Complete repair service manual with Electrical Wiring Diagrams for Bobcat 463 Loader, with technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Bobcat Loaders 463 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

6901175 (6-02) - 463 Loader Operation & Maintenance Manual.pdf
6901175 (08–01) - 463 Loader Operation & Maintenance Manual.pdf
6901177 (3-06) - 463 Loader Service Manual.pdf
6901177 (06-12) - 463 Loader Service Manual.pdf.pdf
6901811 (8-04) - 463 Loader Operation & Maintenance Manual.pdf
6901811 (10-04) - 463 Loader Operation & Maintenance Manual.pdf
6901812 (3-06) - 463 Loader Service Manual.pdf
6901812 (10-12) - 463 Loader Service Manual.pdf
6903710 (5-07) - 463 Operation & Maintenance Manual.pdf
6903710 (12-04) - 463 Loader Operation & Maintenance Manual.pdf
6903711 (8-07) - 463 Loader Service Manual.pdf
6903711 (10-12) - 463 Loader Service Manual.pdf

Total Pages: 1,433 pages
File Format: PDF (bookmarked, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
6901175 (08–01) - 463 Loader Operation & Maintenance Manual................1
  OPERATOR SAFETY WARNINGS................3
  CONTENTS................5
    REFERENCE INFORMATION................5
    BOBCAT COMPANY IS ISO 9001 CERTIFIED................6
    REGULAR MAINTENANCE ITEMS................6
  FOREWORD................7
    SERIAL NUMBER LOCATIONS................9
    LOADER SERIAL NUMBER................9
    ENGINE SERIAL NUMBER................9
    DELIVERY REPORT................9
    BOBCAT SKID STEER LOADER IDENTIFICATION................10
    FEATURES AND ACCESSORIES................11
  SAFETY................13
    SAFETY INSTRUCTIONS FOR BOBCAT SKID STEER LOADERS AND ATTACHMENTS................15
      Safe Operation Is The Operator's Responsibility................15
      Before Operating The Bobcat Loader................16
      Safe Operation Needs A Qualified Operator................16
    FIRE PREVENTION................17
    MACHINE SIGNS (DECALS)................18
  OPERATING INSTRUCTIONS................21
    INSTRUMENT PANEL................23
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)................24
      Lift Arm By-Pass Control................24
      Traction Lock Override................25
    ENGINE SPEED CONTROL................25
    PARKING BRAKE (Later Models)................26
    PARKING BRAKE (Early Models)................26
    STEERING LEVERS................27
    STOPPING THE BOBCAT LOADER................27
    SEAT BAR RESTRAINT SYSTEM................28
    HYDRAULIC CONTROLS................29
      Foot Pedals................29
      Lift Arm Operation................29
      Lift Arm Float Position................29
      Tilt Operation................29
      Bucket Position Valve Operation (If Equipped)................29
      Auxiliary Hydraulics (If Equipped)................30
        Quick Couplers................30
      Auxiliary HydraulicContinuous Operation................31
      Relieving Hydraulic Pressure................31
    DAILY INSPECTION................32
    GETTING READY FOR OPERATION................33
    STARTING THE ENGINE................35
      Normal Starting................35
      Cold Temperature Starting................37
      Warming The Hydraulic / Hydrostatic System................37
    STOPPING THE ENGINE................37
    ATTACHMENTS AND BUCKETS................38
      Installing The Bucket Or Attachment................39
      Removing The Bucket Or Attachment................40
    OPERATING PROCEDURE................41
      Filling The Bucket................42
      Emptying The Bucket................42
      Digging Into The Ground................43
      Leveling The Ground (Using Lift Arms In Float Position)................44
      Backfilling................44
    PARKING THE BOBCAT LOADER................44
    TRANSPORTING THE BOBCAT LOADER................45
    LIFTING THE BOBCAT LOADER................46
    TOWING THE BOBCAT LOADER................46
  PREVENTIVE MAINTENANCE................47
    MAINTENANCE SAFETY................48
    SERVICE SCHEDULE................49
      Chart................49
    LIFT ARM SUPPORT DEVICE................50
      Engaging The Lift Arm Support Device................50
      Disengaging The Lift Arm Support Device................51
    OPERATOR CAB................52
      Raising The Operator Cab................52
      Lowering The Operator Cab................53
      Emergency Exit................54
    SEAT BAR RESTRAINT SYSTEM................55
      Seat Bar Inspection................55
      Seat Bar Maintenance................55
      Foot Pedal Clean Out................55
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)................56
      Inspecting The BICS™ Controller................56
      Inspecting The Seat Bar Sensor (Engine RUNNING)................56
      Inspecting The Traction Lock (Engine RUNNING)................56
      Inspecting The Lift Arm By-Pass Control................56
    REAR DOOR................57
    AIR CLEANER SERVICE................58
    FUEL SYSTEM................59
      Fuel Specifications................59
      Filling The Fuel Tank................59
      Fuel Filter................60
      Removing Air From The Fuel System................61
    ENGINE LUBRICATION SYSTEM................62
      Oil Chart................62
      Replacing Oil And Filter................62
    COOLING SYSTEM................63
      Checking The Coolant Level................63
      Propylene Glycol................63
      Cleaning The Cooling System................63
      Removing Coolant From The Cooling System................63
    ALTERNATOR BELT ADJUSTMENT................64
    ELECTRICAL SYSTEM................64
      Description................64
      Fuse Location................64
      Electrical System Service................64
      Battery Removal And Installation................65
      Using A Booster Battery (Jump Starting)................66
    HYDRAULIC / HYDROSTATIC SYSTEM................67
      Checking And Adding Fluid................67
      Breather Cap................67
      Replacing The Hydraulic / Hydrostatic Filter Element................68
      Removing The Hydraulic / Hydrostatic Fluid................68
    SPARK ARRESTOR MUFFLER................69
    TIRE MAINTENANCE................70
      Wheel Nuts................70
      Tire Rotation................70
      Tire Inflation................70
    FINAL DRIVE TRANSMISSION (CHAINCASE)................71
      Checking And Adding Oil................71
    AUXILIARY CONTROL LOCKBOLT................71
    LUBRICATING THE LOADER................72
    PIVOT PINS................74
    BOB-TACH................74
      Inspection And Maintenance................74
  SYSTEMS ANALYSIS................75
    TROUBLESHOOTING THE ENGINE................77
    TROUBLESHOOTING THE HYDRAULIC SYSTEM................78
    TROUBLESHOOTING THE HYDROSTATIC SYSTEM................78
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)................80
  MACHINE SIGN TRANSLATIONS................81
    IMPORTANT - 6560573................83
    WARNING - 6579511................84
    SERVICE SCHRDULE - 6708212................85
    WARNING - 6579510................87
    WARNING - 6579528................88
    DANGER - 6702302................88
    WARNING - 6577754................88
    DANGER - 6702301................88
    DANGER - 6717343................89
  SPECIFICATIONS................91
    SKID STEER LOADER SPECIFICATIONS................93
      Performance................93
      Engine................93
      Loader Controls................93
      Drive System................93
      Hydraulic System................93
      Electrical System................93
      Capacities................93
    BOBCAT APRROVED ATTACHMENTS & ACCESSORIES................94
    ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS................95
  WARRANTY................97
6901175 (6-02) - 463 Loader Operation & Maintenance Manual................99
  OPERATOR SAFETY WARNINGS................101
  CONTENTS................103
    REFERENCE INFORMATION................103
    BOBCAT COMPANY IS ISO 9001 CERTIFIED................104
    REGULAR MAINTENANCE ITEMS................104
  FOREWORD................105
    SERIAL NUMBER LOCATIONS................107
    LOADER SERIAL NUMBER................107
    ENGINE SERIAL NUMBER................107
    DELIVERY REPORT................107
    BOBCAT SKID STEER LOADER IDENTIFICATION................108
    FEATURES AND ACCESSORIES................109
  SAFETY................111
    SAFETY INSTRUCTIONS FOR BOBCAT SKID STEER LOADERS AND ATTACHMENTS................113
      Safe Operation Is The Operator's Responsibility................113
      Before Operating The Bobcat Loader................114
      Safe Operation Needs A Qualified Operator................114
    FIRE PREVENTION................115
    MACHINE SIGNS (DECALS)................116
  OPERATING INSTRUCTIONS................119
    INSTRUMENT PANEL................121
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)................122
      Lift Arm By-Pass Control................122
      Traction Lock Override................123
    ENGINE SPEED CONTROL................123
    PARKING BRAKE (Later Models)................124
    PARKING BRAKE (Early Models)................124
    STEERING LEVERS................125
    STOPPING THE BOBCAT LOADER................125
    SEAT BAR RESTRAINT SYSTEM................126
    HYDRAULIC CONTROLS................127
      Foot Pedals................127
      Lift Arm Operation................127
      Lift Arm Float Position................127
      Tilt Operation................127
      Bucket Position Valve Operation (If Equipped)................127
      Auxiliary Hydraulics (If Equipped)................128
        Quick Couplers................128
      Auxiliary HydraulicContinuous Operation................129
      Relieving Hydraulic Pressure................129
    DAILY INSPECTION................130
    GETTING READY FOR OPERATION................131
    STARTING THE ENGINE................133
      Normal Starting................133
      Cold Temperature Starting................135
      Warming The Hydraulic / Hydrostatic System................135
    STOPPING THE ENGINE................135
    ATTACHMENTS AND BUCKETS................136
      Installing The Bucket Or Attachment................137
      Removing The Bucket Or Attachment................138
    OPERATING PROCEDURE................139
      Filling The Bucket................140
      Emptying The Bucket................140
      Digging Into The Ground................141
      Leveling The Ground (Using Lift Arms In Float Position)................142
      Backfilling................142
    PARKING THE BOBCAT LOADER................142
    TRANSPORTING THE BOBCAT LOADER................143
    LIFTING THE BOBCAT LOADER................144
    TOWING THE BOBCAT LOADER................144
  PREVENTIVE MAINTENANCE................145
    MAINTENANCE SAFETY................146
    SERVICE SCHEDULE................147
      Chart................147
    LIFT ARM SUPPORT DEVICE................148
      Engaging The Lift Arm Support Device................148
      Disengaging The Lift Arm Support Device................149
    OPERATOR CAB................150
      Raising The Operator Cab................150
      Lowering The Operator Cab................151
      Emergency Exit................152
    SEAT BAR RESTRAINT SYSTEM................153
      Seat Bar Inspection................153
      Seat Bar Maintenance................153
      Foot Pedal Clean Out................153
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)................154
      Inspecting The BICS™ Controller................154
      Inspecting The Seat Bar Sensor (Engine RUNNING)................154
      Inspecting The Traction Lock (Engine RUNNING)................154
      Inspecting The Lift Arm By-Pass Control................154
    REAR DOOR................155
    AIR CLEANER SERVICE................156
    FUEL SYSTEM................157
      Fuel Specifications................157
      Filling The Fuel Tank................157
      Fuel Filter................158
      Removing Air From The Fuel System................159
    ENGINE LUBRICATION SYSTEM................160
      Oil Chart................160
      Replacing Oil And Filter................160
    COOLING SYSTEM................161
      Checking The Coolant Level................161
      Propylene Glycol................161
      Cleaning The Cooling System................161
      Removing Coolant From The Cooling System................161
    ALTERNATOR BELT ADJUSTMENT................162
    ELECTRICAL SYSTEM................162
      Description................162
      Fuse Location................162
      Electrical System Service................162
      Battery Removal And Installation................163
      Using A Booster Battery (Jump Starting)................164
    HYDRAULIC / HYDROSTATIC SYSTEM................165
      Checking And Adding Fluid................165
      Breather Cap................165
      Replacing The Hydraulic / Hydrostatic Filter Element................166
      Removing The Hydraulic / Hydrostatic Fluid................166
    SPARK ARRESTOR MUFFLER................167
    TIRE MAINTENANCE................168
      Wheel Nuts................168
      Tire Rotation................168
      Tire Inflation................168
    FINAL DRIVE TRANSMISSION (CHAINCASE)................169
      Checking And Adding Oil................169
    AUXILIARY CONTROL LOCKBOLT................169
    LUBRICATING THE LOADER................170
    PIVOT PINS................172
    BOB-TACH................172
      Inspection And Maintenance................172
  SYSTEMS ANALYSIS................173
    TROUBLESHOOTING THE ENGINE................175
    TROUBLESHOOTING THE HYDRAULIC SYSTEM................176
    TROUBLESHOOTING THE HYDROSTATIC SYSTEM................176
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)................178
  MACHINE SIGN TRANSLATIONS................179
    IMPORTANT - 6560573................181
    WARNING - 6579511................182
    SERVICE SCHRDULE - 6708212................183
    WARNING - 6579510................185
    WARNING - 6579528................186
    DANGER - 6702302................186
    WARNING - 6577754................186
    DANGER - 6702301................186
    DANGER - 6717343................187
  SPECIFICATIONS................189
    SKID STEER LOADER SPECIFICATIONS................191
      Performance................191
      Engine................191
      Loader Controls................191
      Drive System................191
      Hydraulic System................191
      Electrical System................191
      Capacities................191
    BOBCAT APRROVED ATTACHMENTS & ACCESSORIES................192
    ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS................193
  WARRANTY................195
6901177 (06-12) - 463 Loader Service Manual.pdf................197
  MAINTENANCE SAFETY................199
  ALPHABETICAL INDEX................201
  CONTENTS................203
    FOREWORD................204
    SAFETY INSTRUCTIONS................207
      Fire Prevention................209
    SERIAL NUMBER LOCATIONS................211
      Bobcat Loader Serial Number................211
      Engine Serial Number................211
    DELIVERY REPORT................211
    BOBCAT SKID STEER LOADER IDENTIFICATION................212
  SAFETY AND MAINTENANCE................213
    LIFTING AND BLOCKING THE LOADER................215
      Procedure................215
    LIFT ARM SUPPORT DEVICE................217
      Engaging The Lift Arm Support Device................217
      Disengaging The Lift Arm Support Device................218
    OPERATOR CAB................219
      Description................219
      Raising The Operator Cab................219
      Lowering The Operator Cab................220
      Emergency Exit................221
    TRANSPORTING THE LOADER................223
      Procedure................223
      Adjusting The Bumper................223
    TOWING THE LOADER................225
      Procedure................225
    REMOTE START SWITCH................227
      Procedure................227
    SERVICE SCHEDULE................229
      Chart................229
    AIR CLEANER SERVICE................231
      Replacing Filter Element................231
    ENGINE COOLING SYSTEM................233
      Checking The Coolant Level................233
      Cleaning The Cooling System................233
      Replacing The Coolant................234
    FUEL SYSTEM................235
      Fuel Specification................235
      Filling The Fuel Tank................235
      Fuel Filter................237
      Removing Air From The Fuel System................238
    ENGINE LUBRICATION SYSTEM................239
      Checking Engine Oil................239
      Oil Chart................239
      Replacing Oil And Filter................239
    HYDRAULIC/HYDROSTATIC SYSTEM................241
      Checking And Adding Fluid................241
      Hydraulic/Hydrostatic Filter Replacement................242
      Replacing The Hydraulic/Hydrostatic Fluid................242
    FINAL DRIVE TRANSMISSION (CHAINCASE)................243
      Checking And Adding Oil................243
    AUXILIARY CONTROL LOCKBOLT................245
      Procedure................245
    BOB-TACH................247
      Inspection And Maintenance................247
    LUBRICATING THE LOADER................249
      Procedure................249
    TIRE MAINTENANCE................251
      Wheel Nuts................251
      Tire Rotation................251
      Tire Inflation................251
    SPARK ARRESTOR MUFFLER................253
      Cleaning Procedure................253
    PIVOT PINS................255
    SEAT BAR RESTRAINT SYSTEM................257
      Seat Bar Inspection................257
      Seat Bar Maintenance................257
      Foot Pedal Clean Out................258
  HYDRAULIC SYSTEM................259
    HYDRAULIC/HYDROSTATIC SCHEMATICS................261
    HYDRAULIC SYSTEM INFORMATION................265
      Troubleshooting Chart................269
    CYLINDER (LIFT)................271
      Checking The Lift Cylinder(s)................271
      Removal And Installation................272
      Parts Identification................274
      Disassembly And Assembly................275
    CYLINDER (TILT)................279
      Checking The Tilt Cylinder................279
      Removal And Installation................279
      Parts Identification................281
      Disassembly And Assembly................282
    MAIN RELIEF VALVE................285
      Checking The Main Relief Valve Without Auxiliaries................285
      Checking The Main Relief Valve With Auxiliaries................286
      Removal And Installation................287
      Main Relief Valve Adjustment................287
    HYDRAULIC CONTROL VALVE................289
      Removal And Installation................289
      Identification Chart................291
      Disassembly And Assembly................291
      Load Check Valves................292
      Main Relief Valve................292
      Port Relief/Anti-Cavitation Valve................293
      Port Relief Valves................293
      Rubber Boot................294
      Lift Spool Detent................294
      Tilt Centering Spring................299
      Auxiliary Spool Detent................299
      Spool Seal Installation................300
    BICS™ BLOCK VALVE................301
      Description................301
      Disassembly And Assembly................302
    HYDRAULIC PUMP................305
      Checking The Output Of The Pump................305
      Removal And Installation................306
      Parts Identification................309
      Disassembly And Assembly................310
    HYDRAULIC FILTER................313
      Block Removal And Installation................313
      Block Disassembly And Assembly................314
    HYDRAULIC RESERVOIR................317
      Removal And Installation................317
    CONTROLS................319
      Pedal Interlock Linkage Removal And Installation................319
      Control Pedals Removal And Installation................320
      Pedal Adjustment................320
  HYDROSTATIC SYSTEM................321
    HYDROSTATIC SYSTEM INFORMATION................323
      Troubleshooting Chart................323
      Replentishing The Valve Function................324
    CONTROL PANEL................325
      Control Shield And Steering Lever Panels Removal And Installation................325
    STEERING................327
      Lever Removal And Installation................327
      Lever Disassembly And Assembly................329
      Linkage Adjustment................329
      Pintle Arm Removal And Installation................330
      Pintle Arm Disassembly And Assembly................331
    HYDROSTATIC MOTOR................333
      Removal And Installation................333
      Parts Identification................334
      Disassembly................335
      Inspection................339
      Assembly................341
    CHARGE PRESSURE................345
      Checking................345
    HYDROSTATIC PUMP................347
      Parts Identification................347
      Removal And Installation................348
      Disassembly And Assembly................351
    DRIVE BELT................361
      Removal And Installation................361
      Tension Pulley And Spring Removal And Installation................361
  DRIVE SYSTEM................365
    PARKING BRAKE................367
      Pedal Removal And Installation................367
      Pedal Disassembly And Assembly................368
      Disc Removal And Installation................369
    DRIVE COMPONENTS................371
      Axle Hub Removal And Installation................371
      Axle Seal Removal And Installation................372
      Removing The Axle................373
      Removing And Installing The Axle Bearing................374
      Removing The Bearing Races................375
      Installing The Bearing Races................377
      Installing The Inner Bearing And Axle Sprocket................377
      Drive Chain Removal And Installation................378
    CHAINCASE................379
      Removing Oil From The Chaincase................379
      Chaincase Cover Removal And Installation................379
      Chaincase Cover Assembly And Disassembly................380
  MAIN FRAME................381
    SEAT BAR................383
      Removal And Installation................383
      Assembly................386
    OPERATOR CAB................387
      Removal And Installation................387
      Gas Cylinder Removal And Installation................389
    OPERATOR SEAT................391
      Removal And Installation................391
    BOB-TACH................393
      Removal................393
      Installation................394
      Seal Removal And Installation................395
      Lever And Wedge Removal................396
    LIFT ARMS................397
      Removal And Installation................397
    REAR WINDOW................399
      Removal................399
      Installation................399
    REAR DOOR................401
      Exhaust Pipe Removal And Installation................401
      Removal And Installation................401
    FUEL TANK................403
      Removal And Installation................403
  ELECTRICAL SYSTEM & ANALYSIS................405
    ELECTRICAL SCHEMATICS................407
    ELECTRICAL SYSTEM INFORMATION................413
      Troubleshooting Chart................413
      Description................414
      Fuse Location................414
      Relay Switches Location................415
    BATTERY................417
      Removal And Installation................417
      Servicing................419
      Using A Booster Battery (Jump Starting)................420
    ALTERNATOR................421
      Removal And Installation................421
      Adjusting The Alternator Belt................422
      Alternator Belt Removal And Installation................422
      Description................424
      Tests................424
      Alternator Output Test................424
      Full Field Test................425
      Alternator Regulator Test................425
      Alternator Regulator Test Using Voltmeter................426
    STARTER................427
      Removal And Installation................427
      Checking The Starter In The Loader................428
      Parts Identification................429
      Disassembly................430
      Inspection And Repair................435
      No Load Test................438
      Assembly................439
    INSTRUMENT PANEL................447
      Removal And Installation................447
    LIGHTS................449
      Front Lights Removal And Installation................449
      Rear Lights Removal And Installation................450
    BICS™ SYSTEM CONTROLLER................451
      Trouble Shooting Guide................451
      Removal And Installation................452
    BICS™ SYSTEM (WITH PRESS TO OPERATE BUTTON)................455
      Inspecting The BICS™ Controller (Engine STOPPED - Key ON)................455
      Inspecting The Seat Bar Sensor (Engine RUNNING)................455
      Inspecting The Traction Lock (Engine RUNNING)................455
      Inspecting The Lift Arm By-Pass Control................455
      Troubleshooting Chart................456
    SEAT BAR SENSOR................457
      Troubleshooting Guide................457
      Seat Bar Sensor Test................458
      Removal And Installation................459
      BICS™ Controller Seat Bar Sensor Circuit Test................461
    TRACTION LOCK................463
      Troubleshooting Guide................463
      Removal And Installation................464
  ENGINE SERVICE................467
    TROUBLESHOOTING................469
      Chart................469
    ENGINE SPEED CONTROL................471
      Adjustment................471
      Removal And Installation................471
    MUFFLER................473
      Removal And Installation................473
    AIR CLEANER................475
      Housing Removal And Installation................475
    RADIATOR................477
      Removal And Installation................477
      Mounting Bracket Removal And Installation................477
    FAN................479
      Removal And Installation................479
    ENGINE COMPONENTS AND TESTING................481
      Valve Clearance Adjustment................481
      Fuel Injection Pump Check................482
      Fuel Lift Pump Removal And Installation................483
      Fuel Injection Pump Removal And Installation................483
      Fuel Injection Pump Timing................484
      Fuel Injector Nozzles Checking................486
      Fuel Injector Nozzles Removal................487
      Fuel Injector Nozzles Installation................488
      Glow Plugs Checking................489
      Engine Compression Test Procedure................489
    ENGINE................491
      Removal And Installation................491
    FLYWHEEL................499
      Removal And Installation................499
    ENGINE MOUNTING BRACKET................501
      Removal And Installation................501
    RECONDITIONING THE ENGINE................503
      Cylinder Head Removal And Installation................503
      Cylinder Head Inspection................504
      Cylinder Head Top Clearance................505
      Rocker Arm And Shaft Checking................505
      Valve Removal................506
      Valve Spring Checking................506
      Valve Guide Checking................507
      Reconditioning The Valve And Valve Seat................509
      Timing Gearcase Cover Removal And Installation................510
      Idler Gear And Camshaft Removal And Installation................512
      Servicing The Idler Gear And Shaft................514
      Checking Timing Gear Backlash................515
      Fuel Camshaft Removal And Installation................515
      Governor................516
      Crankshaft Gear Removal And Installation................516
      Oil Pump Removal And Installation................517
      Oil Pump Service................517
      Checking Engine Oil Pressure................518
      Relief Valve................518
      Piston And Connecting Rod Removal And Installation................519
      Piston And Connecting Rod Servicing................521
      Connecting Rod Alignment................523
      Crankshaft Bearings Removal And Installation................524
      Inspection Of Crankshaft And Bearings................526
      Cylinder Bore Inspection................528
      Hydraulic Oil Cooler And Shrouding Removal And Installation................528
      Thermostat Removal And Installation................529
      Testing The Thermostat................530
      Water Pump Removal And Installation................530
      Water Pump Disassembly And Assembly................530
  SPECIFICATIONS................531
    LOADER SPECIFICATIONS................533
      Machine Specifications................533
      Performance................533
      Controls................534
      Engine................534
      Hydraulic System................535
      Electrical................535
      Drive System................536
      Capacities................536
      Tires................536
      Floor Pressure................536
    ENGINE SPECIFICATIONS................537
      Engine................537
      Fuel Injector Nozzles................537
      Fuel Injection Pump................537
      Cylinder Head................537
      Valves................537
      Valve Springs................538
      Rocker Arms................538
      Camshaft................538
      Cylinders................538
      Piston Rings................539
      Pistons................539
      Crankshaft................539
      Oil Pump................540
      Thermostat................540
      Engine Bolt Torque................541
      Bolt Torques................541
      Re-Grinding The Crankshaft................542
    TORQUE SPECIFICATIONS FOR BOLTS................543
      Torque For General SAE Bolts................543
      Torque For General Metric Bolts................543
    HYDRAULIC CONNECTION SPECIFICATIONS................545
      O-Ring Face Seal Connection................545
      Straight Thread O-Ring Fitting................545
      Tubelines And Hoses................545
      Flare Fitting................546
      O-Ring Flare Fitting................547
      Port Seal Fitting................548
    HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS................551
      Specifications................551
    CONVERSIONS................553
      Decimal And Millimeter Equivalents................553
      U.S. To Metric Conversion................554
  SMR................555
    Revision No: 463-1................555
    Revision No: 463-2................557
    Revision No: 463-3................559
    Revision No: 463-4................561
    Revision No: 463-5................563
6901177 (3-06) - 463 Loader Service Manual................565
6901811 (10-04) - 463 Loader Operation & Maintenance Manual................931
  OPERATOR SAFETY WARNINGS................933
  CONTENTS................935
  FOREWORD................937
    BOBCAT COMPANY IS ISO 9001 CERTIFIED................939
    REGULAR MAINTENANCE ITEMS................939
    MOTOR OIL................939
    SERIAL NUMBER LOCATIONS................941
    LOADER SERIAL NUMBER................941
    ENGINE SERIAL NUMBER................942
    DELIVERY REPORT................942
    BOBCAT LOADER IDENTIFICATION................943
    FEATURES, ACCESSORIES AND ATTACHMENTS................944
      Standard Items................944
      Options and Accessories................944
      Attachments................944
  SAFETY................945
    SAFETY INSTRUCTIONS................947
      Before Operation................947
      Safe Operation Is The Operator’s Responsibility................948
      Safe Operation Needs A Qualified Operator................948
      Fire Prevention................949
    MACHINE SIGNS (DECALS)................950
  OPERATING INSTRUCTIONS................953
    INSTRUMENT PANELS................955
      Left, Right And Accessory Panels................955
    BOBCAT INTERLOCK CONTROL SYSTEM (bics™)................956
      Description................956
      Lift Arm By-Pass Control................956
      Traction Lock Override................957
    ENGINE SPEED CONTROL................957
      Operation................957
    PARKING BRAKE................957
      Operation................957
    STEERING LEVERS................958
      Operation................958
    STOPPING THE BOBCAT LOADER................958
      Procedure................958
    SEAT BAR RESTRAINT SYSTEM................959
    HYDRAULIC CONTROLS................960
      Foot Pedals................960
      Bucket Position Valve Operation (If Equipped)................960
      Auxiliary Hydraulics................961
      Quick Couplers................961
      Auxiliary Hydraulic Continuous Operation................962
      Relieving Hydraulic Pressure................962
    DAILY INSPECTION................963
      Daily Inspection and Maintenance................963
    GETTING READY FOR OPERATION................964
    STARTING THE ENGINE................965
      Normal Starting................966
      Cold Temperature Starting................966
      Warming The Hydraulic/Hydrostatic System................967
    STOPPING THE ENGINE................967
    ATTACHMENTS AND BUCKETS................968
      Choosing The Correct Bucket................968
      Pallet Forks................968
      Installing The Bucket or Attachment................969
      Removing The Bucket Or Attachment................970
    OPERATING PROCEDURE................971
      Operating With A Full Bucket................971
      Filling The Bucket................972
      Emptying the Bucket................972
      Digging Into The Ground................973
      Leveling The Ground (Using Lift Arms In Float Position)................973
      Backfilling................973
    PARKING THE BOBCAT LOADER................974
    TRANSPORTING THE BOBCAT LOADER................974
      Loading Onto Transport Vehicle................974
      Fastening To Transport Vehicle................975
    LIFTING THE LOADER................976
    TOWING THE LOADER................977
  PREVENTIVE MAINTENANCE................979
    MAINTENANCE SAFETY................981
    SERVICE SCHEDULE................983
      Chart................983
    LIFT ARM SUPPORT DEVICE................984
      Engaging The Lift Arm Support Device................984
      Disengaging The Lift Arm Support Device................985
    OPERATOR CAB................986
      Description................986
      Raising The Operator Cab................986
      Lowering The Operator Cab................987
      Emergency Exit................988
    SEAT BAR RESTRAINT SYSTEM................989
      Inspecting The Seat Bar................989
      Maintaining The Seat Bar................989
      Foot Pedal Clean Out................989
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)................990
      Inspecting The BICS Controller (Engine Stopped - Key ON)................990
      Inspecting The Seat Bar Sensor (Engine RUNNING)................990
      Inspecting The Traction Lock (Engine RUNNING)................990
      Inspecting The Lift Arm By-Pass Control................990
    REAR DOOR................991
      Opening And Closing The Rear Door................991
    AIR CLEANER SERVICE................992
      Replacing Filter Elements................992
    FUEL SYSTEM................993
      Fuel Specifications................993
      Filling The Fuel Tank................993
      Fuel Filter................993
      Removing Air From The Fuel System................994
      Removing Air From The Fuel System................994
    ENGINE LUBRICATION SYSTEM................995
      Checking Engine Oil................995
      Replacing The Oil And Filter................995
    ENGINE COOLING SYSTEM................996
      Checking The Coolant Level................996
      Cleaning The Cooling System................996
      Removing & Replacing Coolant In The Cooling System................996
    ALTERNATOR BELT................997
      Adjusting The Alternator Belt................997
    ELECTRICAL SYSTEM................998
      Description................998
      Fuse Location................998
      Using A Booster Battery (Jump Starting)................999
      Removing And Installing The Battery................1000
    HYDRAULIC / HYDROSTATIC SYSTEM................1001
      Checking And Adding Fluid................1001
      Replacing Hydraulic/Hydrostatic Filter................1001
      Replacing Hydraulic Fluid................1002
      Reservoir Breather................1002
    SPARK ARRESTOR MUFFLER................1003
      Maintenance................1003
    TIRE MAINTENANCE................1004
      Wheel Nuts................1004
      Tire Rotation................1004
      Mounting................1004
    FINAL DRIVE TRANSMISSION (CHAINCASE)................1005
      Checking And Adding Oil................1005
    AUXILIARY CONTROL LOCKBOLT................1005
    LUBRICATING THE BOBCAT LOADER................1006
      Lubrication Locations................1006
    PIVOT PINS................1007
      Inspection And Maintenance................1007
    BOB-TACH................1008
      Inspection And Maintenance................1008
  SYSTEM SETUP & ANALYSIS................1009
    TROUBLESHOOTING................1011
      Troubleshooting The Engine................1011
      Troubleshooting The Hydraulic System................1012
      Troubleshooting The Hydrostatic System................1012
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)................1013
      Troubleshooting Chart................1013
  MACHINE SIGN TRANSLATIONS................1015
    SERVICE SCHEDULE (6708212)................1017
    SERVICE SCHEDULE (CONT’D) (6708212)................1018
    WARNING (6579510)................1019
    DANGER (6702301)................1020
    WARNING (6577754)................1020
    DANGER (6702302)................1021
    WARNING (6579528)................1021
    WARNING (6717343)................1022
    WARNING (6576048)................1022
    IMPORTANT (6560573)................1023
    WARNING (6710358)................1023
    WARNING (6579511)................1024
  SPECIFICATIONS................1025
    LOADER SPECIFICATIONS (463)................1027
      Machine Dimensions................1027
      Performance................1028
      Controls................1028
      Engine................1028
      Hydraulic System................1029
      Electrical................1029
      Drive System................1030
      Capacities................1030
      Tires................1030
    ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS................1031
  WARRANTY................1033
6901811 (8-04) - 463 Loader Operation & Maintenance Manual................1035
  OPERATOR SAFETY WARNINGS................1037
  CONTENTS................1039
  FOREWORD................1041
    BOBCAT COMPANY IS ISO 9001 CERTIFIED................1043
    REGULAR MAINTENANCE ITEMS................1043
    MOTOR OIL................1043
    SERIAL NUMBER LOCATIONS................1045
    LOADER SERIAL NUMBER................1045
    ENGINE SERIAL NUMBER................1046
    DELIVERY REPORT................1046
    BOBCAT LOADER IDENTIFICATION................1047
    FEATURES, ACCESSORIES AND ATTACHMENTS................1048
      Standard Items................1048
      Options and Accessories................1048
      Attachments................1048
  SAFETY................1049
    SAFETY INSTRUCTIONS................1051
      Before Operation................1051
      Safe Operation Is The Operator’s Responsibility................1052
      Safe Operation Needs A Qualified Operator................1052
      Fire Prevention................1053
    MACHINE SIGNS (DECALS)................1054
  OPERATING INSTRUCTIONS................1057
    INSTRUMENT PANELS................1059
      Left, Right And Accessory Panels................1059
    BOBCAT INTERLOCK CONTROL SYSTEM (bics™)................1060
      Description................1060
      Lift Arm By-Pass Control................1060
      Traction Lock Override................1061
    ENGINE SPEED CONTROL................1061
      Operation................1061
    PARKING BRAKE................1061
      Operation................1061
    STEERING LEVERS................1062
      Operation................1062
    STOPPING THE BOBCAT LOADER................1062
      Procedure................1062
    SEAT BAR RESTRAINT SYSTEM................1063
    HYDRAULIC CONTROLS................1064
      Foot Pedals................1064
      Bucket Position Valve Operation (If Equipped)................1064
      Auxiliary Hydraulics................1065
      Quick Couplers................1065
      Auxiliary Hydraulic Continuous Operation................1066
      Relieving Hydraulic Pressure................1066
    DAILY INSPECTION................1067
      Daily Inspection and Maintenance................1067
    GETTING READY FOR OPERATION................1068
    STARTING THE ENGINE................1069
      Normal Starting................1070
      Cold Temperature Starting................1070
      Warming The Hydraulic/Hydrostatic System................1071
    STOPPING THE ENGINE................1071
    ATTACHMENTS AND BUCKETS................1072
      Choosing The Correct Bucket................1072
      Pallet Forks................1072
      Installing The Bucket or Attachment................1073
      Removing The Bucket Or Attachment................1074
    OPERATING PROCEDURE................1075
      Operating With A Full Bucket................1075
      Filling The Bucket................1076
      Emptying the Bucket................1076
      Digging Into The Ground................1077
      Leveling The Ground (Using Lift Arms In Float Position)................1077
      Backfilling................1077
    PARKING THE BOBCAT LOADER................1078
    TRANSPORTING THE BOBCAT LOADER................1078
      Loading Onto Transport Vehicle................1078
      Fastening To Transport Vehicle................1079
    LIFTING THE LOADER................1080
    TOWING THE LOADER................1081
  PREVENTIVE MAINTENANCE................1083
    MAINTENANCE SAFETY................1085
    SERVICE SCHEDULE................1087
      Chart................1087
    LIFT ARM SUPPORT DEVICE................1088
      Engaging The Lift Arm Support Device................1088
      Disengaging The Lift Arm Support Device................1089
    OPERATOR CAB................1090
      Description................1090
      Raising The Operator Cab................1090
      Lowering The Operator Cab................1091
      Emergency Exit................1092
    SEAT BAR RESTRAINT SYSTEM................1093
      Inspecting The Seat Bar................1093
      Maintaining The Seat Bar................1093
      Foot Pedal Clean Out................1093
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)................1094
      Inspecting The BICS Controller (Engine Stopped - Key ON)................1094
      Inspecting The Seat Bar Sensor (Engine RUNNING)................1094
      Inspecting The Traction Lock (Engine RUNNING)................1094
      Inspecting The Lift Arm By-Pass Control................1094
    REAR DOOR................1095
      Opening And Closing The Rear Door................1095
    AIR CLEANER SERVICE................1096
      Replacing Filter Elements................1096
    FUEL SYSTEM................1097
      Fuel Specifications................1097
      Filling The Fuel Tank................1097
      Fuel Filter................1097
      Removing Air From The Fuel System................1098
      Removing Air From The Fuel System................1098
    ENGINE LUBRICATION SYSTEM................1099
      Checking Engine Oil................1099
      Replacing The Oil And Filter................1099
    ENGINE COOLING SYSTEM................1100
      Checking The Coolant Level................1100
      Cleaning The Cooling System................1100
      Removing & Replacing Coolant In The Cooling System................1100
    ALTERNATOR BELT................1101
      Adjusting The Alternator Belt................1101
    ELECTRICAL SYSTEM................1102
      Description................1102
      Fuse Location................1102
      Using A Booster Battery (Jump Starting)................1103
      Removing And Installing The Battery................1104
    HYDRAULIC / HYDROSTATIC SYSTEM................1105
      Checking And Adding Fluid................1105
      Replacing Hydraulic/Hydrostatic Filter................1105
      Replacing Hydraulic Fluid................1106
      Reservoir Breather................1106
    SPARK ARRESTOR MUFFLER................1107
      Maintenance................1107
    TIRE MAINTENANCE................1108
      Wheel Nuts................1108
      Tire Rotation................1108
      Mounting................1108
    FINAL DRIVE TRANSMISSION (CHAINCASE)................1109
      Checking And Adding Oil................1109
    AUXILIARY CONTROL LOCKBOLT................1109
    LUBRICATING THE BOBCAT LOADER................1110
      Lubrication Locations................1110
    PIVOT PINS................1111
      Inspection And Maintenance................1111
    BOB-TACH................1112
      Inspection And Maintenance................1112
  SYSTEM SETUP & ANALYSIS................1113
    TROUBLESHOOTING................1115
      Troubleshooting The Engine................1115
      Troubleshooting The Hydraulic System................1116
      Troubleshooting The Hydrostatic System................1116
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS™)................1117
      Troubleshooting Chart................1117
  MACHINE SIGN TRANSLATIONS................1119
    SERVICE SCHEDULE (6708212)................1121
    SERVICE SCHEDULE (CONT’D) (6708212)................1122
    WARNING (6579510)................1123
    DANGER (6702301)................1124
    WARNING (6577754)................1124
    DANGER (6702302)................1125
    WARNING (6579528)................1125
    WARNING (6717343)................1126
    WARNING (6576048)................1126
    IMPORTANT (6560573)................1127
    WARNING (6710358)................1127
    WARNING (6579511)................1128
  SPECIFICATIONS................1129
    LOADER SPECIFICATIONS (463)................1131
      Machine Dimensions................1131
      Performance................1132
      Controls................1132
      Engine................1132
      Hydraulic System................1133
      Electrical................1133
      Drive System................1134
      Capacities................1134
      Tires................1134
    ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS................1135
  WARRANTY................1137
6901812 (10-12) - 463 Loader Service Manual................1139
  MAINTENANCE SAFETY................1141
  ALPHABETICAL INDEX................1143
  CONTENTS................1145
    FOREWORD................1146
    SAFETY INSTRUCTIONS................1149
      Fire Prevention................1151
    SERIAL NUMBER LOCATIONS................1153
      Bobcat Loader Serial Number................1153
      Engine Serial Number................1153
    DELIVERY REPORT................1153
    BOBCAT LOADER IDENTIFICATION................1154
  SAFETY AND MAINTENANCE................1155
    LIFTING AND BLOCKING THE LOADER................1157
      Procedure................1157
    LIFT ARM SUPPORT DEVICE................1159
      Engaging The Lift Arm Support Device................1159
      Disengaging The Lift Arm Support Device................1160
    OPERATOR CAB................1161
      Description................1161
      Raising The Operator Cab................1161
      Lowering The Operator Cab................1162
      Emergency Exit................1163
    TRANSPORTING THE LOADER................1165
      Procedure................1165
      Adjusting The Bumper................1165
    TOWING THE LOADER................1167
      Procedure................1167
    REMOTE START SWITCH................1169
      Procedure................1169
    SERVICE SCHEDULE................1171
      Chart................1171
    AIR CLEANER SERVICE................1173
      Replacing Filter Element................1173
    ENGINE COOLING SYSTEM................1175
      Checking The Coolant Level................1175
      Cleaning The Cooling System................1175
      Replacing The Coolant................1176
    FUEL SYSTEM................1177
      Fuel Specification................1177
      Filling The Fuel Tank................1177
      Fuel Filter................1179
      Removing Air From The Fuel System................1180
    ENGINE LUBRICATION SYSTEM................1181
      Checking Engine Oil................1181
      Oil Chart................1181
      Replacing Oil And Filter................1181
    HYDRAULIC/HYDROSTATIC SYSTEM................1183
      Checking And Adding Fluid................1183
      Hydraulic/Hydrostatic Filter Replacement................1184
      Replacing The Hydraulic/Hydrostatic Fluid................1184
    FINAL DRIVE TRANSMISSION (CHAINCASE)................1185
      Checking And Adding Oil................1185
    AUXILIARY CONTROL LOCKBOLT................1187
      Procedure................1187
    BOB-TACH................1189
      Inspection And Maintenance................1189
    LUBRICATING THE LOADER................1191
      Procedure................1191
    TIRE MAINTENANCE................1193
      Wheel Nuts................1193
      Tire Rotation................1193
      Tire Inflation................1193
    SPARK ARRESTOR MUFFLER................1195
      Cleaning Procedure................1195
    PIVOT PINS................1197
      Procedure................1197
    SEAT BAR RESTRAINT SYSTEM................1199
      Seat Bar Inspection................1199
      Seat Bar Maintenance................1199
      Foot Pedal Clean Out................1200
  HYDRAULIC SYSTEM................1201
    HYDRAULIC/HYDROSTATIC SCHEMATICS................1203
    HYDRAULIC SYSTEM INFORMATION................1207
      Troubleshooting Chart................1211
    CYLINDER (LIFT)................1213
      Checking The Lift Cylinder(s)................1213
      Removal And Installation................1214
      Parts Identification................1216
      Disassembly And Assembly................1217
    CYLINDER (TILT)................1221
      Checking The Tilt Cylinder................1221
      Removal And Installation................1221
      Parts Identification................1223
      Disassembly And Assembly................1224
    MAIN RELIEF VALVE................1227
      Checking The Main Relief Valve Without Auxiliaries................1227
      Checking The Main Relief Valve With Auxiliaries................1228
      Removal And Installation................1229
    HYDRAULIC CONTROL VALVE................1231
      BICS™ Valve Removal And Installation................1231
      BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation................1232
      BICS™ Valve, Pressure Differential Valve Removal And Installation................1233
      BICS™ Valve, Check Valve Removal And Installation................1233
      BICS™ Valve, Solenoid Removal And Installation................1234
      BICS™ Valve, Solenoid Testing................1235
      BICS™ Valve, Identification Chart................1236
      Removal And Installation................1236
      Identification Chart................1238
      Disassembly And Assembly................1239
      Load Check Valves Removal And Installation................1239
      Main Relief Valve Removal And Installation................1239
      Port Relief/Anti-Cavitation Valve Removal And Installation................1240
      Anti Cavitation/Check Valves Removal And Installation................1241
      Rubber Boot Removal And Installation................1242
      Lift And Tilt Lock Block Removal And Installation................1242
      Lift Spool And Detent Removal................1243
      Lift Spool And Detent Disassembly................1244
      Lift Spool And Detent Assembly................1246
      Lift Spool Detent Installation................1248
      Tilt Spool Removal And Installation................1249
      Tilt Spool Disassembly And Assembly................1250
      Auxiliary Spool Removal And Installation................1251
      Auxiliary Spool Disassembly And Assembly................1251
      Spool Seal Installation................1254
      Auxiliary Pivot Bracket Removal And Installation................1255
      Auxiliary Pivot Bracket Disassembly And Assembly................1255
    LIFT ARM BY-PASS VALVE................1257
      Removal And Installation................1257
      Disassembly And Assembly................1257
    HYDRAULIC PUMP................1259
      Checking The Output Of The Pump................1259
      Removal And Installation................1260
      Parts Identification................1263
      Disassembly And Assembly................1264
    HYDRAULIC FILTER................1267
      Block Removal And Installation................1267
      Block Disassembly And Assembly................1268
    HYDRAULIC RESERVOIR................1269
      Removal And Installation................1269
    CONTROLS................1271
      Pedal Interlock Linkage Removal And Installation................1271
      Control Pedals Removal And Installation................1272
      Pedal Adjustment................1272
  HYDROSTATIC SYSTEM................1273
    HYDROSTATIC SYSTEM INFORMATION................1275
      Troubleshooting Chart................1275
    CONTROL PANEL................1277
      Control Shield And Steering Lever Panels Removal And Installation................1277
    STEERING................1279
      Lever Removal And Installation................1279
      Lever Disassembly And Assembly................1281
      Linkage Adjustment................1281
      Pintle Arm Removal And Installation................1282
      Pintle Arm Disassembly And Assembly................1283
    HYDROSTATIC MOTOR................1285
      Removal And Installation................1285
      Parts Identification................1286
      Disassembly................1287
      Inspection................1291
      Assembly................1293
    CHARGE PRESSURE................1297
      Checking................1297
    HYDROSTATIC PUMP................1299
      Parts Identification................1299
      Removal And Installation................1300
      Disassembly And Assembly................1301
    DRIVE BELT................1311
      Removal And Installation................1311
      Tension Pulley And Spring Removal And Installation................1311
    OIL COOLER................1315
      Removal And Installation................1315
  DRIVE SYSTEM................1317
    PARKING BRAKE................1319
      Disc Removal And Installation................1319
    DRIVE COMPONENTS................1321
      Axle Hub Removal And Installation................1321
      Axle Seal Removal And Installation................1322
      Removing The Axle................1323
      Removing And Installing The Axle Bearing................1324
      Removing The Bearing Races................1325
      Installing The Bearing Races................1327
      Installing The Inner Bearing And Axle Sprocket................1327
      Drive Chain Removal And Installation................1328
    CHAINCASE................1329
      Removing Oil From The Chaincase................1329
      Chaincase Cover Removal And Installation................1329
      Chaincase Cover Assembly And Disassembly................1329
  MAIN FRAME................1331
    SEAT BAR................1333
      Removal And Installation................1333
      Assembly................1336
    OPERATOR CAB................1337
      Removal And Installation................1337
      Gas Cylinder Removal And Installation................1339
    OPERATOR SEAT................1341
      Removal And Installation................1341
    BOB-TACH................1343
      Removal................1343
      Installation................1344
      Seal Removal And Installation................1345
      Lever And Wedge Removal................1346
    LIFT ARMS................1347
      Removal And Installation................1347
    REAR WINDOW................1351
      Removal................1351
      Installation................1351
    REAR DOOR................1353
      Removal And Installation................1353
    FUEL TANK................1355
      Removal And Installation................1355
  ELECTRICAL SYSTEM & ANALYSIS................1357
    ELECTRICAL SCHEMATICS................1359
    ELECTRICAL SYSTEM INFORMATION................1365
      Troubleshooting Chart................1365
      Description................1366
      Fuel Shutoff Timer and Fuel Pull Solenoid Locations................1366
      Fuse And Relay Switches Location................1366
    BATTERY................1367
      Removal And Installation................1367
      Servicing................1368
      Using A Booster Battery (Jump Starting)................1369
    ALTERNATOR................1371
      Removal And Installation................1371
      Adjusting The Alternator Belt................1372
      Alternator Belt Removal And Installation................1372
      Description................1373
      Alternator Output Test................1373
    STARTER................1375
      Removal And Installation................1375
      Checking The Starter In The Loader................1375
      Parts Identification................1376
      Disassembly................1377
      Inspection And Repair................1382
      No Load Test................1385
      Assembly................1386
    INSTRUMENT PANEL................1393
      Removal And Installation................1393
    LIGHTS................1395
      Front Lights Removal And Installation................1395
      Rear Lights Removal And Installation................1396
      Cab Light Removal And Installation................1397
    BICS™ SYSTEM CONTROLLER................1399
      Troubleshooting Guide................1399
      Removal And Installation................1400
    BICS™ SYSTEM (WITH PRESS TO OPERATE BUTTON)................1401
      Inspecting The BICS™ Controller (Engine STOPPED - Key ON)................1401
      Inspecting The Seat Bar Sensor (Engine RUNNING)................1401
      Inspecting The Traction Lock (Engine RUNNING)................1401
      Inspecting The Lift Arm By-Pass Control................1401
      Troubleshooting Chart................1402
    SEAT BAR SENSOR................1403
      Troubleshooting Guide................1403
      Seat Bar Sensor Test................1404
      Removal And Installation................1405
      BICS™ Controller Seat Bar Sensor Circuit Test................1407
    TRACTION LOCK................1409
      Troubleshooting Guide................1409
      Removal And Installation................1410
  ENGINE SERVICE................1413
    TROUBLESHOOTING................1415
      Chart................1415
    ENGINE SPEED CONTROL................1417
      Adjustment................1417
      Removal And Installation................1417
    MUFFLER................1419
      Removal And Installation................1419
    AIR CLEANER................1421
      Removal And Installation................1421
    RADIATOR................1423
      Removal And Installation................1423
    COOLING FAN................1425
      Removal And Installation................1425
    ENGINE COMPONENTS AND TESTING................1427
      Fuel Injection Pump Check................1427
      Fuel Injection Pump Removal And Installation................1427
      Fuel Injection Pump Timing................1429
      Fuel Injector Nozzles Checking................1430
      Fuel Injector Nozzles Removal................1432
      Fuel Injector Nozzles Installation................1433
      Glow Plugs Checking................1433
      Engine Compression Test Procedure................1434
      Fuel Lift Pump Removal And Installation................1434
    ENGINE................1435
      Removal And Installation................1435
    FLYWHEEL................1443
      Removal And Installation................1443
    ENGINE MOUNTING BRACKET................1445
      Removal And Installation................1445
    RECONDITIONING THE ENGINE................1447
      Thermostat Removal And Installation................1447
      Water Pump Removal And Installation................1447
      Timing Gear Case Cover Removal And Installation................1448
      Oil Pump Removal And Installation................1450
      Crankshaft Front Seal Removal And Installation................1452
      Engine Speed Control Plate Removal And Installation................1453
      Governor Spring Removal................1453
      Start Spring Removal................1454
      Idle Limit And Fuel Limit Adjustment................1454
      Exhaust Manifold Removal And Installation................1454
      Valve Cover Removal And Installation................1455
      Rocker Arm Removal And Installation................1456
      Push Rod Removal And Installation................1457
      Tappet Removal And Installation................1458
      Water Flange Removal And Installation................1458
      Cylinder Head Removal................1459
      Cylinder Head Installation................1459
      Checking Piston Top Clearance................1460
      Cylinder Head Disassembly................1461
      Cylinder Head Assembly................1461
      Servicing The Cylinder Head................1462
      Combustion Chamber Removal And Installation................1464
      Idler Gear Removal And Installation................1465
      Camshaft Removal And Installation................1467
      Fuel Camshaft Removal And Installation................1469
      Oil Pan Removal And Installation................1470
      Governor Shaft Removal And Installation................1471
      Governor Fork Lever Removal And Installation................1474
      Piston Removal And Installation................1475
      Checking The Piston And Connecting Rod................1476
      Connecting Rod Alignment................1477
      Piston Ring Gap................1477
      Piston Ring Installation................1478
      Connecting Rod Installation................1478
      Checking Engine Cylinder Bore................1479
      Crankshaft Removal And Installation................1479
      Checking Crankshaft Journal And Block Bearing................1482
      Checking The Crankshaft Journal And Main Bearing................1483
      Connecting Rod Journal................1484
      Checking the End Play Of The Crankshaft................1485
      Crankshaft Alignment................1485
      Engine Timing Installation................1486
      Idler Gear And Crankshaft................1486
      Idler Gear And Camshaft Gear................1487
      Idler Gear And Fuel Camshaft Gear................1487
      Fuel Camshaft Gear And Governor Shaft Gear................1487
  SPECIFICATIONS................1489
    LOADER SPECIFICATIONS................1491
      Machine Specifications................1491
      Performance................1492
      Controls................1492
      Engine................1492
      Hydraulic System................1493
      Electrical................1493
      Drive System................1494
      Capacities................1494
      Tires................1494
      Floor Pressure................1494
    ENGINE SPECIFICATIONS................1495
      Engine................1495
      Fuel Injector Nozzles................1495
      Fuel Injection Pump................1495
      Cylinder Head................1495
      Valves................1495
      Valve Springs................1496
      Rocker Arms................1496
      Camshaft................1496
      Cylinders................1496
      Piston Rings................1497
      Pistons................1497
      Crankshaft................1497
      Oil Pump................1498
      Thermostat................1498
      Engine Bolt Torque................1498
      Bolt Torques................1499
      Re-Grinding The Crankshaft................1500
    TORQUE SPECIFICATIONS FOR BOLTS................1501
      Torque For General SAE Bolts................1501
      Torque For General Metric Bolts................1501
    HYDRAULIC CONNECTION SPECIFICATIONS................1503
      O-Ring Face Seal Connection................1503
      Straight Thread O-Ring Fitting................1503
      Tubelines And Hoses................1503
      Flare Fitting................1504
      O-Ring Flare Fitting................1505
      Port Seal Fitting................1506
    HYDRAULIC FLUID SPECIFICATIONS................1509
      Specifications................1509
    CONVERSIONS................1511
      Decimal And Millimeter Equivalents................1511
      U.S. To Metric Conversion................1512
  SMR................1513
    463-1................1513
    463-2................1515
    463-3................1517
6901812 (3-06) - 463 Loader Service Manual................1519
6903710 (12-04) - 463 Loader Operation & Maintenance Manual................1897
  OPERATOR SAFETY WARNINGS................1899
  CONTENTS................1901
  FOREWORD................1903
    BOBCAT COMPANY IS ISO 9001 CERTIFIED................1905
    REGULAR MAINTENANCE ITEMS................1905
    MOTOR OIL................1905
    SERIAL NUMBER LOCATIONS................1906
      Loader Serial Number................1906
      Engine Serial Number................1906
    DELIVERY REPORT................1906
    BOBCAT LOADER IDENTIFICATION................1907
    FEATURES, ACCESSORIES AND ATTACHMENTS................1908
      Standard Items................1908
      Options and Accessories................1908
      Attachments................1908
  SAFETY................1909
    SAFETY INSTRUCTIONS................1911
      Before Operation................1911
      Safe Operation Is The Operator’s Responsibility................1912
      Safe Operation Needs A Qualified Operator................1912
      Fire Prevention................1913
    MACHINE SIGNS (DECALS)................1914
  OPERATING INSTRUCTIONS................1917
    INSTRUMENT PANELS................1919
      Left, Right And Accessory Panels................1919
    BOBCAT INTERLOCK CONTROL SYSTEM (bics)................1920
      Description................1920
      Lift Arm By-Pass Control................1920
      Traction Lock Override................1921
    BACK-UP ALARM SYSTEM................1921
      Operation................1921
    ENGINE SPEED CONTROL................1922
      Operation................1922
    PARKING BRAKE................1922
      Operation................1922
    STEERING LEVERS................1923
      Operation................1923
    STOPPING THE BOBCAT LOADER................1923
      Procedure................1923
    SEAT BAR RESTRAINT SYSTEM................1924
    HYDRAULIC CONTROLS................1925
      Foot Pedals................1925
      Hydraulic Bucket Positioning................1925
      Auxiliary Hydraulics................1926
      Quick Couplers................1926
      Auxiliary Hydraulic Continuous Operation................1927
      Relieving Hydraulic Pressure................1927
    DAILY INSPECTION................1928
      Daily Inspection and Maintenance................1928
    GETTING READY FOR OPERATION................1929
    STARTING THE ENGINE................1930
      Normal Starting................1931
      Cold Temperature Starting................1931
      Warming The Hydraulic/Hydrostatic System................1932
    STOPPING THE ENGINE................1932
    ATTACHMENTS AND BUCKETS................1933
      Choosing The Correct Bucket................1933
      Pallet Forks................1933
      Installing The Bucket or Attachment................1934
      Removing The Bucket Or Attachment................1935
    OPERATING PROCEDURE................1936
      Operating With A Full Bucket................1936
      Filling The Bucket................1937
      Emptying the Bucket................1937
      Digging Into The Ground................1938
      Leveling The Ground (Using Lift Arms In Float Position)................1938
      Backfilling................1938
    PARKING THE BOBCAT LOADER................1939
    TRANSPORTING THE BOBCAT LOADER................1939
      Loading Onto Transport Vehicle................1939
      Fastening To Transport Vehicle................1940
    LIFTING THE LOADER................1941
    TOWING THE LOADER................1942
  PREVENTIVE MAINTENANCE................1943
    MAINTENANCE SAFETY................1945
    SERVICE SCHEDULE................1947
      Chart................1947
    LIFT ARM SUPPORT DEVICE................1948
      Engaging The Lift Arm Support Device................1948
      Disengaging The Lift Arm Support Device................1949
    BACK-UP ALARM SYSTEM................1950
      Description................1950
      Inspecting................1950
      Adjusting Switch Position................1950
    OPERATOR CAB................1951
      Description................1951
      Raising The Operator Cab................1951
      Lowering The Operator Cab................1952
      Emergency Exit................1953
    SEAT BAR RESTRAINT SYSTEM................1954
      Inspecting The Seat Bar................1954
      Maintaining The Seat Bar................1954
      Foot Pedal Clean Out................1954
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)................1955
      Inspecting The BICS Controller (Engine Stopped - Key ON)................1955
      Inspecting The Seat Bar Sensor (Engine RUNNING)................1955
      Inspecting The Traction Lock (Engine RUNNING)................1955
      Inspecting The Lift Arm ByPass Control................1955
    REAR DOOR................1956
      Opening And Closing The Rear Door................1956
    AIR CLEANER SERVICE................1957
      Replacing Filter Elements................1957
    FUEL SYSTEM................1958
      Fuel Specifications................1958
      Filling The Fuel Tank................1958
      Fuel Filter................1958
      Removing Air From The Fuel System................1959
      Checking Engine Oil................1960
      Replacing The Oil And Filter................1960
    ENGINE COOLING SYSTEM................1961
      Checking The Coolant Level................1961
      Cleaning The Cooling System................1961
      Removing and Replacing Coolant In The Cooling System................1961
    ALTERNATOR BELT................1962
      Adjusting The Alternator Belt................1962
    ELECTRICAL SYSTEM................1963
      Description................1963
      Fuse Location................1963
      Using A Booster Battery (Jump Starting)................1964
      Removing And Installing The Battery................1965
    HYDRAULIC / HYDROSTATIC SYSTEM................1966
      Checking And Adding Fluid................1966
      Replacing Hydraulic / Hydrostatic Filter................1966
      Replacing Hydraulic Fluid................1967
      Reservoir Breather................1967
    SPARK ARRESTOR MUFFLER................1968
      Maintenance................1968
    TIRE MAINTENANCE................1969
      Wheel Nuts................1969
      Tire Rotation................1969
      Mounting................1969
    FINAL DRIVE TRANSMISSION (CHAINCASE)................1970
      Checking And Adding Oil................1970
    AUXILIARY CONTROL LOCKBOLT................1970
      Description................1970
    LUBRICATING THE BOBCAT LOADER................1971
      Lubrication Locations................1971
    PIVOT PINS................1972
      Inspection And Maintenance................1972
    BOB-TACH................1973
      Inspection And Maintenance................1973
  SYSTEM SETUP & ANALYSIS................1975
    TROUBLESHOOTING................1977
      Troubleshooting The Engine................1977
      Troubleshooting The Hydraulic System................1978
      Troubleshooting The Hydrostatic System................1978
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)................1979
      Troubleshooting Chart................1979
  MACHINE SIGN TRANSLATIONS................1981
    SERVICE SCHEDULE (6708212)................1983
    WARNING (6579510)................1985
    DANGER (6702301)................1986
    DANGER (6702302)................1986
    WARNING (6577754)................1986
    WARNING (6579528)................1986
    DANGER (6717343)................1987
    WARNING (6576048)................1987
    IMPORTANT (6560573)................1987
    WARNING (6710358)................1987
    WARNING (6579511)................1988
  SPECIFICATIONS................1989
    LOADER SPECIFICATIONS (463)................1991
      Dimensions................1991
      Performance................1992
      Controls................1992
      Engine................1992
      Hydraulic System................1993
      Electrical................1993
      Drive System................1994
      Capacities................1994
      Tires................1994
    ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS................1995
  WARRANTY................1997
6903710 (5-07) - 463 Operation & Maintenance Manual................1999
  OPERATOR SAFETY WARNINGS................2001
  CONTENTS................2003
  FOREWORD................2005
    BOBCAT COMPANY IS ISO 9001 CERTIFIED................2007
    REGULAR MAINTENANCE ITEMS................2007
    MOTOR OIL................2007
    SERIAL NUMBER LOCATIONS................2008
      Loader Serial Number................2008
      Engine Serial Number................2008
    DELIVERY REPORT................2008
    BOBCAT LOADER IDENTIFICATION................2009
    FEATURES, ACCESSORIES AND ATTACHMENTS................2010
      Standard Items................2010
      Options and Accessories................2010
      Attachments................2010
  SAFETY................2011
    SAFETY INSTRUCTIONS................2013
      Before Operation................2013
      Safe Operation Is The Operator’s Responsibility................2014
      Safe Operation Needs A Qualified Operator................2014
      Fire Prevention................2015
    MACHINE SIGNS (DECALS)................2016
  OPERATING INSTRUCTIONS................2019
    INSTRUMENT PANELS................2021
      Left, Right And Accessory Panels................2021
    BOBCAT INTERLOCK CONTROL SYSTEM (bics)................2022
      Description................2022
      Lift Arm By-Pass Control................2022
      Traction Lock Override................2023
    BACK-UP ALARM SYSTEM................2023
      Operation................2023
    ENGINE SPEED CONTROL................2024
      Operation................2024
    PARKING BRAKE................2024
      Operation................2024
    STEERING LEVERS................2025
      Operation................2025
    STOPPING THE BOBCAT LOADER................2025
      Procedure................2025
    SEAT BAR RESTRAINT SYSTEM................2026
    HYDRAULIC CONTROLS................2027
      Foot Pedals................2027
      Hydraulic Bucket Positioning................2027
      Auxiliary Hydraulics................2028
      Quick Couplers................2028
      Auxiliary Hydraulic Continuous Operation................2029
      Relieving Hydraulic Pressure................2029
    DAILY INSPECTION................2030
      Daily Inspection and Maintenance................2030
    GETTING READY FOR OPERATION................2031
    STARTING THE ENGINE................2032
      Normal Starting................2033
      Cold Temperature Starting................2033
      Warming The Hydraulic/Hydrostatic System................2034
    STOPPING THE ENGINE................2034
    ATTACHMENTS AND BUCKETS................2035
      Choosing The Correct Bucket................2035
      Pallet Forks................2035
      Installing The Bucket or Attachment................2036
      Removing The Bucket Or Attachment................2037
    OPERATING PROCEDURE................2038
      Operating With A Full Bucket................2038
      Filling The Bucket................2039
      Emptying the Bucket................2039
      Digging Into The Ground................2040
      Leveling The Ground (Using Lift Arms In Float Position)................2040
      Backfilling................2040
    PARKING THE BOBCAT LOADER................2041
    TRANSPORTING THE BOBCAT LOADER................2041
      Loading Onto Transport Vehicle................2041
      Fastening To Transport Vehicle................2042
    LIFTING THE LOADER................2043
    TOWING THE LOADER................2044
  PREVENTIVE MAINTENANCE................2045
    MAINTENANCE SAFETY................2047
    SERVICE SCHEDULE................2049
      Chart................2049
    LIFT ARM SUPPORT DEVICE................2050
      Engaging The Lift Arm Support Device................2050
      Disengaging The Lift Arm Support Device................2051
    BACK-UP ALARM SYSTEM................2052
      Description................2052
      Inspecting................2052
      Adjusting Switch Position................2052
    OPERATOR CAB................2053
      Description................2053
      Raising The Operator Cab................2053
      Lowering The Operator Cab................2054
      Emergency Exit................2055
    SEAT BAR RESTRAINT SYSTEM................2056
      Inspecting The Seat Bar................2056
      Maintaining The Seat Bar................2056
      Foot Pedal Clean Out................2056
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)................2057
      Inspecting The BICS Controller (Engine Stopped - Key ON)................2057
      Inspecting The Seat Bar Sensor (Engine RUNNING)................2057
      Inspecting The Traction Lock (Engine RUNNING)................2057
      Inspecting The Lift Arm ByPass Control................2057
    REAR DOOR................2058
      Opening And Closing The Rear Door................2058
    AIR CLEANER SERVICE................2059
      Replacing Filter Elements................2059
    FUEL SYSTEM................2060
      Fuel Specifications................2060
      Filling The Fuel Tank................2060
      Fuel Filter................2060
      Removing Air From The Fuel System................2061
      Checking Engine Oil................2062
      Replacing The Oil And Filter................2062
    ENGINE COOLING SYSTEM................2063
      Checking The Coolant Level................2063
      Cleaning The Cooling System................2063
      Removing and Replacing Coolant In The Cooling System................2063
    ALTERNATOR BELT................2064
      Adjusting The Alternator Belt................2064
    ELECTRICAL SYSTEM................2065
      Description................2065
      Fuse Location................2065
      Using A Booster Battery (Jump Starting)................2066
      Removing And Installing The Battery................2067
    HYDRAULIC / HYDROSTATIC SYSTEM................2068
      Checking And Adding Fluid................2068
      Replacing Hydraulic / Hydrostatic Filter................2068
      Replacing Hydraulic Fluid................2069
      Reservoir Breather................2069
    SPARK ARRESTOR MUFFLER................2070
      Maintenance................2070
    TIRE MAINTENANCE................2071
      Wheel Nuts................2071
      Tire Rotation................2071
      Mounting................2071
    FINAL DRIVE TRANSMISSION (CHAINCASE)................2072
      Checking And Adding Oil................2072
    AUXILIARY CONTROL LOCKBOLT................2072
      Description................2072
    LUBRICATING THE BOBCAT LOADER................2073
      Lubrication Locations................2073
    PIVOT PINS................2074
      Inspection And Maintenance................2074
    BOB-TACH................2075
      Inspection And Maintenance................2075
  SYSTEM SETUP & ANALYSIS................2077
    TROUBLESHOOTING................2079
      Troubleshooting The Engine................2079
      Troubleshooting The Hydraulic System................2080
      Troubleshooting The Hydrostatic System................2080
    BOBCAT INTERLOCK CONTROL SYSTEM (BICS)................2081
      Troubleshooting Chart................2081
  MACHINE SIGN TRANSLATIONS................2083
    SERVICE SCHEDULE (6708212)................2085
    WARNING (6579510)................2087
    DANGER (6702301)................2088
    DANGER (6702302)................2088
    WARNING (6577754)................2088
    WARNING (6579528)................2088
    DANGER (6717343)................2089
    WARNING (6576048)................2089
    IMPORTANT (6560573)................2089
    WARNING (6710358)................2089
    WARNING (6579511)................2090
  SPECIFICATIONS................2091
    LOADER SPECIFICATIONS (463)................2093
      Dimensions................2093
      Performance................2094
      Controls................2094
      Engine................2094
      Hydraulic System................2095
      Electrical................2095
      Drive System................2096
      Capacities................2096
      Tires................2096
    ADDITIONAL PUBLICATIONS AND TRAINING MATERIALS................2097
  WARRANTY................2099
6903711 (10-12) - 463 Loader Service Manual................2101
  MAINTENANCE SAFETY................2103
  ALPHABETICAL INDEX................2105
  CONTENTS................2107
    FOREWORD................2108
    SAFETY INSTRUCTIONS................2111
      Fire Prevention................2113
    SERIAL NUMBER LOCATIONS................2115
      Bobcat Loader Serial Number................2115
      Engine Serial Number................2115
    DELIVERY REPORT................2115
    BOBCAT LOADER IDENTIFICATION................2116
  SAFETY AND MAINTENANCE................2117
    LIFTING AND BLOCKING THE LOADER................2119
      Procedure................2119
    LIFT ARM SUPPORT DEVICE................2121
      Engaging The Lift Arm Support Device................2121
      Disengaging The Lift Arm Support Device................2122
    OPERATOR CAB................2123
      Description................2123
      Raising The Operator Cab................2123
      Lowering The Operator Cab................2124
      Emergency Exit................2125
    TRANSPORTING THE LOADER................2127
      Procedure................2127
      Adjusting The Bumper................2127
    TOWING THE LOADER................2129
      Procedure................2129
    REMOTE START................2131
      Procedure................2131
    SERVICE SCHEDULE................2133
      Chart................2133
    AIR CLEANER SERVICE................2135
      Replacing Filter Element................2135
    ENGINE COOLING SYSTEM................2137
      Checking The Coolant Level................2137
      Cleaning The Cooling System................2137
      Replacing The Coolant................2138
    FUEL SYSTEM................2139
      Fuel Specification................2139
      Filling The Fuel Tank................2139
      Fuel Filter................2141
      Removing Air From The Fuel System................2142
    ENGINE LUBRICATION SYSTEM................2143
      Checking Engine Oil................2143
      Oil Chart................2143
      Replacing Oil And Filter................2143
    HYDRAULIC/HYDROSTATIC SYSTEM................2145
      Checking And Adding Fluid................2145
      Hydraulic/Hydrostatic Filter Replacement................2146
      Replacing The Hydraulic/Hydrostatic Fluid................2146
    FINAL DRIVE TRANSMISSION (CHAINCASE)................2147
      Checking And Adding Oil................2147
    AUXILIARY CONTROL LOCKBOLT................2149
      Procedure................2149
    BOB-TACH................2151
      Inspection And Maintenance................2151
    LUBRICATING THE LOADER................2153
      Procedure................2153
    TIRE MAINTENANCE................2155
      Wheel Nuts................2155
      Tire Rotation................2155
      Tire Inflation................2155
    SPARK ARRESTOR MUFFLER................2157
      Cleaning Procedure................2157
    PIVOT PINS................2159
      Procedure................2159
    SEAT BAR RESTRAINT SYSTEM................2161
      Seat Bar Inspection................2161
      Seat Bar Maintenance................2161
      Foot Pedal Clean Out................2162
  HYDRAULIC SYSTEM................2163
    HYDRAULIC SCHEMATIC................2165
    HYDRAULIC SYSTEM INFORMATION................2169
      Troubleshooting Chart................2173
    CYLINDER (LIFT)................2175
      Checking The Lift Cylinder(s)................2175
      Removal And Installation................2176
      Parts Identification................2178
      Disassembly And Assembly................2179
    CYLINDER (TILT)................2183
      Checking The Tilt Cylinder................2183
      Removal And Installation................2183
      Parts Identification................2185
      Disassembly And Assembly................2186
    MAIN RELIEF VALVE................2189
      Checking The Main Relief Valve Without Auxiliaries................2189
      Checking The Main Relief Valve With Auxiliaries................2190
      Removal And Installation................2191
    HYDRAULIC CONTROL VALVE................2193
      BICS™ Valve Removal And Installation................2193
      BICS™ Valve, Lift Arm By-Pass Orifice Removal And Installation................2194
      BICS™ Valve, Pressure Differential Valve Removal And Installation................2195
      BICS™ Valve, Check Valve Removal And Installation................2195
      BICS™ Valve, Solenoid Removal And Installation................2196
      BICS™ Valve, Solenoid Testing................2197
      BICS™ Valve, Identification Chart................2198
      Removal And Installation................2198
      Identification Chart................2200
      Disassembly And Assembly................2201
      Load Check Valves Removal And Installation................2201
      Main Relief Valve Removal And Installation................2201
      Port Relief/Anti-Cavitation Valve Removal And Installation................2202
      Anti Cavitation/Check Valves Removal And Installation................2203
      Rubber Boot Removal And Installation................2204
      Lift And Tilt Lock Block Removal And Installation................2204
      Lift Spool And Detent Removal................2205
      Lift Spool And Detent Disassembly................2206
      Lift Spool And Detent Assembly................2208
      Lift Spool Detent Installation................2210
      Tilt Spool Removal And Installation................2211
      Tilt Spool Disassembly And Assembly................2212
      Auxiliary Spool Removal And Installation................2213
      Auxiliary Spool Disassembly And Assembly................2213
      Spool Seal Installation................2216
      Auxiliary Pivot Bracket Removal And Installation................2217
      Auxiliary Pivot Bracket Disassembly And Assembly................2217
    LIFT ARM BY-PASS VALVE................2219
      Removal And Installation................2219
      Disassembly And Assembly................2219
    HYDRAULIC PUMP................2221
      Checking The Output Of The Pump................2221
      Removal And Installation................2222
      Parts Identification................2225
      Disassembly And Assembly................2226
    HYDRAULIC FILTER................2229
      Block Removal And Installation................2229
      Block Disassembly And Assembly................2230
    HYDRAULIC RESERVOIR................2231
      Removal And Installation................2231
    CONTROLS................2233
      Pedal Interlock Linkage Removal And Installation................2233
      Control Pedals Removal And Installation................2234
      Pedal Adjustment................2234
  HYDROSTATIC SYSTEM................2235
    HYDROSTATIC SYSTEM INFORMATION................2237
      Troubleshooting Chart................2237
    CONTROL PANEL................2239
      Control Shield And Steering Lever Panels Removal And Installation................2239
    STEERING................2241
      Lever Removal And Installation................2241
      Lever Disassembly And Assembly................2243
      Linkage Adjustment................2243
      Pintle Arm Removal And Installation................2244
      Pintle Arm Disassembly And Assembly................2245
    HYDROSTATIC MOTOR................2247
      Removal And Installation................2247
      Parts Identification................2248
      Disassembly................2249
      Inspection................2253
      Assembly................2255
    CHARGE PRESSURE................2259
      Checking................2259
    HYDROSTATIC PUMP................2261
      Parts Identification................2261
      Removal And Installation................2262
      Disassembly And Assembly................2263
    DRIVE BELT................2273
      Removal And Installation................2273
      Tension Pulley And Spring Removal And Installation................2273
    OIL COOLER................2277
      Removal And Installation................2277
  DRIVE SYSTEM................2279
    PARKING BRAKE................2281
      Disc Removal And Installation................2281
    DRIVE COMPONENTS................2283
      Axle Hub Removal And Installation................2283
      Axle Seal Removal And Installation................2284
      Removing The Axle................2285
      Removing And Installing The Axle Bearing................2286
      Removing The Bearing Races................2287
      Installing The Bearing Races................2289
      Installing The Inner Bearing And Axle Sprocket................2289
      Drive Chain Removal And Installation................2290
    CHAINCASE................2291
      Removing Oil From The Chaincase................2291
      Chaincase Cover Removal And Installation................2291
      Chaincase Cover Assembly And Disassembly................2291
  MAIN FRAME................2293
    SEAT BAR................2295
      Removal And Installation................2295
      Assembly................2298
    OPERATOR CAB................2299
      Removal And Installation................2299
      Gas Cylinder Removal And Installation................2301
    OPERATOR SEAT................2303
      Removal And Installation................2303
    BOB-TACH................2305
      Removal................2305
      Installation................2306
      Seal Removal And Installation................2307
      Lever And Wedge Removal................2308
    LIFT ARMS................2309
      Removal And Installation................2309
    REAR WINDOW................2313
      Removal................2313
      Installation................2313
    REAR DOOR................2315
      Removal And Installation................2315
    FUEL TANK................2317
      Removal And Installation................2317
  ELECTRICAL SYSTEM & ANALYSIS................2319
    ELECTRICAL SCHEMATICS................2321
    ELECTRICAL SYSTEM INFORMATION................2325
      Troubleshooting Chart................2325
      Description................2326
      Fuel Shutoff Timer and Fuel Pull Solenoid Locations................2326
      Fuse And Relay Switches Location................2326
    BATTERY................2327
      Removal And Installation................2327
      Servicing................2328
      Using A Booster Battery (Jump Starting)................2329
    ALTERNATOR................2331
      Removal And Installation................2331
      Adjusting The Alternator Belt................2332
      Alternator Belt Removal And Installation................2332
      Description................2333
      Alternator Output Test................2333
    STARTER................2335
      Removal And Installation................2335
      Checking The Starter In The Loader................2335
      Parts Identification................2336
      Disassembly................2337
      Inspection And Repair................2342
      No Load Test................2345
      Assembly................2346
    INSTRUMENT PANEL................2353
      Removal And Installation................2353
    LIGHTS................2355
      Front Lights Removal And Installation................2355
      Rear Lights Removal And Installation................2356
      Cab Light Removal And Installation................2357
    BICS™ SYSTEM CONTROLLER................2359
      Troubleshooting Guide................2359
      Removal And Installation................2360
    BICS™ SYSTEM (WITH PRESS TO OPERATE BUTTON)................2361
      Inspecting The BICS™ Controller (Engine STOPPED - Key ON)................2361
      Inspecting The Seat Bar Sensor (Engine RUNNING)................2361
      Inspecting The Traction Lock (Engine RUNNING)................2361
      Inspecting The Lift Arm By-Pass Control................2361
      Troubleshooting Chart................2362
    SEAT BAR SENSOR................2363
      Troubleshooting Guide................2363
      Seat Bar Sensor Test................2364
      Removal And Installation................2365
      BICS™ Controller Seat Bar Sensor Circuit Test................2367
    TRACTION LOCK................2369
      Troubleshooting Guide................2369
      Removal And Installation................2370
  ENGINE SERVICE................2373
    TROUBLESHOOTING................2375
      Chart................2375
    ENGINE SPEED CONTROL................2377
      Adjustment................2377
      Removal And Installation................2377
    MUFFLER................2379
      Removal And Installation................2379
    AIR CLEANER................2381
      Removal And Installation................2381
    RADIATOR................2383
      Removal And Installation................2383
    COOLING FAN................2385
      Removal And Installation................2385
    ENGINE COMPONENTS AND TESTING................2387
      Fuel Injection Pump Check................2387
      Fuel Injection Pump Removal And Installation................2387
      Fuel Injection Pump Timing................2389
      Fuel Injector Nozzles Checking................2390
      Fuel Injector Nozzles Removal................2392
      Fuel Injector Nozzles Installation................2393
      Glow Plugs Checking................2393
      Engine Compression Test Procedure................2394
      Fuel Lift Pump Removal And Installation................2394
    ENGINE................2395
      Removal And Installation................2395
    FLYWHEEL................2403
      Removal And Installation................2403
    ENGINE MOUNTING BRACKET................2405
      Removal And Installation................2405
    RECONDITIONING THE ENGINE................2407
      Thermostat Removal And Installation................2407
      Water Pump Removal And Installation................2407
      Timing Gear Case Cover Removal And Installation................2408
      Oil Pump Removal And Installation................2410
      Crankshaft Front Seal Removal And Installation................2412
      Engine Speed Control Plate Removal And Installation................2413
      Governor Spring Removal................2413
      Start Spring Removal................2414
      Idle Limit And Fuel Limit Adjustment................2414
      Exhaust Manifold Removal And Installation................2414
      Valve Cover Removal And Installation................2415
      Rocker Arm Removal And Installation................2416
      Push Rod Removal And Installation................2417
      Tappet Removal And Installation................2418
      Water Flange Removal And Installation................2418
      Cylinder Head Removal................2419
      Cylinder Head Installation................2419
      Checking Piston Top Clearance................2420
      Cylinder Head Disassembly................2421
      Cylinder Head Assembly................2421
      Servicing The Cylinder Head................2422
      Combustion Chamber Removal And Installation................2424
      Idler Gear Removal And Installation................2425
      Camshaft Removal And Installation................2427
      Injection Pump Shaft Removal And Installation................2429
      Oil Pan Removal And Installation................2430
      Governor Shaft Removal And Installation................2431
      Governor Fork Lever Removal And Installation................2434
      Piston Removal And Installation................2435
      Checking The Piston And Connecting Rod................2436
      Connecting Rod Alignment................2437
      Piston Ring Gap................2437
      Piston Ring Installation................2438
      Connecting Rod Installation................2438
      Checking Engine Cylinder Bore................2439
      Crankshaft Removal And Installation................2439
      Checking Crankshaft Journal And Block Bearing................2442
      Checking The Crankshaft Journal And Main Bearing................2443
      Connecting Rod Journal................2444
      Checking The End Play Of The Crankshaft................2445
      Crankshaft Alignment................2445
      Engine Timing Installation................2446
      Idler Gear And Crankshaft................2446
      Idler Gear And Camshaft Gear................2447
      Idler Gear And Injection Pump Shaft Gear................2447
      Injection Pump Shaft And Governor Shaft Gear................2447
  SPECIFICATIONS................2449
    LOADER SPECIFICATIONS................2451
      Dimensions................2451
      Performance................2452
      Controls................2452
      Engine................2452
      Hydraulic System................2453
      Electrical................2453
      Drive System................2454
      Capacities................2454
      Tires................2454
      Floor Pressure................2454
    ENGINE SPECIFICATIONS................2455
      Engine................2455
      Fuel Injector Nozzles................2455
      Fuel Injection Pump................2455
      Cylinder Head................2455
      Valves................2455
      Valve Springs................2456
      Rocker Arms................2456
      Camshaft................2456
      Cylinders................2456
      Piston Rings................2457
      Pistons................2457
      Crankshaft................2457
      Oil Pump................2458
      Thermostat................2458
      Bolt Torques................2459
    TORQUE SPECIFICATIONS FOR BOLTS................2461
      Torque For General SAE Bolts................2461
      Torque For General Metric Bolts................2461
    HYDRAULIC CONNECTION SPECIFICATIONS................2463
      O-Ring Face Seal Connection................2463
      Straight Thread O-Ring Fitting................2463
      Tubelines And Hoses................2463
      Flare Fitting................2464
      O-Ring Flare Fitting................2465
      Port Seal Fitting................2466
    HYDRAULIC FLUID SPECIFICATIONS................2469
      Specifications................2469
    CONVERSIONS................2471
      Decimal And Millimeter Equivalents................2471
      U.S. To Metric Conversion................2472
  SMR................2473
    463-1................2473
    463-2................2475
    463-3................2477
6903711 (8-07) - 463 Loader Service Manual................2479

Bobcat Loaders 463 Repair Service Manuals