Bobcat 463 Loader Service Manual 6901812 (10-12) – PDF DOWNLOAD

Description

Bobcat 463 Loader Service Manual 6901812 (10-12) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 463 Loader Service Manual 6901812 (10-12) – PDF DOWNLOAD

Language : English
Pages : 380
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat 463 Loader Service Manual 6901812 (10-12) – PDF DOWNLOAD

S/N 522211001 & Above
S/N 522111001 & 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 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 6901812 (10-12) – 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 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
Procedure 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
HYDRAULIC CONTROL VALVE 93
BICS™ Valve Removal And Installation 93
BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation 94
BICS™ Valve, Pressure Differential Valve Removal And Installation 95
BICS™ Valve, Check Valve Removal And Installation 95
BICS™ Valve, Solenoid Removal And Installation 96
BICS™ Valve, Solenoid Testing 97
BICS™ Valve, Identification Chart 98
Removal And Installation 98
Identification Chart 100
Disassembly And Assembly 101
Load Check Valves Removal And Installation 101
Main Relief Valve Removal And Installation 101
Port Relief/Anti-Cavitation Valve Removal And Installation 102
Anti Cavitation/Check Valves Removal And Installation 103
Rubber Boot Removal And Installation 104
Lift And Tilt Lock Block Removal And Installation 104
Lift Spool And Detent Removal 105
Lift Spool And Detent Disassembly 106
Lift Spool And Detent Assembly 108
Lift Spool Detent Installation 110
Tilt Spool Removal And Installation 111
Tilt Spool Disassembly And Assembly 112
Auxiliary Spool Removal And Installation 113
Auxiliary Spool Disassembly And Assembly 113
Spool Seal Installation 116
Auxiliary Pivot Bracket Removal And Installation 117
Auxiliary Pivot Bracket Disassembly And Assembly 117
LIFT ARM BY-PASS VALVE 119
Removal And Installation 119
Disassembly And Assembly 119
HYDRAULIC PUMP 121
Checking The Output Of The Pump 121
Removal And Installation 122
Parts Identification 125
Disassembly And Assembly 126
HYDRAULIC FILTER 129
Block Removal And Installation 129
Block Disassembly And Assembly 130
HYDRAULIC RESERVOIR 131
Removal And Installation 131
CONTROLS 133
Pedal Interlock Linkage Removal And Installation 133
Control Pedals Removal And Installation 134
Pedal Adjustment 134
HYDROSTATIC SYSTEM 135
HYDROSTATIC SYSTEM INFORMATION 137
Troubleshooting Chart 137
CONTROL PANEL 139
Control Shield And Steering Lever Panels Removal And Installation 139
STEERING 141
Lever Removal And Installation 141
Lever Disassembly And Assembly 143
Linkage Adjustment 143
Pintle Arm Removal And Installation 144
Pintle Arm Disassembly And Assembly 145
HYDROSTATIC MOTOR 147
Removal And Installation 147
Parts Identification 148
Disassembly 149
Inspection 153
Assembly 155
CHARGE PRESSURE 159
Checking 159
HYDROSTATIC PUMP 161
Parts Identification 161
Removal And Installation 162
Disassembly And Assembly 163
DRIVE BELT 173
Removal And Installation 173
Tension Pulley And Spring Removal And Installation 173
OIL COOLER 177
Removal And Installation 177
DRIVE SYSTEM 179
PARKING BRAKE 181
Disc Removal And Installation 181
DRIVE COMPONENTS 183
Axle Hub Removal And Installation 183
Axle Seal Removal And Installation 184
Removing The Axle 185
Removing And Installing The Axle Bearing 186
Removing The Bearing Races 187
Installing The Bearing Races 189
Installing The Inner Bearing And Axle Sprocket 189
Drive Chain Removal And Installation 190
CHAINCASE 191
Removing Oil From The Chaincase 191
Chaincase Cover Removal And Installation 191
Chaincase Cover Assembly And Disassembly 191
MAIN FRAME 193
SEAT BAR 195
Removal And Installation 195
Assembly 198
OPERATOR CAB 199
Removal And Installation 199
Gas Cylinder Removal And Installation 201
OPERATOR SEAT 203
Removal And Installation 203
BOB-TACH 205
Removal 205
Installation 206
Seal Removal And Installation 207
Lever And Wedge Removal 208
LIFT ARMS 209
Removal And Installation 209
REAR WINDOW 213
Removal 213
Installation 213
REAR DOOR 215
Removal And Installation 215
FUEL TANK 217
Removal And Installation 217
ELECTRICAL SYSTEM & ANALYSIS 219
ELECTRICAL SCHEMATICS 221
ELECTRICAL SYSTEM INFORMATION 227
Troubleshooting Chart 227
Description 228
Fuel Shutoff Timer and Fuel Pull Solenoid Locations 228
Fuse And Relay Switches Location 228
BATTERY 229
Removal And Installation 229
Servicing 230
Using A Booster Battery (Jump Starting) 231
ALTERNATOR 233
Removal And Installation 233
Adjusting The Alternator Belt 234
Alternator Belt Removal And Installation 234
Description 235
Alternator Output Test 235
STARTER 237
Removal And Installation 237
Checking The Starter In The Loader 237
Parts Identification 238
Disassembly 239
Inspection And Repair 244
No Load Test 247
Assembly 248
INSTRUMENT PANEL 255
Removal And Installation 255
LIGHTS 257
Front Lights Removal And Installation 257
Rear Lights Removal And Installation 258
Cab Light Removal And Installation 259
BICS™ SYSTEM CONTROLLER 261
Troubleshooting Guide 261
Removal And Installation 262
BICS™ SYSTEM (WITH PRESS TO OPERATE BUTTON) 263
Inspecting The BICS™ Controller (Engine STOPPED – Key ON) 263
Inspecting The Seat Bar Sensor (Engine RUNNING) 263
Inspecting The Traction Lock (Engine RUNNING) 263
Inspecting The Lift Arm By-Pass Control 263
Troubleshooting Chart 264
SEAT BAR SENSOR 265
Troubleshooting Guide 265
Seat Bar Sensor Test 266
Removal And Installation 267
BICS™ Controller Seat Bar Sensor Circuit Test 269
TRACTION LOCK 271
Troubleshooting Guide 271
Removal And Installation 272
ENGINE SERVICE 275
TROUBLESHOOTING 277
Chart 277
ENGINE SPEED CONTROL 279
Adjustment 279
Removal And Installation 279
MUFFLER 281
Removal And Installation 281
AIR CLEANER 283
Removal And Installation 283
RADIATOR 285
Removal And Installation 285
COOLING FAN 287
Removal And Installation 287
ENGINE COMPONENTS AND TESTING 289
Fuel Injection Pump Check 289
Fuel Injection Pump Removal And Installation 289
Fuel Injection Pump Timing 291
Fuel Injector Nozzles Checking 292
Fuel Injector Nozzles Removal 294
Fuel Injector Nozzles Installation 295
Glow Plugs Checking 295
Engine Compression Test Procedure 296
Fuel Lift Pump Removal And Installation 296
ENGINE 297
Removal And Installation 297
FLYWHEEL 305
Removal And Installation 305
ENGINE MOUNTING BRACKET 307
Removal And Installation 307
RECONDITIONING THE ENGINE 309
Thermostat Removal And Installation 309
Water Pump Removal And Installation 309
Timing Gear Case Cover Removal And Installation 310
Oil Pump Removal And Installation 312
Crankshaft Front Seal Removal And Installation 314
Engine Speed Control Plate Removal And Installation 315
Governor Spring Removal 315
Start Spring Removal 316
Idle Limit And Fuel Limit Adjustment 316
Exhaust Manifold Removal And Installation 316
Valve Cover Removal And Installation 317
Rocker Arm Removal And Installation 318
Push Rod Removal And Installation 319
Tappet Removal And Installation 320
Water Flange Removal And Installation 320
Cylinder Head Removal 321
Cylinder Head Installation 321
Checking Piston Top Clearance 322
Cylinder Head Disassembly 323
Cylinder Head Assembly 323
Servicing The Cylinder Head 324
Combustion Chamber Removal And Installation 326
Idler Gear Removal And Installation 327
Camshaft Removal And Installation 329
Fuel Camshaft Removal And Installation 331
Oil Pan Removal And Installation 332
Governor Shaft Removal And Installation 333
Governor Fork Lever Removal And Installation 336
Piston Removal And Installation 337
Checking The Piston And Connecting Rod 338
Connecting Rod Alignment 339
Piston Ring Gap 339
Piston Ring Installation 340
Connecting Rod Installation 340
Checking Engine Cylinder Bore 341
Crankshaft Removal And Installation 341
Checking Crankshaft Journal And Block Bearing 344
Checking The Crankshaft Journal And Main Bearing 345
Connecting Rod Journal 346
Checking the End Play Of The Crankshaft 347
Crankshaft Alignment 347
Engine Timing Installation 348
Idler Gear And Crankshaft 348
Idler Gear And Camshaft Gear 349
Idler Gear And Fuel Camshaft Gear 349
Fuel Camshaft Gear And Governor Shaft Gear 349
SPECIFICATIONS 351
LOADER SPECIFICATIONS 353
Machine Specifications 353
Performance 354
Controls 354
Engine 354
Hydraulic System 355
Electrical 355
Drive System 356
Capacities 356
Tires 356
Floor Pressure 356
ENGINE SPECIFICATIONS 357
Engine 357
Fuel Injector Nozzles 357
Fuel Injection Pump 357
Cylinder Head 357
Valves 357
Valve Springs 358
Rocker Arms 358
Camshaft 358
Cylinders 358
Piston Rings 359
Pistons 359
Crankshaft 359
Oil Pump 360
Thermostat 360
Engine Bolt Torque 360
Bolt Torques 361
Re-Grinding The Crankshaft 362
TORQUE SPECIFICATIONS FOR BOLTS 363
Torque For General SAE Bolts 363
Torque For General Metric Bolts 363
HYDRAULIC CONNECTION SPECIFICATIONS 365
O-Ring Face Seal Connection 365
Straight Thread O-Ring Fitting 365
Tubelines And Hoses 365
Flare Fitting 366
O-Ring Flare Fitting 367
Port Seal Fitting 368
HYDRAULIC FLUID SPECIFICATIONS 371
Specifications 371
CONVERSIONS 373
Decimal And Millimeter Equivalents 373
U S To Metric Conversion 374
SMR 375
463-1 375
463-2 377
463-3 379

IMAGES PREVIEW OF THE MANUAL:

Need help? Contact: [email protected]

PLEASE NOTE:

• This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
• Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.

S.V