 1 [0]

Detent Switch Item 2 [0]
Rear Aux. Switch (Base & Rod) Item 3 [0]
963 Bobcat Loader

A
Olt GREEN/WH I TE - 20
7 - - OltGREEN ~ L T.GREEN/REO - 3
30 OltGREEN/L T.GREEN LT .GREEN/PINK -21
18 - YELLOW - - - - , YELLOW/L T.GREEN - 10
2 9 - PINK/WHITE L T.GREENIBLUE - 22
~ OltCREENIL T.BLUE I
17 - BROWN/WH ITE III L~,,,,
PURPLE/WHITE - II
4 _PU:] GRAY 3
~-GRAY/BLA~K~ANGE/DK. CREEN- 2
6 - OPEN ~ORANGE/GRAY- I 27 - PURPLE/REO YELLOW/BROWN - 12
C4Z9 * PURPLE/BROWN - A
~ PURPLEIL T.BLUE-B
26 -ORANGE
L T.BLUE/ORANGE - 5
*Schematic Connector Number I MC-02420

A.H.C'/PWM CONTROLLER (Cont'd)
Description
Connector No. Pin No. Descri~tion Voltage Comments
C 430* A Battery Power 12.0
-~-
B Ground 0
C 428* 1 Power 12.0
2 Model Input 0
3 Model Select-lnl2ut A Not Used
4 Model Select-Input B Not Used
5 Model Select-Input C Not Used
6 Ol2en 0
C 429* A Diagnostic Light 4.0-11 .0 Light ON-Light OFF
B Diagnostic Light 4.0-11.0 Light ON-Light OFF
C 431* 1 Attachment Control Signal 00r12 .0
2 Signal from Lift Control Input Handle 0.80-1.89-2.90 Low-Neutral-High
3 Return from Aux. Module Switch Inl2ut 9.5
4 Signal from Tilt Control Input Handle 0.80-1 .89-2.90 Low-Neutral-High
5 Power to Tilt Spool Actuator Not Used
6 Signal from Lift Actuator Feedback InQut 0.40-1 .72-3.0 Low-Neutral-High
7 Return from Aux. Detent Switch Input 12.0
8 Power to Lift Spool Actuator Not Used
9 Signal from Tilt Actuator Feedback InQut 0.40-1.72-3.0 Low-Neutral-High
10 Return from Aux. Rear Base Switch Input 11 .0
11 BICS Status Input 00r12.0 Bar UP-Bar DOWN
12 B~tU[D frQm 8u~, 8~ar 8QQ Switcb IO(;lU! 12.Q
13 High Flow Solenoid Output 00r12 .0
14 Diagnostic Input No function
15 Low Reference to Resistive Inl2uts Ground
16 Signal from Aux. Resistive Inputs 0.98-2.24-3.24 Low-Neutral-High
17 Lift Actuator Reverse Motor Output Ot012.0
18 Di~er:te[ SQleoQid Qutput 12.Q
19 BICS Aux. Lock Input Oor11 .0 Bar UP-Bar DOWN
20 Auxiliary Relief Input 12.0 Key Left
21 Aux. Switch Module Detent Light 3.5 between 8.5 Light ON-Light OFF
22 Aux. Switch Module Momentary Light 3.5-8.5 Light ON-Light OFF
23 Lift Actuator Forward Motor Output o to 12.0
24 Aux. Sl200l Base End Outl2ut 0-6.0 Kel::: Left (12 Volt}
25 High Reference to Resistive Inputs 4.3 ± 0.1
26 Power to Aux. Switch Module 9.99-10.68
27 AHQ Struu~ QutQUl Q Q[ 12.Q 6ar UP-Bar QQWN
28 Switch Power 12.0 Key On
29 Tilt Actuator Reverse Motor Output o to 12.0
30 Aux. Sl200l Rod End Outl2ut 0-6.0
31 Tilt Actuator Forward Motor Output o to 12.0
963 Bobcat Loader
A.H.C.lPWM CONTROLLER (Cont'd)
Conditions
• Auxiliary Hydraulic Switch lights will not come ON.

Check the following :
PWM fuse
Wires disconnected , shorted, or open.
Auxiliary hydraulic switch failure .
Module failure .
Use the voltage tests in the wire identification

section to determine the cause. (See Page
10-14.)
The controller sends a diagnostic code to the Auxiliary

Hydraulic Switch lights when the conditions listed in the
chart below occur.
• When the lights are flashing, the key needs to be

turned OFF and then ON . If the problem still exists they
will continue to flash .
• Proportional flow cannot be engaged if the lights are
blinking.
• Continuous flow (detent) can be engaged if alternate
blinking lights are OFF after the key switch is turned
OFF and then ON (during a proportional flow switch
failure) .
Momentary LED Detent LED

(Item 1) [A] (Item 2) [A] PROBLEM AREA PROBLEM CAUSE
Light Blinking Light OFF Base End Solenoid or Wiring • Wires Disconnected
• Wires Shorted
• Wires Open
coil test.
Light Off Light Blinking Rod End Solenoid or Wiring • Wires Disconnected
• Wires Shorted
• Wires Open
coil test.
Light Blinking Light Blinking Diverter Solenoid or Wiring • Wires Disconnected

• Wires Shorted
• Wires Open
coil test.
• PWM module failed. I
·Blinking/OFF ·OFF/Blinking Proportional Flow Switch • Wires Disconnected I

(Right Handle) • Wires Shorted
• Wires Open
• Proportional flow switch failed .
Check voltage to switch .
Perform handle test.
• PWM module failed .
•Alternate Blinking Lights
963 Bobcat Loader

AHC/PWM CONTROLLER (Cont'd)
Handle Testing
A
The right side steering lever handle switch (Item 1) [A]
controls the proportional flowto front auxiliary. Use a Ohm
meter to test the switch .
Disconnect the handle switch harness from the controls

harness (Item 1) [B]. Use the chart below to test the
handle switch.
Handle Switch Position

Test between
handle wires Full Left Center Full Right P-02129
Dk. Blue & 4.5-5.5 4.5-5.5 4.5-5.5

Dk. Blue/White K-Ohms K-Ohms K-Ohms
Dk. BluelYellow 0.5-1.5 2.3-2.7 3.5-4.5

& Dk. Blue/White K-Ohms K-Ohms K-Ohms
Dk. BluelYellow 3.5-4.5 2.3-2 .7 0.5-1.5

& Dk. Blue K-Ohms K-Ohms K-Ohms
One K-Ohm is equal to 1000 Ohms.
NOTE: Push the switch gradually from center to

either left or right. The Ohm reading must
change gradually. Replace the handle switch
assembly if required.
Solenoid Coil Testing
The front auxiliary solenoid coils (Item 1) [C] are located

in the hydraulic control valve. Test the solenoid coils with
a Ohm test meter.
Disconnectthe coil from the controls harness. The correct

reading is 1-5 Ohms.
N-17493
963 Bobcat Loader

HANDLE CONTROL UNIT
To remove the handle control unit, slide the rubber handle

cover (Item 1) [A] up the handle .
Remove the two mounting bolts (Item 2) [A] from the

control cover.
Remove the control cover.
Disconnect the loader control harness (Item 1) [8] from

the handle control harness.
963 Bobcat Loader

HANDLE CONTROL UNIT (Cont'd)
Using a small screwdrive remove the handle control

electrical connector from the clip [A].
P-13737
Using an allen wrench , remove the two mounting screws

(Item 1) [B] from the control unit.
NOTE: A small screwdriver (Item 2) [B] in the control

unit may be needed to hold the center spacer
from turning.
963 Bobcat Loader

Remove the mounting bolt and nut (Item 1) [A] from the
control handle and shaft.
Remove the control unit (Item 2) [A] from the control

handle.
NOTE: The control unit (Item 1) [8] can only be

replaced as a complete assembly.
Check the spacer (Item 2) [8] and screws (Item 3) [8] and
B jJ)
replace as needed.
0*
N-17392
Installation: When installing the control unit into the I C

steering handle, check the routing of the switch handle
wire harness (Item 1) [C] to assure proper return of the
control handle to neutral.
N-17470
963 Bobcat Loader

Control Unit Connector

A
The wire connector (Item 1) [A] can be removed from the
handle control unit wires, use the following procedure.
'"
N-17392
Remove the wedge (Item 1) [B] from the connector.
3732
With a pointed tool, liftthetab (Item 1) [C] and pull thewire

from the connector.
c
Assembly: Install the wires into the connector as listed
below [C]:
1-Terminal- Red
2-Terminal - Black ..
3-Terminal - Green
'"
~~'
P-17333
963 Bobcat Loader

SWITCH HANDLE
Remove the handle control unit from the steering lever.

(See Page 10-17.)
To remove the switch handle the connector (Item 1) [A]

must be removed from the wires , use the folloWing
procedure:
N- 17505
Remove the wedge (Item 1) [8] from the connector. B
P-13725 P-13732
Using a pointed tool , press down on the tab (Item 1) [C]

and pull the wire from the connector.
IC
Installation: Install the wires into the connector as listed
below [C]:
Right Steering Lever Switch Handle

1-Terminal - Pink/Red
2-Terminal - Pink/Black
3-Terminal - Pink/Green
Left Steering Lever Switch Handle

1-Terminal - Brown/Red
2-Terminal - Brown/Black
3-Terminal - Brown/Green
P-17335
963 Bobcat Loader

SWITCH HANDLE (Cont'd)
Disconnect the right switch handle connectors (Items 1,

2 & 3) [AJ from the loader wiring harness connectors.
Disconnect the left switch handle connectors (Items 1 &

2) [B] from loader wiring harness connectors.
Remove the connector locks and connectors from the

wires to remove the switch handle from the steering
handle.
Installation:The wire colors of the steering lever harness

are as follows:
B -......;=----------------.
-~.,,~.
wr- t:I
Right Switch Handle
Eight-Pin Connecter
. "'- '-.-...
A-Terminal - Dark. OrangeIWhite
Fr ~
~ ..' -="';;''~1~>:~\
A : __ • Li \ I \ \ \
~ . rr~(I ~.,
B-Terminal- Green
C-Terminal - Dark Blue

_ ".: .' ..
• ~/"""
_.~7~~ "' \
D-Terminal - Dark BluelWhite
E-Terminal - Dark BlueNeliow

. ". -._o~
. ~ ..
I. .·. ~-~'. ' ~

rr:1'~J!.'..'.-' -
F-Terminal - Pink/Red
G-Terminal - Pink/Black
H-Terminal - Pink/Gray
'.~
';f. ':
-.:: '-~. \>. ..,1;
Six-Pin Connector
~ 8' -~"if
. 1',;.
. ll . ...
:t°\'
~,-
. \, '" ,.--' -::, j
A-Terminal - Orange
",
....
" • ..J
B-Terminal - Light GreenIWhite
C-Terminal - Light Green
D-Terminal - Yellow
E-Terminal - Blank
F-Terminal - Blank
Left Switch Handle
Eight-Pin Connector
A-Terminal - Yellow
B-Terminal - Green
C-Terminal - Brown
D-Terminal - Orange
E-Terminal - Orange/Blue
F-Terminal - Brown/Red
G-Terminal - Brown/Black
H-Terminal - Brown/Green
Three-Pin Connector
A-Terminal - OrangeIWhite
B-Terminal - Yellow/Red
C-Terminal - Yellow/Green
Two-Pin Connector
A-Terminal- Purple
B-Terminal - Purple/Blue
Two-Pin Connector (Water Kit)
A-Terminal - White
B-Terminal - Blue
963 Bobcat Loader

SWITCH HAN DLE (Cont'd)
A
Roll the pistol grip handle cover (Item 1) [A] down.
Using a small screwdriver, lift the handle tabs (Item 2) [A] :~ '"
and slightly rotate the switch handle. ,,~'it '
1-'
~.
"\i.
t
.$'
Pull the switch handle and wiring harness assembly (Item

1) [B] from the steering lever. B
Installation: When installing the switch handle and

wiring harness assembly into the steering handle, route
the harness (Item 1) [C] to assure proper return of the
control handle to neutral position.
963 Bobcat Loader

A.H.C. HANDLE
A
Remove the handle control unit. (See Page 10-17.)
Remove the switch handle. (See Page 10-21.)
Remove the rubber handle cover (Item 1) [A] from the
handle.
Using a small screwdriver, hold the handle spacer (Item

1) [B] and remove the allen head screws (Item 2) [B] from I8
the handle assembly.
N-17385
963 Bobcat Loader

-10-24- Service Manua'
A.H.C. HANDLE (Cont'd)

A
Remove the handle sleeve (Item 1) [A] and bushings
(Item 2) [A] from the handle.
Check all parts for wear and replace as needed.
~
N-17394
Check the mounting bolt (Item 1) [B] that connects the

handle to the handle control unit for wear, replace as IB
needed .
963 Bobcat Loader

A.H.C. STEERING LEVER
Remove the handle control unit. (See Page 10-17.)
Remove the switch handle from the steering lever. (See

Page 10-21.)
Remove the handle from the steering lever. (See Page

10-24.)
Loosen the two u-damps (Item 1) [A] nuts.
Remove the steering lever from the cross shaft and
control panel.
The steering lever (Item 1) [B] must be replace as a

complete unit.
The connector clip (Item 2) [B] can be replaced

separately from the steering lever.
Steering Lever Boot
Disconnect the switch handle harness connectors from

the loader wiring harness connectors . (See Page 10-22.)
Remove the connectors from the switch handle wiring

harness. (See Page 10-22.)
Loosen the two u-clamps (Item 1) [A] and remove the

steering lever.
Remove the four pop rivets from the boot retainer (Item
1) [C] and control panel.
Remove the steering lever boot.
963 Bobcat Loader

ACTUATORS

NOTE: For correction installation of the actuator,
mark all the wire connections (Item 1) [A]
before disconnecting them.
Remove the steering levers/control panel assembly. (See
Page 3-1 .)
Disconnect the wiring harness connectors (Item 1) [A]

from the actuator connectors.
Remove the pins (Item 1) [B] from the actuator couplers.

control valve mounting plate and actuator mounting
block.
Installation: Tighten the mounting bolts to 30 ft .-Ibs.

(40 ,7 Nm) torque.
Remove the actuators and mounting block assembly.
963 Bobcat Loader

ACTUATORS (Cont'd)
Remove the two mounting bolts (Item 1) [A] from the

actuator mounting block.
Installation: Tighten the mount bolts to 10-12 ft.-Ibs .

(13,5-16 ,2 Nm) torque .
NOTE: There must be a small amount of free play

between the actuators and the mount block
when properly installed.
N-17737
Check the mounting block (Item 1) [B] and bolts for wear
and replace as needed .
.:', ...
N-17738
Remove the rubber boot (Item 1) [C] and tie strap from the
actuator shaft.
Check the rubber boot (Item 1) [C] for wear and replace
as needed.
Check the actuator wiring harness connector (Item 1) [0]

and replace if broken .
Installation: Install the wires into the connector as listed

below. The terminal numbers are written on the back of
the connector (Item 2) [0].
Lift and Tilt Actuator

1 - Terminal-Black-Larger diameter wire (16 gauge)
2 - Terminal-Green-Larger diameter wire (16 gauge)
3 - Terminal-Red/Green-Larger diameter wire
(16 gauge)
4 - Terminal-Open
5 - Terminal-Red-Smaller diameter wire (18 gauge)
6 - Terminal-Open
7 - Terminal-Open
8 - Terminal-Black-Smaller diameter wire (18 gauge)
963 Bobcat Loader

BICSTM VALVE
Lift Arm By-Pass Orifice
To remove , replace or check the orifice for the lift arm

by-pass function , use the following procedure.
.'
A WARNING

unless the lift arms are secured by an approved ~: '.: :t,
lift arm support device. Failure to use an N-17S06
or death. W-20S9-oS98
A DANGER
AVOID DEATH
• Disoonnecting or loosening any hydraulic
tubeline, hose, fitting, component or a part
failure cOIn COIuse lift arms 10 aop .
• Keep out o"f Ilie Blea when lift arms are

raised unl,,~s supported by an approved
1it1 ann support. Replace il damaged. !>:}I4S SW 9$ 5711343
Remove the fitting (Item 1) [A] from the BICS valve.
The orifice (Item 1) [B] is slotted so a flat blade

screwdriver can be used to remove it.
Remove the orifice from the valve.
....
~'''::
~~
"
Clean and inspect the orifice (Item 1) [C]. Replace as

needed.
'" . 'j' "
" .~\
" ...,
,:~I
.,
;,.
P-13727
963 Bobcat Loader

81CSTM VALVE (Cont'd)
Check Valve
A
Loosen and remove the check valve (Item 1) [A] .
Installation: Tighten the check valve to 20 ft.-Ibs. (27

Nm) torque.
Inspect and clean the screen (Item 1) [8] on the end of

the check valve . I B
Inspect the check valve for damage. Replace the O-rings ~
and back-up washers before installation.
Replace the check valve if necessary.
Lock Valve
There are two lock valves on the BICS valve, lift lock valve
(Item 2) [A] and tilt lock valve (Item 3) [A].
P-13728
Loosen and remove the lock valve (Item 1) [C] from the
valve. IC
Installation: Tighten the lock valve(s) to 25 ft.-Ibs. (34
Nm) torque. Replace all the O-rings and back-up
washers before installation .
Inspect the lock valve(s) for damage .
Replace the lock valve(s) if necessary.
'0
N-17295
963 Bobcat Loader

BICSTM Valve Solenoid
Loosen the mounting nut (Item 1) [A] at the solenoid.
Remove the mounting nut (Item 1) [B], O-ring (Item 2)

[B] , coil (Item 3) [B], O-ring (Item 4) [B].
B
Remove the solenoid cartridge (Item 5) [B] from the
valve .
~
~ .·.. AO
Installation: Tighten the cartridge to 20 ft.-Ibs. (27 Nm)
5 '
torque.
:
N-17298
c
»
Inspect the solenoid cartridge (Item 1) [C] for damage.
installation.
Replace the solenoid cartridge as needed.
N-17299
963 Bobcat Loader

A
Loosen the six mounting bolts (Item 1) [A] at the BICS
valve.
Remove the mounting bolts (Item 1) [A].
N-17507
Remove the BICS valve assembly (Item 1) [B] from the

top of the control valve (Item 2) [B].
Installation: Always replace the four large O-rings (Item

3) [B] and small O-ring (Item 4) [B].
Installation: The chart below lists the correct torque

specifications and tightening sequence [C] when
reinstalling the BICSTM valve assembly to the hydraulic
control valve . Thoroughly clean and dry bolts and threads
in valve. Use liquid adhesive LOCTITE #242 .
Step Torque *Sequence

1 110-130 in.-Ibs.
(12,4-14,7 Nm)
2 190-210 in .-Ibs.
(21 ,5-23,7 Nm) 1, 2, 3, 4, 5 & 6
3* 190-210 in .-Ibs.
(21 ,5-23,7 Nm)
*Torque must be 190-210 in .-Ibs . (21,5-23,7 Nm) for

*
every bolt or the complete sequence must be repeated.
963 Bobcat Loader

A WARNING

A DANGER
AVOID DEATH
• Disconnecting or loosening ony hydraulic
tuboone, hose, fitting, component or a part
failure can cause lift arms 10 drop .
• K Bep out of Ilia area when lift arms are
raised mle.s support9d by an approved
liN ann support. Replace it damaged. ~.,
Stop the engine. Raise the seat bar.
Remove the steering levers/control panel assembly. (See
Page 3-1.)
Remove the advance hand control actuators. (See Page
10-27.)
Disconnect the wire harness connectors (Item 1) [A] from

the auxiliary solenoid connectors.
Disconnect the wire (Item 2) [A] from the charge pressure

sender at the control valve.
Disconnect the hose (Item 1) [8] which goes to the two

speed/brake block.
Disconnect and remove the hose (Item 2) [8] from the

control valve and lift lock valve.
Disconnect the hose (Item 3) [8] which comes from the
hydrostatic controller.
Disconnect and remove the tubeline (Item 1) [e].
Disconnect and remove the tubeline (Item 2) [el
Disconnect the hose (Item 3) [e] which goes to the
hydraulic reservoir.
Disconnect and remove the charge tubeline (Item 1) [0]
at the main relief valve.
963 Bobcat Loader

NOTE: Install caps on all control valve fittings when

disconnecting tubelines to protect the
Flare-O fitting O-rings.
Disconnect the both auxiliary tubelines (Item 1) [A] from

the control valve fittings .
Disconnect both tilt hoses (Item 2) [A] from the control

valve.
Disconnect the lift hose (Item 1) [B] from the control

valve.
Disconnect the lift tubeline (Items 2 & 3) [B] from the

control valve tee fitting.
Disconnect the solenoid connector (Item 4) [B] from the

wiring harness.
Disconnect the inlet hose (Item 1) [C] at the bottom of the

control valve.
Support the control valve with a chain hoist.
NOTE: Control valve/mounting plate assembly is

shown removed for photo clarity in Fig. [D].
Remove the two control valve mounting bolts (Item 1) [D].
Installation: Tighten the two 3/8 x 1-1/4 inch mounting

bolts to 30 ft.-Ibs . (41 Nm) torque.
Remove the control valve from the loader.
963 Bobcat Loader

Mounting Plate
Remove the two mounting bolts (Item 1) [0] to remove the

actuator/control valve mounting plate (Item 2) [0] from
the loader frame .
963 Bobcat Loader

HYDRAULIC CONTROL VALVE (Cont'd) H3 H1
Identification Chart
Item 963 A.H.C. Loader
A1 Lift Cylinder Base End
A2 Tilt Cylinder Base End

I
A3 Auxiliary Hydraulics
B1 Lift Cylinder Rod End I 1---L---.i' D2
B2 Tilt Cylinder Rod End D1

B3 Auxiliary Hydraulics
C1 Load Check Valve/Lift Function I
C2 Load Check Valve/Tilt Function MC-02430
C3 Orificed Load Check Valve/Auxiliary Function
C4 Outlet Fluid Flow

I
D1 Lift Spool Centering Spring
,
D2 Tilt Spool Centering Spring
D3 Auxiliary Spool/Centering Springs I
E1 Port Relief Valve - 3500 PSI
E2 Anti-Cavitation/Port Relief Valve - 2500 PSI
F1 Anti-Cavitation Valve
F2 Port Relief Valve
G1 Lift Spool End
G2 Tilt Spool End
G3 Auxiliary Spool/Centering Springs
H2 Plug/Port Relief (Optional) - 2500 PSI
MR Main Relief Valve - Dual Stage
963 Bobcat Loader

HYDRAULIC CONTROL VALVE (Cont 'd)

A
Remove the BICS valve assembly from the control valve.
(See Page 10-32.)
Remove the four large O-rings (Item 1) [A] and small

O-ring (Item 2) [A]. Always replace these O-rings before
installing the BICS valve assembly. ~. { ~;
t
.a ,
The anti--cavitation valve, port relief valves and plugs are

at different locations in the control valve. Refer to Control
Valve Identification Chart for the correct location of the
parts. (See Page 10-36.)
N- 17509
IMPORTANT
When making repairs on hydrostatic and

hydraulic systems, clean the work area before
the system.
1-2003--0284
Mark each valve section, spool and related parts so that

they will be returned to its original valve location during
assembly.
N-17510
Load Check Valve
Loosen the load check valve plug (Item 1) [8].
Installation: Always use new O-ring. Tighten the plug to
35-40 ft.-Ibs. (47-54 Nm) torque .
Remove the load check plug (Item 1) [C].
Remove the spring (Item 2) [C] and poppet (Item 3) [C].
The auxiliary section (Item 2) [B] uses an orifice load

check poppet.
N-1 7511
963 Bobcat Loader

Main Relief Valve

A
Loosen the main relief valve (Item 1) [A].
Installation: Tighten the main relief to 35-40 ft.-Ibs ..

(47-54 Nm) torque.
N-1751 2
Remove the main relief valve (Item 1) [B] from the control IB
valve.
,! ' ~
' I"~
y
?
Remove the fitting (Item 1) [C] , orifice (Item 2) [C] , and

c
second stage housing (Item 3) [C] from the main relief
valve housing.
Installation: Always use new O-rings. sleeve, and glide

G? . . .
~~
.. ...
ring.
NOTE: See Page 2-1 for setting the pressure at the

main relief valve after the control valve is
installed in the loader.
N-15681
963 Bobcat Loader

-10--38- Service Manual
Port Relief Valve (Lift)
Loosen the port relief valve (Item 1) [A] (Port E1).
Installation : Tighten port relief to 35-40 ft.-Ibs . (47-54

Nm) torque.
Remove the port relief valve from the control valve [8].
Remove the O-rings and back-up washer from the port

relief valve.

washers.
Anti-Cavitation/Port Relief Valve
Loosen the anti-cavitation valve/port relief (Item 2) [A]
(Port E2).
Installation: Tighten cartridge to 35-40 ft.-Ibs. (47- 54

Nm) torque. N-17284
Remove the anti-cavitation valve/port relief from the

control valve [C]. I C
Remove the O-rings and back-up washer from the
anti-cavitation/port relief .

washers.
N-17285
963 Bobcat Loader

Port Relief Valve (Tilt)
Loosen the port relief valve (Item 1) [A] (Pon F2).
Installation: lighten the anti-cavitation/port relief valve
to 35-40 ft.-Ibs. (47-54 Nm) torque.
N-17514
Remove the anti-cavitation/port relief from the control

valve [8).
B
Remove the O-rings from the anti-cavitation/port relief
valve.

washers.
Anti-Cavitation Valve
Loosen the anti-cavitation valve (Item 2) [A] (Pon F1).
c
Installation: lighten the anti-cavitation valve to 35-40
Remove the anti-cavitation valve from the control valve

[C).
Remove the O-rings from the anti-cavitation valve.

washers.
N-17277
963 Bobcat Loader

-10-40- Service Manua'
Rubber Boot
Remove the two screws (Item 1) [A] on the rubber boot

retainer.

(10,2-11,3 Nm) torque.
.i'"
',.'
Remove the rubber boot (Item 1) [B) and retainer (Item

2) [B).
Remove the seal retainer (Item 3) [B) and O-ring (Item

4) [B).
'--~
~'
N-17516
963 Bobcat Loader

Lift and Tilt Spool
Remove the rubber boot from the other end of the spool.
(See Page 10--41 .)
Remove the two screws (Item 1) [A] from the end cap (lift
or tilt) .
0.~
· ..:.
(10,2-11,3 Nm) torque.
-;''\.
Remove the end cap (Item 2) [A] (lift or tilt) .
~ -
N-17286
Remove the spool (Item 1) [B], centering spring, back-up

washer and seal from the control valve.
At the other end of the spool bore , remove the spool seal
(Item 1) [C] and O-ring (Item 2) [C].
NOTE: To install new spool seal (Item 2) [B], remove

the centering spring or See Page 10-48 for
seal rep lacement without removing the
centering spring.
Installation: If both spools are removed at the same

time, mark the lift spool (Item 1) [0] and tilt spool (Item 2) I0
[0] so they will be put in their original bore.
963 Bobcat Loader

Lift and Tilt Spool (Cont'd)

A
procedure;
..:
MEL1285 - Spring Tool
,.
.,t"".
Put the linkage end of the spool in the vice [A].
Install the spring tool (Item 1) [A] over the centering
spring.
?!
NOTE: Be careful when removing the bolt from the

centering spring, because there is spring :f
pressure.
Loosen the bolt (Item 2) [A] holding the centering spring
to the spool .
Installation: Tighten the bolt to 90--100 in .-Ibs.

(10,2-11,3 Nm) torque.
Remove the adapter (Item 1) [B], spring cap (Item 2) [B], IB

spring (Item 3) [B], and washer (Item 4) [B] from the
spool.
N-17290
963 Bobcat Loader

Lift and Tilt Spool (Cont'd)
Lift Spool Only: To remove the plastic plug from the lift
spool :
Make a center point in the plug using a 1/16 inch drill.
Drill a hole all the way through the plug using a 7/64 inch
tap drill.
Plastic --.1 1"
Turn a 6-32 tap into the plug. Pull the tap and plug out of Plug
the spool. Be careful, do not break the tap . 0.60 "
(15,2 mm)
Clean all the debris from the inside of the spool bore. . .-.----=--~
MC-D2421
Installation: Slide the O-ring over the nipple on the
plastic plug . Install the plastic plug in the spool. Install the
bolt so that the end of the plug is about 0.60 inch (15,2 IB
mm) from the end of the spool [A).
NOTE: During installation of the centering spring to

the spool, make sure the adapter is centered ~ -
in the washer hole (Item 1) [B]. If the adapter 7/[ ,..- - -
is not centered, it can cause the bolt to break
during installation.
!, f .t--p I
Inspection
:p -/
Check the spools for wear or scratches.
Check that the spools are not loose in their bore.
II '
Check that the centering springs are not broken .
N-17260
Check that the load check valve seats are not worn .
Check the load check poppet for damage.
Check the rubber boots and retainers that they are not
worn or damage.
Replace all parts as needed .
963 Bobcat Loader

Auxiliary Spool
A
Remove the end cap screws (Item 1) [A] & [8].
Installation : Tighten the screws to 90-100 in.-Ibs.

(10,2-11 ,3 Nm) torque.
1 .1
M
N-15701
Remove the end cap (Item 2) [A] & [8] , O-ring (Item 3)
[A] & [6].
Remove the large spring (Item 4) [A] & [8] and small
o
3; .t.: . .,.I?. '.
spring (Item 5) [A] & [6].
Remove the spring retainer (Item 6) [A] & [8].

..," .
J " r?JJo
.. , ~ . ",1 .
~J@
: '~
.. 4 ',
7) 0 ~J' ' ' '
N-17264
Remove the auxiliary spool (Item 1) [C].
N-17263
963 Bobcat Loader

Auxiliary Electrical Solenoid
Remove the nut (Item 1) [A] from the end of the solenoid.
Installation: Tighten the nut to 9-12 in.-Ibs. (1,02-1,36
Nm) torque.
N-17493
Remove the metal housing (Item 1) [B], coil (Item 2) [B] ,
and end plate (Item 3) [B].
Remove the electric solenoid valve (Item 4) [8].

B
Installation: Tighten the solenoid valve to 96-144
in .-Ibs. (10,8-16,3 Nm) torque.
Installation: Always install new O-rings and back-up

washers on the solenoid valve [C]. IC I;
N-17269
963 Bobcat Loader

- 10-46- Service Manual
H-Port Auxiliary Section
Loosen the plug (Item 1) [A].
Installation: Tighten the plug to 35-40 tt.-Ibs. (47-54
Nm) torque.
'. N-17495
Remove the plug from the control valve [8]. B
'ii'llf~~
. ~~t
N-17266
Depending on the application of the auxiliaries, the control

valve may be equipped with a port relief valve (Item 1) [C).
N-17494
If so equipped, remove the port relief from the control

valve [0]. I0
Installation: Replace the O-rings and back-up washers.
Tighten the port relief valve 35-40 ft.-Ibs. (47-54 Nm)
torque.
N-17284
963 Bobcat Loader

Spool Seal Installation
To install new spool seals when the centering spring is not

removed from the spool, use the following procedure:
Check the seal surface area in the control valve (Item 1)

[A] for rust, corrosion, scratches, etc . Correct any
irregularities before continuing.
Put plastic material (Example: Plastic food wrap) on the

valve spool [B] . I 8
Put clean oil on the spool seal. Install the spool seal (Item
1) [8] on the spool. Be careful not to damage the seal on
the sharp edges.
NOTE: Seal must be installed with lip face toward

valve body. Lip face has largest outside
diameter.
Remove the plastic material.
CD-15080
Install the linkage end spool seal [C] into the control valve
(Item 1) [0].
Install the O-ring (Item 2) [0].
Install the spool into the control valve.
Be careful not to damage the spool seal.
Continue assembling the control valve.
963 Bobcat Loader

~~ bobcat
MELROE
963-1
INGERSOLL-RAND 0/ i,;'
®
Revision Number
8 June 1998
SERVICE MANUAL
Date
REVISION
ROUTE TO
ATTENTION
AFFECTING:
Product BOBCAT LOADER
PARTS MAN AGE R 0
SERVICE MANAGER [X]
Model 963 SALES MANAGER 0
Manual No. 6724545 (11-97)
NOTICE Insert This Sheet With The Appropriate Manual For Future Reference.
Take out the pages shown and put in the revised pages as follows:
TAKE OUT PUTIN
1-3 thru 1-4 1-3 thru 1-4

1-7 thru 1-8 1-7 thru 1-8
1-17 thru 1-18 1-17 thru 1-18
2-1 thru 2-4 2-1 thru 2-4

2-31 thru 2-32 2-31 thru 2-32
3-1 , thru3-2 3-1 thru 3-2

3-7 thru 3-8 3-7 thru 3-8
3-17 thru 3-18 3-17 thru 3-18
3-31 thru 3-32 3-31 thru3-32
3-57 thru 3-58 3-57 thru 3-58
4-7 thru 4-8 4-7 thru 4-8
5-23 thru 5-26 5-23 thru 5-26
6-5 thru 6-6 6-5 thru 6-6
7-3 thru 7-4 7-3 thru 7-4

7-33 thru 7-38 7-33 thru 7-38
7-51 thru 7-56 7-51 thru 7-56
7-61 thru 7-62 7-61 thru 7-62
7-73 thru 7-74 7-73 thru 7-74
8-3 thru 8-4 8-3 thru 8-4
9-1 thru 9-12 9-1 thru 9-20

MELROE
INGERSOLL-RAND ~ bobcat "
'l?./ ~
963-2
Revision Number
13 October 1998
SERVICE MANUAL
Date
REVISION
ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER D
SE RVICE MANAGER [&I
Model 963 SALES MANAGER D
Manual No. 6724545 (11-97)
Take out the pages shown and put in the revised and/or added pages as follows :
TAKE OUT
PUT IN
MAINTENANCE SAFETY PAGE (BICS 9-96)

MAINTEt\IANCE SAFETY PAGE (MSW01-0698)
ALPHABETICAL INDEX
ALPHABETICAL INDEX
2--49 thru 2-50

2--49 thru 2-50
3-1 thru 3-66

3-1 thru 3-70
4-5 thru 4-6

4-5 thru 4-6
7-17thru7-18
7-17 thru 7-18
8-1 thru 8-20

8-1 thru 8-28
MElROE
INGERSOLL-RAND ~~ bobcat
0/ it;'
®
963-3
Revision Number
4 December 1998
SERVICE MANUAL
Date
REVISION
ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER 0
SERVICE MANAGER [].I
Model 963 SALES MANAGER 0
Manual No. 6724545(11-97}
Take out the pages shown and put in the revised and/or added pages as follows:
TAKE OUT PUTIN
ALPHABETICAL INDEX ALPHABETICAL INDEX
3-59 thru 3-62 3-59 thru 3-62
Remove ALL Pages Of The All NEW Pages Of

963 BICS w , WIRING DIAGRAMS, WIRING SCHEMATICS CONTENTS and 8 Schematics
INDEXES and LEGENDS 963
(Printed November 1997) (Printed December 1998)
8-25 thru 8-26 8-25 thru 8-26
NOTE: Put the new Section 10 for Advanced Hand Control System and Wiring Schematics in the Service Manual
after Specifications Section (Nine).
ADVANCED HAND CONTROL SYSTEM (A.H .C.)
10-1 thru 10-48
WIRING SCHEMATIC CONTENTS and
2 Schematics With Advanced Hand Control Option
963
(Printed December 1998)
MELROE
INGERSOLL-RAND ~
., bobcat®
963-4
Revision Number
19 March 1999
SERVICE MANUAL
Date
REVISION
ROUTE TO
ATTENTION
AFFECTING:
PARTS MANAGER D
SERVICE MANAGER [XJ
Model 963 SALES MANAGER D
Manual No. 6724545 (11-97)
Take out the pages shown and put in the revised and/or added pages as follows:
TAKE OUT
PUT IN
MAINTENANCE SAFETY (MSW01-G698)

MAINTENANCE SAFETY (MSW01-G299)
ALPHABETICAL INDEX
ALPHABETICAL INDEX
i thru x
i thru viii
1-1 th ru 1--6
1-1 thru 1--6
1-11 thru 1-12

1-11 thru 1-12
1-27 thru 1-30

1-27 thru 1-30
Glossary of Hydraulic/Hxdrostatic
Symbols for Loader (6/2/98)
ALL HYDRAULIC/HYDROSTATIC HYDRAULIC/HYDROSTATIC
SCHEMATICS & LEGENDS SCHEMATICS & LEGENDS
(Printed November 1997) (Printed March 1999)
2-3 thru 2--4 2-3 thru 2--4
2-27 thru 2-32 2-27 thru 2-32
2-39 thru 2-42 2-39 thru 2--42
2-51 thru 2-56 2-51 thru 2-56
2--61 thru 2--64 2--61 thru 2--64
3-1 thru 3-20 3-1 thru 3-20
3-33 thru 3-34 3-33 thru 3-34
4-21 thru 4-30 4-21 thu 4-30
5-23 thru 5-24 5-23 thru 5-24
6-3 thru 6-4 6-3 thru 6--4
7-41 thru7-42 7--41 thru 7--42
8-1 thru 8-28 8-1 thru 8-28
9-3 thru 9-4 9-3 thru 9--4
10-3 thru 10-8 10-3 thru 10-8
10-21 thru 10-22 10-21 thru 10-22
10-29 thru 10-34 10-29 thru 10-34
10-45 thru 10-46 10-45 thru 10-46

Bobcat 963 BICS SM 04670

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Bobcat 963 BICS SM 04670

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Service

EQUIPPED WITH MELROE

8-10731 8-12365 8-7469

8-11799 8-15231 8-15280

ACTUATORS . ............ . ... . .. .. . ....... . . 10-1

ACTUATOR VOLTAGE TEST . ..... . . . . .. .... .. 10-1

A.H.C . COMPONENTS . .. .......... . . .. ...... 10-1

A.H .C'/PWM CONTROLLER ... . .. ... . .. ...... 10-1

ENGINE COOLER . .. . . ... . . ........ . ... .... .. . 7-1

A.H .C. HANDLE .. .. .. .. ...... . . .. .... . . .. ... 10-1

A.H.C . STEERING LEVER .. . . . . . . . .... . . .. . .. 10-1

AIR CLEANER HOUSING .. . .. . ... . . . .. . . . ... .. 7-1

AIR CLEANER SERVICE . . . . . . .... .. ...... . . . . 1-1

ALTERNATOR .. ... ...... . . . .. . .. ... . . ........ 6-1

ALTERNATOR BELT .. .... ... . . ..... . . . ..... .. 1- 1

AXLE SEAL .. ...... . . .. . . ... .. ....... . . ...... 4-1

EXHAUST MANIFOLD .. ...... . . .............. .. 7-1

AXLE, BEARINGS AND SPROCKET ...... . . . ... 4-1

FAN DRIVE TENSIOt\1 PULLEY .. . . . ....... . ..... 7-1

BATTERY .... .. . . .. . ..... . . .... .. . ...... . ... . 6-1

BICSTM .. . ...... .. ...... .. . .. ...... . ... .. 8-1 , 10-1

BICSTM SYSTEM CONTROLLER .... . .. . . . ..... . 8-1

BICSTM VALVE .. . . .... . . ... .. .... .. . . .. .. 2-1,10-1

FRONT FUEL TANK .. .. . ........ . .. ...... . . .... 5-1

BOB-TACH . ... ........... . . . . . ...... .. . ... .. 5-1

BOSS DIAGNOSTIC TOOL ........... . . ... . . .. 8-1

BOSS INSTRUMENT PANEL ... . .. ..... ... ..... 8-1

BOSS UNIT .. . . . . . .... ..... . . . ..... . . ... . . . . . 8-1

BRAKEfTWO SPEED BLOCK . . .... . . .. ... .. . . . 4-1

BUCKET POSITION VALVE ........ . . .... . . . . . . 2-1

HANDLE CONTROL UNIT . ................ . .. . 10-1

CAMSHAFT AND TAPPETS ... ... . ...... . ...... 7-1

HANDLE CONTROL UNIT TEST . . . . .. .... . . .... 10- 1

CHAINCASE FLUID ... . ...... . . .. ...... . . .. . . . 4-1

COOLANT RECOVERY TANK .. ..... . . ... ... .. . 7-1

COOLING SYSTEM . . . .. ... ...... .... ..... . . . . 7-1

CONTROL PANEL . ....... ... .. ... . . . . ...... .. 3-1

CONTROL PEDALS . . ...... .... ...... .. ....... 2-1

CONTROL PEDALS MOUNTING PANEL . . .. .... 2-1

CRANKSHAFT AND BEARINGS ... ...... ... . . .. 7-1

HYDRAULIC SYSTEM INFORMATION ... . .... . .. 2-1

CYLINDER HEAD . . .. . ... ....... . . . . . .. . ...... 7-1

HYDROSTATIC CONTROLLER .... ..... . .. . . . . .. 3-1

DECIMAL & MILLIMETER EQUiVALENTS . .. . . . . 9-1

DRIVE BELT .... ... . ... ... .. .... ......... .. .. 3-1

DRIVE BELT IDLER PULLEY . .. .. .... .......... 3-1

DRIVE BELT SHIELD .. ....... ...... ...... . .... 3-1

DRIVE BELT TENSIONER PULLEY ...... .. .. . .. 3-1

INTAKE MAINIFOLD .... ...... . . . . ... ... .. ..... 7-1

DRIVE CHAINS ........ . . . ... .. . . . ....... .. ... 4-1

LIFT ARMS . . ... ... ...... . . .. . . .. .... ...... .. .. 5-1

LIFT ARM BY-PASS CONTROL VALVE . .... ... .. 2-1

LIFT ARM SUPPORT DEVICE . ........ .. ..... . . . 1-1

LIFT CYLINDER(S) . ......... ... .. . . . ... . . . ..... 2-1

LIFTING AND BLOCKING THE LOADER .. . ... . . . 1-1

LOADER SPECIFICATIONS ....... ....... . .. .. .. 9-1

LOADER TORQUE ..... . .. ..... . . . ... ... ....... 9-1

LUBRICATING THE LOADER ..... . .. ... ..... . .. 1-1

LUBRICATION SySTEM .... . ... .. .. . ....... . . . . 7-1

MAIN RELIEF VALVE . ....... ... .... ... . . . ..... . 2-1

BICS--BOBCAT INTERLOCK CONTROL SYSTEM

Cont'd On Next Page

PARKING BRAKE 0 0 0 0 0 •• 0 0 •• 0 0 0 0 0 0 0 0 • • 0 • 0 0 • 0 0 0 4-1