Bobcat 463 Skid-Steer Loader Repair Service Manual – 6901177

(S/N: 52001100 & Above – S/N: 519911001 & Above)
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This workshop repair service manual PDF download for the 463 Bobcat Skid-Steer Loader has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

Bobcat Loader 463
S/N: 52001100 & Above
S/N: 519911001 & Above

TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATIONS
DELIVERY REPORT
BOBCAT SKID STEER LOADER IDENTIFICATION
SAFETY AND MAINTENANCE
HYDRAULIC SYSTEM
HYDROSTATIC SYSTEM
DRIVE SYSTEM
MAIN FRAME
ELECTRICAL SYSTEM & ANALYSIS
ENGINE SERVICE
SPECIFICATIONS
SERVICE MANUAL REVISIONS

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : 6901177 (3-06)
Total Pages : 366

This Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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MAINTENANCE SAFETY
ALPHABETICAL INDEX
CONTENTS
FOREWORD
SAFETY INSTRUCTIONS
Fire Prevention
SERIAL NUMBER LOCATIONS
Bobcat Loader Serial Number
Engine Serial Number
DELIVERY REPORT
BOBCAT SKID STEER LOADER IDENTIFICATION

SAFETY AND MAINTENANCE
LIFTING AND BLOCKING THE LOADER
Procedure
LIFT ARM SUPPORT DEVICE
Engaging The Lift Arm Support Device
Disengaging The Lift Arm Support Device
OPERATOR CAB
Description
Raising The Operator Cab
Lowering The Operator Cab
Emergency Exit
TRANSPORTING THE LOADER
Procedure
Adjusting The Bumper
TOWING THE LOADER
Procedure
REMOTE START SWITCH
Procedure
SERVICE SCHEDULE
Chart
AIR CLEANER SERVICE
Replacing Filter Element
ENGINE COOLING SYSTEM
Checking The Coolant Level
Cleaning The Cooling System
Replacing The Coolant
FUEL SYSTEM
Fuel Specification
Filling The Fuel Tank
Fuel Filter
Removing Air From The Fuel System
ENGINE LUBRICATION SYSTEM
Checking Engine Oil
Oil Chart
Replacing Oil And Filter
HYDRAULIC/HYDROSTATIC SYSTEM
Checking And Adding Fluid
Hydraulic/Hydrostatic Filter Replacement
Replacing The Hydraulic/Hydrostatic Fluid
FINAL DRIVE TRANSMISSION (CHAINCASE)
Checking And Adding Oil
AUXILIARY CONTROL LOCKBOLT
Procedure
BOB-TACH
Inspection And Maintenance
LUBRICATING THE LOADER
Procedure
TIRE MAINTENANCE
Wheel Nuts
Tire Rotation
Tire Inflation
SPARK ARRESTOR MUFFLER
Cleaning Procedure
PIVOT PINS
SEAT BAR RESTRAINT SYSTEM
Seat Bar Inspection
Seat Bar Maintenance
Foot Pedal Clean Out

HYDRAULIC SYSTEM
HYDRAULIC/HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Troubleshooting Chart
CYLINDER (LIFT)
Checking The Lift Cylinder(s)
Removal And Installation
Parts Identification
Disassembly And Assembly
CYLINDER (TILT)
Checking The Tilt Cylinder
Removal And Installation
Parts Identification
Disassembly And Assembly
MAIN RELIEF VALVE
Checking The Main Relief Valve Without Auxiliaries
Checking The Main Relief Valve With Auxiliaries
Removal And Installation
Main Relief Valve Adjustment
HYDRAULIC CONTROL VALVE
Removal And Installation
Identification Chart
Disassembly And Assembly
Load Check Valves
Main Relief Valve
Port Relief/Anti-Cavitation Valve
Port Relief Valves
Rubber Boot
Lift Spool Detent
Tilt Centering Spring
Auxiliary Spool Detent
Spool Seal Installation
BICS™ BLOCK VALVE
Description
Disassembly And Assembly
HYDRAULIC PUMP
Checking The Output Of The Pump
Removal And Installation
Parts Identification
Disassembly And Assembly
HYDRAULIC FILTER
Block Removal And Installation
Block Disassembly And Assembly
HYDRAULIC RESERVOIR
Removal And Installation
CONTROLS
Pedal Interlock Linkage Removal And Installation
Control Pedals Removal And Installation
Pedal Adjustment

HYDROSTATIC SYSTEM
HYDROSTATIC SYSTEM INFORMATION
Troubleshooting Chart
Replentishing The Valve Function
CONTROL PANEL
Control Shield And Steering Lever Panels Removal And Installation
STEERING
Lever Removal And Installation
Lever Disassembly And Assembly
Linkage Adjustment
Pintle Arm Removal And Installation
Pintle Arm Disassembly And Assembly
HYDROSTATIC MOTOR
Removal And Installation
Parts Identification
Disassembly
Inspection
Assembly
CHARGE PRESSURE
Checking
HYDROSTATIC PUMP
Parts Identification
Removal And Installation
Disassembly And Assembly
DRIVE BELT
Removal And Installation
Tension Pulley And Spring Removal And Installation

DRIVE SYSTEM
PARKING BRAKE
Pedal Removal And Installation
Pedal Disassembly And Assembly
Disc Removal And Installation
DRIVE COMPONENTS
Axle Hub Removal And Installation
Axle Seal Removal And Installation
Removing The Axle
Removing And Installing The Axle Bearing
Removing The Bearing Races
Installing The Bearing Races
Installing The Inner Bearing And Axle Sprocket
Drive Chain Removal And Installation
CHAINCASE
Removing Oil From The Chaincase
Chaincase Cover Removal And Installation
Chaincase Cover Assembly And Disassembly

MAIN FRAME
SEAT BAR
Removal And Installation
Assembly
OPERATOR CAB
Removal And Installation
Gas Cylinder Removal And Installation
OPERATOR SEAT
Removal And Installation
BOB-TACH
Removal
Installation
Seal Removal And Installation
Lever And Wedge Removal
LIFT ARMS
Removal And Installation
REAR WINDOW
Removal
Installation
REAR DOOR
Exhaust Pipe Removal And Installation
Removal And Installation
FUEL TANK
Removal And Installation

ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Troubleshooting Chart
Description
Fuse Location
Relay Switches Location
BATTERY
Removal And Installation
Servicing
Using A Booster Battery (Jump Starting)
ALTERNATOR
Removal And Installation
Adjusting The Alternator Belt
Alternator Belt Removal And Installation
Description
Tests
Alternator Output Test
Full Field Test
Alternator Regulator Test
Alternator Regulator Test Using Voltmeter
STARTER
Removal And Installation
Checking The Starter In The Loader
Parts Identification
Disassembly
Inspection And Repair
No Load Test
Assembly
INSTRUMENT PANEL
Removal And Installation
LIGHTS
Front Lights Removal And Installation
Rear Lights Removal And Installation
BICS™ SYSTEM CONTROLLER
Trouble Shooting Guide
Removal And Installation
BICS™ SYSTEM (WITH PRESS TO OPERATE BUTTON)
Inspecting The BICS™ Controller (Engine STOPPED – Key ON)
Inspecting The Seat Bar Sensor (Engine RUNNING)
Inspecting The Traction Lock (Engine RUNNING)
Inspecting The Lift Arm By-Pass Control
Troubleshooting Chart
SEAT BAR SENSOR
Troubleshooting Guide
Seat Bar Sensor Test
Removal And Installation
BICS™ Controller Seat Bar Sensor Circuit Test
TRACTION LOCK
Troubleshooting Guide
Removal And Installation

ENGINE SERVICE
TROUBLESHOOTING
Chart
ENGINE SPEED CONTROL
Adjustment
Removal And Installation
MUFFLER
Removal And Installation
AIR CLEANER
Housing Removal And Installation
RADIATOR
Removal And Installation
Mounting Bracket Removal And Installation
FAN
Removal And Installation
ENGINE COMPONENTS AND TESTING
Valve Clearance Adjustment
Fuel Injection Pump Check
Fuel Lift Pump Removal And Installation
Fuel Injection Pump Removal And Installation
Fuel Injection Pump Timing
Fuel Injector Nozzles Checking
Fuel Injector Nozzles Removal
Fuel Injector Nozzles Installation
Glow Plugs Checking
Engine Compression Test Procedure
ENGINE
Removal And Installation
FLYWHEEL
Removal And Installation
ENGINE MOUNTING BRACKET
Removal And Installation
RECONDITIONING THE ENGINE
Cylinder Head Removal And Installation
Cylinder Head Inspection
Cylinder Head Top Clearance
Rocker Arm And Shaft Checking
Valve Removal
Valve Spring Checking
Valve Guide Checking
Reconditioning The Valve And Valve Seat
Timing Gearcase Cover Removal And Installation
Idler Gear And Camshaft Removal And Installation
Servicing The Idler Gear And Shaft
Checking Timing Gear Backlash
Fuel Camshaft Removal And Installation
Governor
Crankshaft Gear Removal And Installation
Oil Pump Removal And Installation
Oil Pump Service
Checking Engine Oil Pressure
Relief Valve
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod Servicing
Connecting Rod Alignment
Crankshaft Bearings Removal And Installation
Inspection Of Crankshaft And Bearings
Cylinder Bore Inspection
Hydraulic Oil Cooler And Shrouding Removal And Installation
Thermostat Removal And Installation
Testing The Thermostat
Water Pump Removal And Installation
Water Pump Disassembly And Assembly

SPECIFICATIONS
LOADER SPECIFICATIONS
Machine Specifications
Performance
Controls
Engine
Hydraulic System
Electrical
Drive System
Capacities
Tires
Floor Pressure
ENGINE SPECIFICATIONS
Engine
Fuel Injector Nozzles
Fuel Injection Pump
Cylinder Head
Valves
Valve Springs
Rocker Arms
Camshaft
Cylinders
Piston Rings
Pistons
Crankshaft
Oil Pump
Thermostat
Engine Bolt Torque
Bolt Torques
Re-Grinding The Crankshaft
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
Torque For General Metric Bolts
HYDRAULIC CONNECTION SPECIFICATIONS
O-Ring Face Seal Connection
Straight Thread O-Ring Fitting
Tubelines And Hoses
Flare Fitting
O-Ring Flare Fitting
Port Seal Fitting
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS
Specifications
CONVERSIONS
Decimal And Millimeter Equivalents
U.S. To Metric Conversion

SERVICE MANUAL REVISIONS
Revision No: 463-1
Revision No: 463-2
Revision No: 463-3
Revision No: 463-4

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