Bobcat 463 Skid-Steer Loader Repair Service Manual – 6903711

(S/N: 538911001 & Above – S/N: 539011001 & 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: 538911001 & Above
S/N: 539011001 & Above

TABLE OF CONTENTS :

FOREWORD
SAFETY INSTRUCTIONS
SERIAL NUMBER LOCATIONS
DELIVERY REPORT
BOBCAT 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 : 6903711 (8-07)
Total Pages : 376

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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 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
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
Procedure
SEAT BAR RESTRAINT SYSTEM
Seat Bar Inspection
Seat Bar Maintenance
Foot Pedal Clean Out

HYDRAULIC SYSTEM
HYDRAULIC SCHEMATIC
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
HYDRAULIC CONTROL VALVE
BICS™ Valve Removal And Installation
BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation
BICS™ Valve, Pressure Differential Valve Removal And Installation
BICS™ Valve, Check Valve Removal And Installation
BICS™ Valve, Solenoid Removal And Installation
BICS™ Valve, Solenoid Testing
BICS™ Valve, Identification Chart
Removal And Installation
Identification Chart
Disassembly And Assembly
Load Check Valves Removal And Installation
Main Relief Valve Removal And Installation
Port Relief/Anti-Cavitation Valve Removal And Installation
Anti Cavitation/Check Valves Removal And Installation
Rubber Boot Removal And Installation
Lift And Tilt Lock Block Removal And Installation
Lift Spool And Detent Removal
Lift Spool And Detent Disassembly
Lift Spool And Detent Assembly
Lift Spool Detent Installation
Tilt Spool Removal And Installation
Tilt Spool Disassembly And Assembly
Auxiliary Spool Removal And Installation
Auxiliary Spool Disassembly And Assembly
Spool Seal Installation
Auxiliary Pivot Bracket Removal And Installation
Auxiliary Pivot Bracket Disassembly And Assembly
LIFT ARM BY-PASS VALVE
Removal And Installation
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
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
OIL COOLER
Removal And Installation

DRIVE SYSTEM
PARKING BRAKE
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
Removal And Installation
FUEL TANK
Removal And Installation

ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Troubleshooting Chart
Description
Fuel Shutoff Timer and Fuel Pull Solenoid Locations
Fuse And 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
Alternator Output Test
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
Cab Light Removal And Installation
BICS™ SYSTEM CONTROLLER
Troubleshooting 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
Removal And Installation
RADIATOR
Removal And Installation
COOLING FAN
Removal And Installation
ENGINE COMPONENTS AND TESTING
Fuel Injection Pump Check
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
Fuel Lift Pump Removal And Installation
ENGINE
Removal And Installation
FLYWHEEL
Removal And Installation
ENGINE MOUNTING BRACKET
Removal And Installation
RECONDITIONING THE ENGINE
Thermostat Removal And Installation
Water Pump Removal And Installation
Timing Gear Case Cover Removal And Installation
Oil Pump Removal And Installation
Crankshaft Front Seal Removal And Installation
Engine Speed Control Plate Removal And Installation
Governor Spring Removal
Start Spring Removal
Idle Limit And Fuel Limit Adjustment
Exhaust Manifold Removal And Installation
Valve Cover Removal And Installation
Rocker Arm Removal And Installation
Push Rod Removal And Installation
Tappet Removal And Installation
Water Flange Removal And Installation
Cylinder Head Removal
Cylinder Head Installation
Checking Piston Top Clearance
Cylinder Head Disassembly
Cylinder Head Assembly
Servicing The Cylinder Head
Combustion Chamber Removal And Installation
Idler Gear Removal And Installation
Camshaft Removal And Installation
Injection Pump Shaft Removal And Installation
Oil Pan Removal And Installation
Governor Shaft Removal And Installation
Governor Fork Lever Removal And Installation
Piston Removal And Installation
Checking The Piston And Connecting Rod
Connecting Rod Alignment
Piston Ring Gap
Piston Ring Installation
Connecting Rod Installation
Checking Engine Cylinder Bore
Crankshaft Removal And Installation
Checking Crankshaft Journal And Block Bearing
Checking The Crankshaft Journal And Main Bearing
Connecting Rod Journal
Checking The End Play Of The Crankshaft
Crankshaft Alignment
Engine Timing Installation
Idler Gear And Crankshaft
Idler Gear And Camshaft Gear
Idler Gear And Injection Pump Shaft Gear
Injection Pump Shaft And Governor Shaft Gear

SPECIFICATIONS
LOADER SPECIFICATIONS
Dimensions
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
Bolt Torques
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 FLUID SPECIFICATIONS
Specifications
CONVERSIONS
Decimal And Millimeter Equivalents
U.S. To Metric Conversion

SERVICE MANUAL REVISIONS
463-1
463-2

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