Bobcat 463 Loader Service Manual 6901177 (6-12) – PDF DOWNLOAD

Description

Bobcat 463 Loader Service Manual 6901177 (6-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 463 Loader Service Manual 6901177 (6-12) – PDF DOWNLOAD

Language : English
Pages : 368
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat 463 Loader Service Manual 6901177 (6-12) – PDF DOWNLOAD

S/N 52001100 & Above
S/N 519911001 & Above

FOREWORD:

This manual is for the Bobcat loader excavator 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.

SAFETY INSTRUCTIONS:

The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:

TABLE OF CONTENTS:

Bobcat 463 Loader Service Manual 6901177 (6-12) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
ALPHABETICAL INDEX 5
CONTENTS 7
FOREWORD 8
SAFETY INSTRUCTIONS 11
Fire Prevention 13
SERIAL NUMBER LOCATIONS 15
Bobcat Loader Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 15
BOBCAT SKID STEER LOADER IDENTIFICATION 16
SAFETY AND MAINTENANCE 17
LIFTING AND BLOCKING THE LOADER 19
Procedure 19
LIFT ARM SUPPORT DEVICE 21
Engaging The Lift Arm Support Device 21
Disengaging The Lift Arm Support Device 22
OPERATOR CAB 23
Description 23
Raising The Operator Cab 23
Lowering The Operator Cab 24
Emergency Exit 25
TRANSPORTING THE LOADER 27
Procedure 27
Adjusting The Bumper 27
TOWING THE LOADER 29
Procedure 29
REMOTE START SWITCH 31
Procedure 31
SERVICE SCHEDULE 33
Chart 33
AIR CLEANER SERVICE 35
Replacing Filter Element 35
ENGINE COOLING SYSTEM 37
Checking The Coolant Level 37
Cleaning The Cooling System 37
Replacing The Coolant 38
FUEL SYSTEM 39
Fuel Specification 39
Filling The Fuel Tank 39
Fuel Filter 41
Removing Air From The Fuel System 42
ENGINE LUBRICATION SYSTEM 43
Checking Engine Oil 43
Oil Chart 43
Replacing Oil And Filter 43
HYDRAULIC/HYDROSTATIC SYSTEM 45
Checking And Adding Fluid 45
Hydraulic/Hydrostatic Filter Replacement 46
Replacing The Hydraulic/Hydrostatic Fluid 46
FINAL DRIVE TRANSMISSION (CHAINCASE) 47
Checking And Adding Oil 47
AUXILIARY CONTROL LOCKBOLT 49
Procedure 49
BOB-TACH 51
Inspection And Maintenance 51
LUBRICATING THE LOADER 53
Procedure 53
TIRE MAINTENANCE 55
Wheel Nuts 55
Tire Rotation 55
Tire Inflation 55
SPARK ARRESTOR MUFFLER 57
Cleaning Procedure 57
PIVOT PINS 59
SEAT BAR RESTRAINT SYSTEM 61
Seat Bar Inspection 61
Seat Bar Maintenance 61
Foot Pedal Clean Out 62
HYDRAULIC SYSTEM 63
HYDRAULIC/HYDROSTATIC SCHEMATICS 65
HYDRAULIC SYSTEM INFORMATION 69
Troubleshooting Chart 73
CYLINDER (LIFT) 75
Checking The Lift Cylinder(s) 75
Removal And Installation 76
Parts Identification 78
Disassembly And Assembly 79
CYLINDER (TILT) 83
Checking The Tilt Cylinder 83
Removal And Installation 83
Parts Identification 85
Disassembly And Assembly 86
MAIN RELIEF VALVE 89
Checking The Main Relief Valve Without Auxiliaries 89
Checking The Main Relief Valve With Auxiliaries 90
Removal And Installation 91
Main Relief Valve Adjustment 91
HYDRAULIC CONTROL VALVE 93
Removal And Installation 93
Identification Chart 95
Disassembly And Assembly 95
Load Check Valves 96
Main Relief Valve 96
Port Relief/Anti-Cavitation Valve 97
Port Relief Valves 97
Rubber Boot 98
Lift Spool Detent 98
Tilt Centering Spring 103
Auxiliary Spool Detent 103
Spool Seal Installation 104
BICS™ BLOCK VALVE 105
Description 105
Disassembly And Assembly 106
HYDRAULIC PUMP 109
Checking The Output Of The Pump 109
Removal And Installation 110
Parts Identification 113
Disassembly And Assembly 114
HYDRAULIC FILTER 117
Block Removal And Installation 117
Block Disassembly And Assembly 118
HYDRAULIC RESERVOIR 121
Removal And Installation 121
CONTROLS 123
Pedal Interlock Linkage Removal And Installation 123
Control Pedals Removal And Installation 124
Pedal Adjustment 124
HYDROSTATIC SYSTEM 125
HYDROSTATIC SYSTEM INFORMATION 127
Troubleshooting Chart 127
Replentishing The Valve Function 128
CONTROL PANEL 129
Control Shield And Steering Lever Panels Removal And Installation 129
STEERING 131
Lever Removal And Installation 131
Lever Disassembly And Assembly 133
Linkage Adjustment 133
Pintle Arm Removal And Installation 134
Pintle Arm Disassembly And Assembly 135
HYDROSTATIC MOTOR 137
Removal And Installation 137
Parts Identification 138
Disassembly 139
Inspection 143
Assembly 145
CHARGE PRESSURE 149
Checking 149
HYDROSTATIC PUMP 151
Parts Identification 151
Removal And Installation 152
Disassembly And Assembly 155
DRIVE BELT 165
Removal And Installation 165
Tension Pulley And Spring Removal And Installation 165
DRIVE SYSTEM 169
PARKING BRAKE 171
Pedal Removal And Installation 171
Pedal Disassembly And Assembly 172
Disc Removal And Installation 173
DRIVE COMPONENTS 175
Axle Hub Removal And Installation 175
Axle Seal Removal And Installation 176
Removing The Axle 177
Removing And Installing The Axle Bearing 178
Removing The Bearing Races 179
Installing The Bearing Races 181
Installing The Inner Bearing And Axle Sprocket 181
Drive Chain Removal And Installation 182
CHAINCASE 183
Removing Oil From The Chaincase 183
Chaincase Cover Removal And Installation 183
Chaincase Cover Assembly And Disassembly 184
MAIN FRAME 185
SEAT BAR 187
Removal And Installation 187
Assembly 190
OPERATOR CAB 191
Removal And Installation 191
Gas Cylinder Removal And Installation 193
OPERATOR SEAT 195
Removal And Installation 195
BOB-TACH 197
Removal 197
Installation 198
Seal Removal And Installation 199
Lever And Wedge Removal 200
LIFT ARMS 201
Removal And Installation 201
REAR WINDOW 203
Removal 203
Installation 203
REAR DOOR 205
Exhaust Pipe Removal And Installation 205
Removal And Installation 205
FUEL TANK 207
Removal And Installation 207
ELECTRICAL SYSTEM & ANALYSIS 209
ELECTRICAL SCHEMATICS 211
ELECTRICAL SYSTEM INFORMATION 217
Troubleshooting Chart 217
Description 218
Fuse Location 218
Relay Switches Location 219
BATTERY 221
Removal And Installation 221
Servicing 223
Using A Booster Battery (Jump Starting) 224
ALTERNATOR 225
Removal And Installation 225
Adjusting The Alternator Belt 226
Alternator Belt Removal And Installation 226
Description 228
Tests 228
Alternator Output Test 228
Full Field Test 229
Alternator Regulator Test 229
Alternator Regulator Test Using Voltmeter 230
STARTER 231
Removal And Installation 231
Checking The Starter In The Loader 232
Parts Identification 233
Disassembly 234
Inspection And Repair 239
No Load Test 242
Assembly 243
INSTRUMENT PANEL 251
Removal And Installation 251
LIGHTS 253
Front Lights Removal And Installation 253
Rear Lights Removal And Installation 254
BICS™ SYSTEM CONTROLLER 255
Trouble Shooting Guide 255
Removal And Installation 256
BICS™ SYSTEM (WITH PRESS TO OPERATE BUTTON) 259
Inspecting The BICS™ Controller (Engine STOPPED – Key ON) 259
Inspecting The Seat Bar Sensor (Engine RUNNING) 259
Inspecting The Traction Lock (Engine RUNNING) 259
Inspecting The Lift Arm By-Pass Control 259
Troubleshooting Chart 260
SEAT BAR SENSOR 261
Troubleshooting Guide 261
Seat Bar Sensor Test 262
Removal And Installation 263
BICS™ Controller Seat Bar Sensor Circuit Test 265
TRACTION LOCK 267
Troubleshooting Guide 267
Removal And Installation 268
ENGINE SERVICE 271
TROUBLESHOOTING 273
Chart 273
ENGINE SPEED CONTROL 275
Adjustment 275
Removal And Installation 275
MUFFLER 277
Removal And Installation 277
AIR CLEANER 279
Housing Removal And Installation 279
RADIATOR 281
Removal And Installation 281
Mounting Bracket Removal And Installation 281
FAN 283
Removal And Installation 283
ENGINE COMPONENTS AND TESTING 285
Valve Clearance Adjustment 285
Fuel Injection Pump Check 286
Fuel Lift Pump Removal And Installation 287
Fuel Injection Pump Removal And Installation 287
Fuel Injection Pump Timing 288
Fuel Injector Nozzles Checking 290
Fuel Injector Nozzles Removal 291
Fuel Injector Nozzles Installation 292
Glow Plugs Checking 293
Engine Compression Test Procedure 293
ENGINE 295
Removal And Installation 295
FLYWHEEL 303
Removal And Installation 303
ENGINE MOUNTING BRACKET 305
Removal And Installation 305
RECONDITIONING THE ENGINE 307
Cylinder Head Removal And Installation 307
Cylinder Head Inspection 308
Cylinder Head Top Clearance 309
Rocker Arm And Shaft Checking 309
Valve Removal 310
Valve Spring Checking 310
Valve Guide Checking 311
Reconditioning The Valve And Valve Seat 313
Timing Gearcase Cover Removal And Installation 314
Idler Gear And Camshaft Removal And Installation 316
Servicing The Idler Gear And Shaft 318
Checking Timing Gear Backlash 319
Fuel Camshaft Removal And Installation 319
Governor 320
Crankshaft Gear Removal And Installation 320
Oil Pump Removal And Installation 321
Oil Pump Service 321
Checking Engine Oil Pressure 322
Relief Valve 322
Piston And Connecting Rod Removal And Installation 323
Piston And Connecting Rod Servicing 325
Connecting Rod Alignment 327
Crankshaft Bearings Removal And Installation 328
Inspection Of Crankshaft And Bearings 330
Cylinder Bore Inspection 332
Hydraulic Oil Cooler And Shrouding Removal And Installation 332
Thermostat Removal And Installation 333
Testing The Thermostat 334
Water Pump Removal And Installation 334
Water Pump Disassembly And Assembly 334
SPECIFICATIONS 335
LOADER SPECIFICATIONS 337
Machine Specifications 337
Performance 337
Controls 338
Engine 338
Hydraulic System 339
Electrical 339
Drive System 340
Capacities 340
Tires 340
Floor Pressure 340
ENGINE SPECIFICATIONS 341
Engine 341
Fuel Injector Nozzles 341
Fuel Injection Pump 341
Cylinder Head 341
Valves 341
Valve Springs 342
Rocker Arms 342
Camshaft 342
Cylinders 342
Piston Rings 343
Pistons 343
Crankshaft 343
Oil Pump 344
Thermostat 344
Engine Bolt Torque 345
Bolt Torques 345
Re-Grinding The Crankshaft 346
TORQUE SPECIFICATIONS FOR BOLTS 347
Torque For General SAE Bolts 347
Torque For General Metric Bolts 347
HYDRAULIC CONNECTION SPECIFICATIONS 349
O-Ring Face Seal Connection 349
Straight Thread O-Ring Fitting 349
Tubelines And Hoses 349
Flare Fitting 350
O-Ring Flare Fitting 351
Port Seal Fitting 352
HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS 355
Specifications 355
CONVERSIONS 357
Decimal And Millimeter Equivalents 357
U S To Metric Conversion 358
SMR 359
Revision No: 463-1 359
Revision No: 463-2 361
Revision No: 463-3 363
Revision No: 463-4 365
Revision No: 463-5 367

IMAGES PREVIEW OF THE MANUAL:

Customer Support: [email protected]

PLEASE NOTE:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]

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