PDF Service Manual Bobcat 963 Loader - 4 MB

The official service manual for the Bobcat 963 Loader is the ultimate guide for maintenance and repair.
This detailed manual contains everything you need to know, from routine servicing to complex overhaul procedures.
Technicians rely on these instructions for accurate diagnostics, troubleshooting, and repairs, ensuring the loader operates at peak efficiency.
Keep your Bobcat 963 in top working condition with this essential resource.
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--- Page 1 ---
Service
                                                                             Manual


                                                                                                                          Dealer Copy -- Not for Resale


Doosan purchased Bobcat Company from Ingersoll-Rand Company in
2007. Any reference to Ingersoll-Rand Company or use of trademarks,
service marks, logos, or other proprietary identifying marks belonging
to Ingersoll-Rand Company in this manual is historical or nominative
in nature, and is not meant to suggest a current affiliation between
Ingersoll-Rand Company and Bobcat Company or the products of
either.


    EQUIPPED฀WITH
  BOBCAT฀INTERLOCK
CONTROL฀SYSTEM฀(BICSTM)                                           6724545฀฀(6-12)   Printed฀in฀U.S.A.   ฀Melroe฀Company฀1997
   1 of 502

--- Page 3 ---
SAFETY฀INSTRUCTIONS


  Instructions฀are฀necessary฀before฀operating฀or฀servicing฀machine.฀Read฀and฀understand฀the฀Operation฀&
  Maintenance฀Manual,฀Handbook฀and฀signs฀(decals)฀on฀machine.฀Follow฀warnings฀and฀instructions฀in฀the
  manuals฀ when฀making฀repairs,฀adjustments฀or฀servicing.฀Check฀for฀correct฀function฀after฀adjustments,
  repairs฀or฀service.฀Untrained฀operators฀and฀failure฀to฀follow฀instructions฀can฀cause฀injury฀or฀death.
                                                                                                          W–2003–0299


The฀following฀publications฀provide฀information฀on฀the฀safe฀use฀and฀maintenance฀of฀the฀loader฀and฀attachments:฀

• The฀Delivery฀Report฀is฀used฀to฀assure฀that฀complete฀instructions฀have฀been฀given฀to฀
                                                                                    the฀new฀owner฀and฀that฀the฀machine
  is฀in฀safe฀operating฀condition.฀

• The฀ Operation฀&฀Maintenance฀Manual฀delivered฀with฀the฀loader฀gives฀operating฀information฀as฀well฀as฀routin        e
  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฀yo ur
  Bobcat฀dealer฀for฀more฀information฀on฀translated฀versions.

• The฀EMI฀Safety฀Manual฀(available฀in฀Spanish)฀delivered฀with฀the฀loader฀gives฀general฀safety฀information.
• The฀Service฀Manual฀and฀Parts฀Manual฀are฀available฀from฀your฀dealer฀for฀use฀by฀mechanics฀to฀do฀shop–type฀service฀and
  repair฀work.

• The฀Skid–Steer฀Loader฀Operator฀Training฀Course฀is฀available฀through฀your฀local฀dealer
                                                                                     .฀This฀course฀is฀intended฀to฀provide
  rules฀and฀practices฀for฀correct฀operation฀of฀the฀Bobcat฀loader.฀The฀course฀is฀available฀in฀English฀and฀Spanish฀version.

• The฀Service฀Safety฀Training฀Course฀is฀available฀from฀your฀Bobcat฀dealer.฀This฀course฀provides฀information฀for฀safe฀and
  correct฀service฀procedures฀for฀Bobcat฀Skid–Steer฀loaders.

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


                 Warnings฀ on฀the฀machine฀and฀in฀ the             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.                                                                         I–2019–0284
                                             W–2044–1285


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


                                                                                                               SI05–0299

                                                                                                    963฀Bobcat฀Loader
                                                           v                                           Service฀Manual

--- Page 4 ---
LIFT฀ARM฀SUPPORT฀DEVICE
                                                                        A

                                                                                              2
                                                                                    1

   Never฀work฀on฀a฀machine฀with฀the฀lift฀arms฀up
   unless฀ the฀lift฀arms฀are฀secured฀by฀a฀lift฀ arm
   support฀device.฀Failure฀to฀use฀an฀approved฀lift                                           P–10201
   arm฀support฀device฀can฀allow฀the฀lift฀arms฀or
   attachment฀to฀fall฀and฀cause฀injury฀or฀death.
                                               W–2059–0991

                                                                                              P–10200
Engaging฀The฀Lift฀Arm฀Support฀Device
Maintenance฀and฀service฀work฀can฀be฀done฀with฀the฀lift
arms฀lowered.
                                                                        B
                                                                                1
If฀the฀lift฀arms฀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                                    P–10198
bar฀lowered,฀start฀the฀engine.
Raise฀the฀lift฀arms,฀until฀the฀lift฀arm฀support฀device฀lowers
onto฀the฀lift฀cylinder฀rod฀[C].                                         C
Lower฀the฀lift฀arms฀slowly฀until฀the฀support฀device฀is฀held
between฀the฀lift฀arm฀and฀the฀lift฀cylinder.฀Stop฀the฀engine.
Raise฀the฀seat฀bar฀and฀move฀foot฀pedals฀until฀both฀pedals
lock.


                                                                                              P–10196


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


   Service฀lift฀arm฀support฀device฀if฀damaged฀or฀if
   parts฀ are฀missing.฀Using฀a฀damaged฀lift฀arm
   support฀ or฀with฀missing฀parts฀can฀cause฀lift                            1
   arms฀to฀drop฀causing฀injury฀or฀death.
                                               W–2271–1197
                                                                                              P–10191

                                                                                    963฀Bobcat฀Loader
Revised฀June฀98                                                 –1–7–                  Service฀Manual

--- Page 5 ---
ENGINE฀LUBRICATION฀SYSTEM
Checking฀Engine฀Oil
                                                                                                                A
Check฀the฀engine฀oil฀level฀every฀day฀before฀ starting฀the                                                           2
engine฀for฀the฀work฀shift.                                                                                                                        1
Open฀the฀rear฀door.฀Remove฀the฀dipstick฀(Item฀1)฀[A].
Keep฀the฀oil฀level฀between฀the฀marks฀on฀the฀dipstick฀[B].
Use฀ a฀good฀quality฀motor฀oil฀that฀meets฀API฀Service
Classification฀of฀CD,฀or฀better.
           RECOMMENDED฀SAE฀VISCOSITY฀NUMBER
C°                  (LUBRICATION฀OILS฀FOR฀DIESEL฀ENGINE฀CRANKCASE)
–40    –34    –29   –23   –18   –13   –7    –1    +4    +10   +15   +21   +27   +32   +38   +43 +49

                                                                                                                                                           N–16234
                                                                    SAE฀40W฀or฀20W–50

                          SAE฀10W–30
                                                                                                                B
                                       SAE฀15W–40

                                                                SAE฀30W                                                    Keep฀Oil
                                                                                                                        Level฀Between
             *฀SAE฀5W–30                                                                                                 These฀Marks
                                            SAE฀20W–20

                                SAE฀10W

  SYNTHETIC฀OIL฀Use฀recommendation฀from฀Synthetic฀Oil฀Mfgr.


–40 –30       –20   –10    0    +10   +20   +30   +40   +50   +60   +70   +80   +90   +100 +110 +120
 F°
                                                                                                                                                           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.                                         C
                                                                                                                                              1
Replacing฀The฀Oil฀And฀Filter
See฀the฀SERVICE SCHEDULE฀Page฀1–3฀for฀the฀service
interval฀for฀replacing฀the฀engine฀oil฀and฀filter.
Run฀the฀engine฀until฀it฀is฀at฀operating฀temperature.฀Stop
the฀engine.
Open฀the฀rear฀door.฀Remove฀the฀drain฀hose฀(Item฀1)฀[C]
from฀the฀storage฀position.฀Remove฀the฀drain฀plug฀from฀the                                                                               2
end฀of฀the฀hose.฀Drain฀the฀oil฀into฀a฀container.
Remove฀the฀oil฀filter฀(Item฀2)฀[C].
                                                                                                                                                           N–16235
Clean฀the฀filter฀housing฀surface.฀Put฀clean฀oil฀on฀the฀new
oil฀filter฀gasket.฀Install฀the฀new฀filter฀and฀hand฀tighten.
Install฀and฀tighten฀the฀drain฀plug.
Remove฀the฀filler฀cap฀(Item฀2)฀[A].
Fill฀the฀engine฀crankcase฀with฀oil฀of฀the฀correct฀grade฀and
viscosity.฀(See฀Oil฀Chart฀above.)฀Capacity฀is฀9฀qts.฀(8,5฀L.)
Start฀the฀engine฀and฀let฀it฀run฀for฀several฀minutes.                                                            Always฀clean฀up฀spilled฀fuel฀or฀oil.฀Keep฀heat,
                                                                                                                flames,฀ sparks฀or฀lighted฀tobacco฀away฀from
Stop฀the฀engine.                                                                                                fuel฀ and฀oil.฀Failure฀to฀   use฀ care฀ around
                                                                                                                combustibles฀ can฀cause฀explosion฀or฀fire
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

--- Page 6 ---
LUBRICATING฀THE฀LOADER฀(Cont’d)
                                                        A
Procedure฀(Cont’d)

  5. Rod฀End฀Tilt฀Cylinder฀(Both฀sides)฀[A].


  6. Bob–Tach฀Wedge฀(Both฀Sides)฀[A]                                  5


                                                            6


                                                                          P–10241


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


                                                                7
                                                                          P–10234


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

                                                                      1


                                                                          N–15868


                                                                963฀Bobcat฀Loader
                                               –1–27–              Service฀Manual

--- Page 8 ---
TILT฀CYLINDER฀(Cont’d)
                                                                      A       1
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.


                                                                                             N–15387


Removal฀And฀Installation
                                                                      B
Put฀the฀Bob–Tach฀on฀the฀floor฀[B].฀Stop฀the฀engine.                           1
Remove฀the฀snap฀ring฀and฀washer฀at฀the฀rod฀end฀of฀the
tilt฀cylinder฀(Item฀1)฀[B].


                                                                                             N–15368

Right Side
Mark฀the฀hoses฀for฀correct฀installation.
                                                                      C
                                                                                         2
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.
                                                                                     1


                                                                          1
                                                                                             N–15373

                                                                                  963฀Bobcat฀Loader
                                                              –2–9–                  Service฀Manual

--- Page 9 ---
TILT฀JUNCTION฀BLOCK
Removal฀And฀Installation
                                                                      A
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.                                          1
Pull฀up฀on฀the฀lift฀arm฀by–pass฀control฀and฀move฀ the฀lift
pedal฀to฀release฀the฀hydraulic฀pressure.
                                                                                                           N–15379

                                                     [B].
Remove฀the฀tilt฀junction฀block฀mounting฀bolts฀(Item฀1)฀
                                                                      B


                                                                                          1


                                                                                                           N–15375

Left Side
Disconnect฀ the฀tubelines฀(Item฀ 1)฀ [C]฀ from฀the฀front              C
hydraulic฀couplers.                                                               2
Remove฀the฀mounting฀bolts฀(Item฀2)฀[C]฀and฀remove฀the
mounting฀bracket฀and฀hydraulic฀couplers.
Remove฀the฀front฀step฀mounting฀bolts฀(Item฀3)฀ [C].


                                                                          1


                                                                              1       3


                                                                                          3


                                                                                                           N–15374

                                                                                                  963฀Bobcat฀Loader
                                                             –2–19–                                  Service฀Manual

--- Page 10 ---
BICS฀VALVE฀(Cont’d)
Check฀Valve
                                                                       A
Loosen฀and฀remove฀the฀check฀valve฀(Item฀1)฀[A].
Installation:฀ Tighten฀ the฀ check฀valve฀to฀20฀ft.–lbs.฀(27                         1
Nm)฀torque.


                                                                                        N–15667


Inspect฀and฀clean฀the฀screen฀(Item฀1)฀ [B]฀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.


                                                                           1

                                                                                         P–09057


                                                                               963฀Bobcat฀Loader
                                                              –2–29–              Service฀Manual

--- Page 11 ---
HYDRAULIC฀CONTROL฀VALVE฀(Cont’d)
Anti–Cavitation฀Valve
                                                                    A
Remove฀the฀anti–cavitation฀valve฀(Item฀1)฀ [A]฀from฀the
control฀valve฀for฀the฀lift฀section.
                                                                            1
Installation:฀ Tighten฀ anti–cavitation฀valve฀to฀35–40
ft.–lbs.฀(47–54฀Nm)฀torque.


                                                                                                 N–15687


Remove฀the฀anti–cavititation฀valve฀(Item฀1)฀[B]฀from฀the
control฀for฀the฀lift฀section.
                                                                    B


                                                                        1


                                                                                                 N–15688


Remove฀ the฀O–rings฀and฀back–up฀washer฀from฀
anti–cavitation฀valve฀[C].
                                                     the
                                                                    C           1          2
                                                                                                3    4

Installation:฀ Always฀use฀new฀O–rings฀and฀back–up
washers.

                                                                                                 E–01509

                                                                                1.฀Anti–Cavitation฀Valve
                                                                                2.฀O–ring
                                                                                3.฀Backup฀Washer
                                                                                4.฀O–ring


                                                                                                CD–15102


                                                                                      963฀Bobcat฀Loader
                                                           –2–39–                        Service฀Manual

--- Page 12 ---
HYDRAULIC฀CONTROL฀VALVE฀(Cont’d)
H–Port฀–฀Auxiliary฀Section
                                                                        A
Loosen฀the฀plug฀(Item฀1)฀[A].
Installation:฀ Tighten฀ the฀plug฀to฀ 35–40฀ ft.–lbs.฀ (47–54
Nm)฀torque.


                                                                                    1


                                                                                                 N–15739


Remove฀the฀plug฀from฀the฀control฀valve฀[B].                             B
Replace฀the฀O–ring.


                                                                                                 N–15740


Depending฀on฀the฀application฀of฀the฀
                                  auxiliaries,฀the฀control
                                                      [C]
valve฀may฀be฀equipped฀with฀a฀port฀relief฀valve฀(Item฀1)฀                C
(H฀port).


Remove฀the฀port฀relief฀valve฀(Item฀1)฀[D].
                                                                                1
Installation: Replace฀the฀O–rings฀and฀back–up฀washers.
Tighten฀the฀port฀relief฀valve฀to฀35–40฀ft.–lbs.฀(47–54฀Nm)
torque.                                                                                          N–15742


Inspection
                                                                        D
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.                                                            1
Replace฀the฀parts฀as฀needed.                                                                     N–15741

                                                                                        963฀Bobcat฀Loader
                                                               –2–49–                      Service฀Manual

--- Page 13 ---
HYDRAULIC฀PUMP฀(Cont’d)
                                                                   A
Disassembly฀And฀Assembly฀(Cont’d)
Remove฀the฀end฀housing฀(Item฀1)฀[A].


                                                                                                    1


                                                                                                N–15718

Remove฀the฀bearing฀housing฀(Item฀1)฀[B].
Remove฀the฀back–up฀seal/O–ring฀seal฀(Item฀2)฀[B]฀from
                                                                   B
the฀bearing฀housing.
Remove฀ the฀large฀O–ring฀(Item฀3)฀ [B]฀ from฀the฀ pump
housing.

                                                                       3       2                1


                                                                                                N–15719


Assembly:฀The฀O–ring฀and฀back–up฀washer฀(Item฀1)฀[C]
must฀be฀installed฀toward฀the฀pressure฀side฀of฀the฀pump.
                                                                   C
                                                                                   1


                                                                                                N–16079


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                                       4
the฀bearing฀housing.

                                                                   1


                                                                       2   3
                                                                                                N–15720

                                                                                       963฀Bobcat฀Loader
                                                          –2–59–                          Service฀Manual

--- Page 14 ---
CONTROL฀PEDALS฀MOUNTING฀PANEL฀(Cont’d)
Removal฀and฀Installation฀(Cont’d)
                                                                     A
Remove฀ the฀right฀side฀interlock฀ shield฀ mounting฀ nuts
(Item฀1)฀[A].                                                            3
                                                                                     1                   3
Installation: Tighten฀the฀shield฀mounting฀nuts฀to฀25–28
ft.–lbs.฀฀(34–38฀Nm)฀torque.
                                                                                                 2
Remove฀the฀interlock฀shield฀(Item฀2)฀[A].
Remove฀the฀right฀side฀mounting฀bolts฀(Item฀3)฀[A].                                           3
Remove฀the฀right฀side฀panel.
                                                                                                                 N–15475


Remove฀the฀mounting฀bolt฀(Item฀1)฀[B]฀from฀the฀left฀front
side฀panel฀(Item฀2)฀[B].
                                                                     B
Remove฀the฀left฀front฀panel.฀(Repeat฀the฀procedure฀for
right฀side฀panel.)                                                                                           2
                                                                                 1


                                                                                                                 N–15480


Remove฀the฀mounting฀bolts฀(Item฀1)฀[C]฀from฀the฀control
pedals฀mounting฀panel.                                               C
Remove฀ the฀control฀pedal฀mounting฀panel฀from฀the
loader.


                                                                             1           1           1

                                                                                                                 N–15484


                                                                                                 963฀Bobcat฀Loader
                                                            –2–69–                                  Service฀Manual

--- Page 15 ---
STEERING฀LEVERS฀(Cont’d)
                                                                     A
Disassembly฀And฀Assembly฀(Cont’d)
Remove฀the฀steering฀cross฀shaft฀mounting฀bolts฀(Item฀1)
[A]฀(both฀sides).
Installation: Tighten฀the฀mounting฀bolts฀to฀15–17฀ft.–lbs.
(21–23฀Nm)฀torque.                                                                                     1
Remove฀the฀steering฀cross฀shaft฀from฀the฀control฀panel.
Disassemble฀ the฀right฀and฀left฀steering฀shaft฀from฀the
cross฀shaft.


                                                                                                           N–15461

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
                                                                     B
steering฀shaft.


                                                                                                   1


                                                                                                           N–15465


Assembly:฀Check฀the฀nylon฀bushings฀(Item฀1)฀ [C]฀and
replace฀as฀needed.฀Make฀sure฀the฀wave฀washer฀(Item฀2)
                                                                     C               3
[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.


                                                                                 2       1
                                                                         1
                                                                                                           N–15466


Remove฀ the฀bolts฀and฀nuts฀(Item฀1)฀ [D]฀ if฀the฀neutral
centering฀bracket฀needs฀to฀be฀replaced.                              D
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.


                                                                             1

                                                                                             1

                                                                                                           N–15464

                                                                                                 963฀Bobcat฀Loader
Revised฀Oct.฀98                                              –3–9–                                  Service฀Manual

--- Page 16 ---
HYDROSTATIC฀CONTROLLER฀(Cont’d)
                                                                      A
Disassembly฀and฀Assembly฀(Cont’d)
Disassemble฀ the฀following฀parts,฀check฀for฀wear฀and
replace฀as฀needed฀[A]:
Item      Description
฀฀1       GUIDE                                                           4
฀฀2       PLUNGER                                                                 3           2
฀฀3       SPOOL/SPRING฀ ASSEMBLY                                                                       1
฀฀4       RETURN฀SPRING


                                                                                                           N–16061

Remove฀the฀locking฀discs฀(Item฀1)฀ [B]฀and฀disassemble
the฀following฀parts,฀check฀for฀wear฀and฀replace฀as฀needed
[B]:
                                                                      B
Item      Description
฀฀1       LOCKING฀DISC
฀฀2       SPRING฀GUIDE
฀฀3       CONTROL฀SPRING
฀฀4       SHIMS
฀฀5       SPOOL                                                                                                1
                                                                              5                   3
                                                                                                      2
                                                                                          4


                                                                                                           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.                                                                       1
                                   [C]฀first,฀then฀loosen฀the
If฀not,฀loosen฀the฀lock฀nut฀(Item฀2)฀
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.
                                                                              2
NOTE: Be฀careful฀when฀turning฀the฀set฀screws,฀they
      will฀break฀if฀the฀lock฀nut฀is฀not฀loose.

                                                                                                           N–16063


                                                                                                           N–16057

                                                                                                  963฀Bobcat฀Loader
Revised฀Oct.฀98                                              –3–19–                                  Service฀Manual

--- Page 17 ---
HYDROSTATIC฀MOTOR฀(Cont’d)
                                                                        A
Assembly


   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.                                                                       N–16106
                                             I–2003–0888


Install฀the฀center฀spring฀into฀the฀center฀pin.฀Put฀grease฀on
the฀washer฀and฀install฀it฀in฀the฀cylinder฀block฀center฀bore
                                                                        B
[A].
Install฀the฀cylinder฀block฀on฀the฀pistons฀[B].


                                                                                     N–16105

For฀easier฀installation฀of฀the฀piston/piston฀rings฀into฀the
cylinder฀block,฀come฀straight฀down฀into฀the฀cylinder฀block
bores฀[C].
                                                                        C
Make฀sure฀all฀the฀parts฀are฀fitted฀together฀correctly.


                                                                                      N–16115

                                                                            963฀Bobcat฀Loader
Revised฀Oct.฀98                                                –3–29–          Service฀Manual

--- Page 18 ---
HYDROSTATIC฀PUMP฀(Cont’d)
                                                                      A
Disassembly฀(Cont’d)
Remove฀the฀charge฀relief฀valve฀(Item฀1)฀[A],฀seat฀(Item฀2)
[A]฀and฀spring฀(Item฀3)฀[A]฀from฀the฀port฀block.


                                                                          3
                                                                                      1
                                                                                  2
                                                                                                   N–16134
Use฀ a฀punch฀and฀hammer฀to฀mark฀the฀charge฀         pump
housing฀and฀port฀block฀housing฀for฀correct฀installation฀of
the฀charge฀pump฀[B].                                                  B
Mark฀ the฀port฀block฀to฀the฀pump฀housing฀for฀correct
installation.


                                                                                                   N–16143

Remove฀ the฀four฀mounting฀bolts฀(Item฀1)฀ [C]฀ from฀the
charge฀pump.                                                          C

                                                                                                    1


                                                                              1


                                                                                                   N–16135


                              [D]฀from฀the฀port฀block.
Remove฀the฀charge฀pump฀(Item฀1)฀                                      D


                                                                              1

                                                                                                   N–16138

                                                                                          963฀Bobcat฀Loader
Revised฀Oct.฀98                                              –3–39–                          Service฀Manual

--- Page 19 ---
HYDROSTATIC฀PUMP฀(Cont’d)
                                                                      A
Assembly


                                                                                         2
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