Bobcat 463 Skid Steer 6901812 Loader Service Manual-21416B320020.pdf -Bookmark created by https://wimanual.com 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 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 Checking And Adding Fluid Hydraulic Replacing The Hydraulic 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 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 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 Fuel Camshaft 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 Fuel Camshaft Gear Fuel Camshaft Gear And Governor Shaft Gear 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 FLUID SPECIFICATIONS Specifications CONVERSIONS Decimal And Millimeter Equivalents U.S. To Metric Conversion SMR 463-1 463-2 . 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