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


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 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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