Service Manual S/N 52001100 & Above S/N 519911001 & Above
EQUIPPED WITH BOBCAT INTERLOCK CONTROL SYSTEM (BICS™) 6901177 (3-06)
Printed in U.S.A.
© Bobcat Company 2006
MAINTENANCE SAFETY WARNING
Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow W-2003-0903 instructions can cause injury or death.
Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.
CORRECT
CORRECT
CORRECT
B-10731a
B-12365
B-7469
Never service the Bobcat SkidSteer Loader without instructions.
Use the correct procedure to lift or lower operator cab.
Cleaning and maintenance are required daily.
WRONG
WRONG
WRONG
B-11799
B-15231
B-15280
Have good ventilation when welding or grinding painted parts. Wear dust mask when grinding painted parts. Toxic dust and gas can be produced. Avoid exhaust fume leaks which can kill without warning. Exhaust system must be tightly sealed.
Disconnecting or loosening any hydraulic tubeline, hose, fitting, component or a part failure can cause lift arms to drop. Do not go under lift arms when raised unless supported by an approved lift arm support device. Replace it if damaged.
Never work on loader with lift arms up unless lift arms are held by an approved lift arm support device. Replace if damaged. Never modify equipment or add attachments not approved by Bobcat Company.
WRONG
WRONG
WRONG
B-6590
B-6580 B-16102
B-6589 B-16102
Stop, cool and clean engine of flammable materials before checking fluids. Never service or adjust loader with the engine running unless instructed to do so in the manual. Avoid contact with leaking hydraulic fluid or diesel fuel under pressure. It can penetrate the skin or eyes. Never fill fuel tank with engine running, while smoking or when near open flame.
Keep body, jewelry and clothing away from moving parts, electrical contact, hot parts and exhaust. Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used. Use eye protection approved for type of welding. Keep rear door closed except for service. Close and latch door before operating the loader.
Lead-acid batteries produce flammable and explosive gases. Keep arcs, sparks, flames and lighted tobacco away from batteries. Batteries contain acid which burns eyes or skin on contact. Wear protective clothing. If acid contacts body, flush well with water. For eye contact flush well and get immediate medical attention.
Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/ operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts. The Service Safety Training Course is available from your Bobcat dealer. MSW01-0805
ALPHABETICAL INDEX AIR CLEANER ........................................................ 70-01 AIR CLEANER SERVICE ....................................... 10-01 ALTERNATOR ....................................................... 60-01 AUXILIARY CONTROL LOCKBOLT....................... 10-01 BATTERY................................................................ 60-01 BICS™ (With Press To Operate Button) ................ 60-01 BICS™ BLOCK VALVE .......................................... 20-01 BICS™ SYSTEM CONTROLLER........................... 60-01 BOB-TACH................................................... 10-01, 50-01 CHARGE PRESSURE ............................................ 30-01 CHAINCASE .......................................................... 40-01 CONTROLS ........................................................... 20-01 CONTROL PANEL ................................................. 30-01 CONVERSIONS ...............................................SPEC-01 CYLINDER ............................................................. 20-01 DRIVE BELT ........................................................... 30-01 DRIVE COMPONENTS .......................................... 40-01 ELECTRICAL SYSTEM INFORMATION ................ 60-01 ENGINE .................................................................. 70-01 ENGINE COMPONENTS AND TESTING .............. 70-01 ENGINE COOLING SYSTEM ................................. 10-01 ENGINE LUBRICATION SYSTEM.......................... 10-01 ENGINE MOUNTING BRACKET ........................... 70-01 ENGINE SPECIFICATIONS.............................. SPEC-01 ENGINE SPEED CONTROL .................................. 70-01 FAN ......................................................................... 70-01 FINAL DRIVE TRANSMISSION (CHAINCASE)......10-01 FLYWHEEL ............................................................ 70-01 FUEL LIFT PUMP ................................................... 70-01 FUEL SYSTEM ....................................................... 10-01 FUEL TANK............................................................. 50-01
LIFTING AND BLOCKING THE LOADER...............10-01 LIGHTS....................................................................60-01 LUBRICATING THE LOADER.................................10-01 MAIN RELIEF VALVE ..............................................20-01 MUFFLER................................................................70-01 OPERATOR CAB .........................................10-01, 50-01 OPERATOR SEAT...................................................20-01 PARKING BRAKE....................................................40-01 PIVOT PINS ............................................................10-01 RADIATOR ..............................................................70-01 REAR DOOR...........................................................50-01 REAR WINDOW .....................................................50-01 REMOTE START SWITCH .....................................10-01 RECONDITIONING THE ENGINE..........................70-01 SEAT BAR ..............................................................50-01 SEAT BAR RESTRAINT SYSSTEM........................40-01 SEAT BAR SENSOR ...............................................60-01 SERVICE SCHEDULE ............................................10-01 SPARK ARRESTOR MUFFLER..............................10-01 STARTER ................................................................60-01 STEERING ..............................................................30-01 TIRE MAINTENANCE .............................................10-01 TOWING THE LOADER .........................................10-01 THERMOSTAT ........................................................70-01 TORQUE SPECIFICATIONS FOR BOLTS ...... SPEC-01 TRACTION LOCK ...................................................60-01 TRANSPORTING THE LOADER ............................10-01 TROUBLESHOOTING ............................................70-01
GLOWPLUGS ........................................................ 70-01 HYDRAULIC CONNECTION SPEC ..................SPEC-01 HYDRAULIC CONTROL VALVE ............................ 20-01 HYDRAULIC FILTER .............................................. 20-01 HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS .................................SPEC-01 HYDRAULIC/HYDROSTATIC SYSTEM ................ 10-01 HYDRAULIC PUMP ................................................ 20-01 HYDRAULIC RESERVOIR ..................................... 20-01 HYDRAULIC SYSTEM INFORMATION.................. 20-01 HYDROSTATIC MOTOR ........................................30-01 HYDROSTATIC PUMP .......................................... 30-01 HYDROSTATIC SYSTEM INFORMATION ............. 30-01 INSTRUMENT PANEL ........................................... 60-01 LIFT ARM SUPPORT DEVICE................................10-01 LIFT ARMS ............................................................. 50-01 463 Bobcat Loader Service Manual
CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
SAFETY AND MAINTENANCE
SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX BOBCAT SKID STEER LOADER IDENTIFICATION . . . . . . . . . . . . X SAFETY AND MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . 10-01 HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01
HYDRAULIC SYSTEM HYDROSTATIC SYSTEM
DRIVE SYSTEM
HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01 MAIN
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01 MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50-01 ELECTRICAL SYSTEM & ANALYSIS. . . . . . . . . . . . . . . . . . . . . 60-01 ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01 SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-01
s FRAME A
ELECTRICAL SYSTEM AND ANALYSIS
ENGINE SERVICE
SPECIFICATIONS
CALIFORNIA PROPOSITION 65 WARNING Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects and other reproductive harm.
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463 Bobcat Loader Service Manual
FOREWORD This manual is for the Bobcat loader excavator mechanic. It provides necessary servicing and adjustment procedures for the Bobcat loader and its component parts and systems. Refer to the Operation & Maintenance Manual for operating instructions, starting procedure, daily checks, etc. A general inspection of the following items must be made after the loader has had service or repair:
1. Check that the ROPS/FOPS (Including side screens) is in good condition and is not modified.
9. The parking brake function correctly.
2. Check that ROPS mounting hardware is tightened and is Melroe approved.
10. Enclosure door latches must open and close freely.
3. The seat belt must be correctly installed, functional and in good condition.
11. Bob-Tach wedges and linkages must function correctly and be in good condition.
4. The seat bar and pedal interlocks must be correctly adjusted, clean and lubricated.
12. Safety treads must be in good condition.
5. Check lift arm suport device, replace if damaged.
13. Check for correect function of indicator lamps (Optional on some models).
6. Machine signs must be legible and in the correct location.
14. Check hydraulic fluid level, engine oil level and fuel supply.
7. Steering levers and foot pedals must return to neutral.
15. Inspect for fuel, hydraulic fluid leaks.
8. Check for correct funtion of the work lights.
16. Lubricate the loader.
II
must
oil
or
463 Bobcat Loader Service Manual
17. Check the condition of the battery and cables.
Recommend to the owner that all necessary corrections be made before the machine is returned to service.
18. Inspect the air cleaner for damage or leaks. Check the condition of the element.
19. Check the electrical charging system.
20. Check tires for wear and pressure.
21. Inspect for loose or broken parts or connections.
22. Operate the loader and check all functions.
23. Check for any field modification not completed.
24. Check for correct function of the Bobcat Interlock Control System (BICS™) before the machine is returned to the customer.
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463 Bobcat Loader Service Manual
SAFETY INSTRUCTIONS
The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments:
Safety Alert Symbol This symbol with a warning statement means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.
•
The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.
•
The Operation & Maintenance Manual delivered with the machine or attachment contains operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.
•
Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.
•
An Operator’s Handbook fastened to the operator cab. It’s brief instructions are convenient to the operator. The handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.
•
The AEM Safety Manual delivered with the machine gives general safety information.
•
The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work.
•
The Skid-Steer Loader Operator Training Course is available through your local dealer or at www.training.bobcat.com or www.bobcat.com. This course is intended to provide rules and practices of correct operation of the Skid-Steer Loader. The course is available in English and Spanish versions.
•
Service Safety Training Courses are available from your Bobcat dealer or at www.training.bobcat.com or www.bobcat.com. They provide information for safe and correct service procedures.
•
The Skid-Steer Loader Safety Video is available from your Bobcat dealer or at www.training.bobcat.com or www.bobcat.com.
WARNING Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death. W-2003-0903
WARNING Warnings on the machine and in the manuals are for your safety. Failure to obey warnings can cause injury or death. W-2044-1285
IMPORTANT This notice identifies procedures which must be followed to avoid damage to the machine. I-2019-0284
SI SSL-0206 SM
V
463 Bobcat Loader Service Manual
SAFETY INSTRUCTIONS (CONT’D)
•
Use the procedure in the Operation & Maintenance Manual for connecting the battery and for jump starting.
•
Use the procedure in the Operation & Maintenance Manual for cleaning the spark arrestor muffler (if equipped).
Fire Prevention The machine and attachments have components that are at high temperature under normal operating conditions. The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcs or sparks.
Figure 1
Flammable debris (leaves, straw, etc.) must be removed regularly. If flammable debris is allowed to accumulate, it will increase fire hazard. Clean often to avoid this accumulation. Flammable debris in the engine compartment is a potential hazard. The spark arrestor muffler is designed to control the emission of hot particles from the engine and exhaust system, but the muffler and the exhaust gases are still hot. •
Do not use the machine where exhaust, arcs, sparks or hot components can contact flammable material, explosive dust or gases.
•
The operator cab, engine compartment, and engine cooling system must be inspected every day and cleaned if necessary to prevent fire hazard and overheating.
•
Check all electrical wiring and connections for damage. Keep the battery terminals clean and tight. Repair or replace any damaged part.
•
Check fuel and hydraulic tubes, hoses and fittings for damage and leakage. Never use open flame or bare skin to check for leaks. Tighten or replace any parts that show leakage. Always clean fluid spills. Do not use gasoline or diesel fuel for cleaning parts. Use commercial nonflammable solvents.
•
Do not use ether or starting fluids on any engine which has glow plugs. These starting aids can cause explosion and injure you or bystanders.
•
Always clean the machine, disconnect the battery, and disconnect the wiring from the controllers before welding. Cover rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the machine when welding. Have good ventilation when grinding or welding painted parts. Wear a dust mask when grinding painted parts. Toxic dust or gas can be produced.
•
Stop the engine and let it cool before adding fuel. NO SMOKING!
•
Know where fire extinguishers and first aid kits are located and how to use them. Fire extinguishers are available from your Bobcat dealer [Figure 1].
SI SSL-0206 SM
VII
463 Bobcat Loader Service Manual
SERIAL NUMBER LOCATIONS
Engine Serial Number
Always use the serial number of the loader when requesting service information or when ordering parts. Early or later models (identification made by serial number) may use different parts, or it may be necessary to use a different procedure in doing a specific service operation.
Figure 3
Bobcat Loader Serial Number Figure 2
P-9791
The engine serial number is located on the engine fuel injection pump [Figure 3]. DELIVERY REPORT Figure 4 P-4399
The loader serial number plate is located on the inside of the operator cab on the right fender and in front of the seat [Figure 2]. Explanation of loader Serial Number:
XXXX
XXXXX Module 2. - Production Sequence (Series)
B-16315
Module 1. - Model/Engine Combination
The Delivery Report must be filled out by the dealer and signed by the owner or operator when the Bobcat loader is delivered. An explanation of the form must be given to the owner. Make sure it is filled out completely [Figure 4].
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463 Bobcat Loader Service Manual
BOBCAT SKID STEER LOADER IDENTIFICATION
OPERATOR HANDBOOK
◆OPERATING LIGHTS SEAT BAR GRAB HANDLES
OPERATOR SEAT
STEERING LEVER SAFETY TREAD
STEPS
TILT CYLINDER †BUCKET B-15914
•OPERATOR CAB (ROPS/FOPS)
◆OPERATING LIGHT
UPRIGHTS REAR DOOR
LIFT ARM SUPPORT DEVICE LIFT ARMS
LIFT CYLINDER TIRES* ◆ FACTORY OPTION OR FIELD ACCESSORY (Not Standard Equipment) * TIRES - Flotation tires (Optional) are shown. Bobcats are base-equipped with standard tires. † BUCKET - Several different buckets and other attachments are available for the Bobcat loader. • ROPS, FOPS - Roll-Over Protective Structure, Falling Object Protective Structure, per SAE J1040 and ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level 1. The Bobcat loader is base-equipped with a standard operator cab as shown. Extra insulated cab is available as an option (Reduced noise level). X
B-15915
463 Bobcat Loader Service Manual
SAFETY AND MAINTENANCE AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1 Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80-1 AUXILIARY CONTROL LOCKBOLT . . . . . . . . . . . . . . . . . . . 10-140-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-140-1
SAFETY & MAINTENANCE
BOB-TACH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-150-1 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . 10-150-1 ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . Checking The Coolant Level . . . . . . . . . . . . . . . . . . . . . . . Cleaning The Cooling System . . . . . . . . . . . . . . . . . . . . . . Replacing The Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . Checking Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . .
10-90-1 10-90-1 10-90-1 10-90-2
DRIVE SYSTEM
10-110-1 10-110-1 10-110-1 10-110-1
FINAL DRIVE TRANSMISSION (CHAINCASE) . . . . . . . . . . 10-130-1 Checking And Adding Oil . . . . . . . . . . . . . . . . . . . . . . . . . 10-130-1
ELECTRICAL SYSTEM & ANALYSIS
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing Air From The Fuel System . . . . . . . . . . . . . . .
10-100-1 10-100-1 10-100-3 10-100-1 10-100-4
ENGINE SERVICE
HYDRAULIC/HYDROSTATIC SYSTEM . . . . . . . . . . . . . . . . Checking And Adding Fluid . . . . . . . . . . . . . . . . . . . . . . . Hydraulic/Hydrostatic Filter Replacement . . . . . . . . . . . . Replacing The Hydraulic/Hydrostatic Fluid . . . . . . . . . . .
10-120-1 10-120-1 10-120-2 10-120-2
SPECIFICATIONS
LIFT ARM SUPPORT DEVICE . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1 Disengaging The Lift Arm Support Device. . . . . . . . . . . . . 10-20-2 Engaging The Lift Arm Support Device . . . . . . . . . . . . . . . 10-20-1 LIFTING AND BLOCKING THE LOADER . . . . . . . . . . . . . . . 10-10-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1 LUBRICATING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . 10-160-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-160-1
Continued On Next Page
10-01-1
463 Bobcat Loader Service Manual
SAFETY AND MAINTENANCE (CONT’D) OPERATOR CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emergency Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lowering The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . Raising The Operator Cab . . . . . . . . . . . . . . . . . . . . . . . . .
10-30-1 10-30-1 10-30-3 10-30-2 10-30-1
PIVOT PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-190-1 REMOTE START SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60-1 SEAT BAR RESTRAINT SYSTEM . . . . . . . . . . . . . . . . . . . . Foot Pedal Clean Out . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Bar Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Seat Bar Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-200-1 10-200-2 10-200-1 10-200-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1 Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-70-1 SPARK ARRESTOR MUFFLER . . . . . . . . . . . . . . . . . . . . . . 10-180-1 Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-180-1 TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tire Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-170-1 10-170-1 10-170-1 10-170-1
TOWING THE LOADER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-50-1 TRANSPORTING THE LOADER . . . . . . . . . . . . . . . . . . . . . . 10-40-1 Adjusting The Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
10-01-2
463 Bobcat Loader Service Manual
LIFTING AND BLOCKING THE LOADER
Figure 10-10-2
WARNING Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death [Figure 10-10-1]. P-7288
W-2003-0199
Put a floor jack under the rear of the loader [Figure 1010-2].
Figure 10-10-1
Lift the rear of the loader and install jackstands [Figure 10-10-2]. Figure 10-10-3
B-7023
Procedure Always park the loader on a level surface. P7289
WARNING
Put the floor jack under the front of the loader [Figure 1010-3].
Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286
Lift the front of the loader and put jackstands under the loader frame. NOTE: Make sure the jackstands do not touch the tires.
10-10-1
463 Bobcat Loader Service Manual
Figure 10-20-2
LIFT ARM SUPPORT DEVICE
1
WARNING Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W-2059-0598
P-19460
Lower the lift arm support device on top of the lift cylinder. Fasten the free end of the spring (Item 1) [Figure 10-20-2] to the lift arm support device so there will be no interference with the support device engagement.
Engaging The Lift Arm Support Device With the operator in the seat, seat belt fastened and seat bar lowered, start the engine. Press the green PRESS TO OPERATE Button.
Figure 10-20-1
Figure 10-20-3
1
P-9773
P-19458
Put jackstands under the rear corners of the loader (Inset) [Figure 10-20-1]. Disconnect the spring from the lift arm support device retaining pin (Item 1) [Figure 10-20-1], hold the support device and remove the retaining pin.
P-9800
Raise the lift arms until the lift arm support device drops onto the lift cylinder (Item 1) [Figure 10-20-3]. Lower the lift arms slowly until the support device is held between the lift arm and the lift cylinder. Stop the engine. Raise the seat bar and move pedals until both pedals lock.
10-20-1
463 Bobcat Loader Service Manual
Figure 10-20-6
LIFT ARM SUPPORT DEVICE (CONT’D) Engaging The Lift Arm Support Device (Cont’d) Figure 10-20-4
1
P-9807
1 Connect the spring from the lift arm support device to the tubeline bracket (Item 1) [Figure 10-20-6] on the lift arms.
P-9808
Install the retaining pin (Item 1) [Figure 10-20-4] into the rear of the lift arm support device below the cylinder rod.
With the operator in the seat, seat belt fastened and seat bar lowered, start the engine. Press the green PRESS TO OPERATE Button. Raise the lift arms a small amount and the spring will lift the support device off the lift cylinder rod. Lower the lift arms. Stop the engine.
WARNING Service lift arm support device if damaged or if parts are missing. Using a damaged lift arm support or with missing parts can cause lift arms to drop causing injury or death. W-2271-1197
Raise the seat bar and move pedals until both pedals lock. Disconnect the spring from the bracket. Figure 10-20-7
Disengaging The Lift Arm Support Device Figure 10-20-5
1 1
P-19458
P-9808
Remove the retaining pin (Item 1) [Figure 10-20-5] from the lift arm support device.
Raise the support device into storage position and insert pin through lift arm support device and bracket (Item 1) [Figure 10-20-7]. Connect spring to pin [Figure 10-20-7].
10-20-2
463 Bobcat Loader Service Manual
OPERATOR CAB
Raising The Operator Cab
Description
Stop the loader on a level surface. Put the lift arms all the way down. Install jackstands under the rear of the loader frame.
WARNING Before the cab or the lift arms are raised for service, jackstands must be put under the rear corners of the frame. Failure to use jackstands can allow the machine to tip backward causing injury or death. W-2014-0895
The Bobcat loader has an operator cab (ROPS and FOPS) as standard equipment to protect the operator from rollover and falling objects. Check with your dealer if the operator cab has been damaged. The seat belt must be worn for roll over protection.
Open the rear door. (See REAR DOOR on Page 50-701.) If the lift arms must be up while raising the cab, install the lift arm support device. (See Engaging The Lift Arm Support Device on Page 10-20-1.) Remove the two fasteners (Item 1) [Figure 10-30-1] at the front (both sides) of the operator cab. Figure 10-30-2
ROPS/FOPS Roll Over Protective Structure per SAE J1040 and ISO 3471, and Falling Object Protective Structure per SAE J1043 and ISO 3449, Level 1. Level 1 - Protection from falling bricks, small concrete blocks and hand tools encountered in operations such as highway maintenance, landscaping, and other construction site services. Check with your dealer if the operator cab has been changed. P-19462
Figure 10-30-1
Stand on the ground. Lift slowly until operator cab is all the way up [Figure 10-30-2]. The operator cab will lock in the raised position
WARNING 1
Never modify operator cab by welding, grinding, drilling holes or adding attachments unless instructed to do so by Bobcat. Changes to the cab can cause loss of operator protection from rollover and falling objects, and result in injury or death.
P-19461
W-2069-1299
The operator cab fastening nuts (Item 1) [Figure 10-301] must be tightened to 40-50 ft.-lbs. (54-68 Nm) torque.
10-30-1
463 Bobcat Loader Service Manual
OPERATOR CAB (CONT’D)
Figure 10-30-4
Lowering The Operator Cab
WARNING The cab must be held to prevent falling while hand is in access hole. W-2205-0695
Figure 10-30-3 P-19499
1 Hold the operator cab. Release the locking mechanism by pushing the lever (Item 1) [Figure 10-30-3] inward from the locked position and lifting the lever until it stays in the unlocked position [Figure 10-30-4].
2
The pin (Item 2) [Figure 10-30-3] must be retracted from the hole in the upright before lowering the operator cab. REMOVE YOUR HAND FROM THE HOLE BEFORE LOWERING THE OPERATOR CAB P19498
Stand on the ground and pull down on the operator cab. Avoid slippery surfaces when lowering the cab. NOTE: Guide the operator cab over the fastening bolts to prevent thread damage. Figure 10-30-5
1
P-19461
Install the cab washers and nuts. Tighten the nuts (Item 1) [Figure 10-30-5] (both sides) to 40-50 ft.-lbs. (54-68 Nm) torque.
10-30-2
463 Bobcat Loader Service Manual
Figure 10-30-7
OPERATOR CAB (CONT’D) Emergency Exit Figure 10-30-6
1
P-19463
Exit throught the rear of the cab [Figure 10-30-7]. P-9829
The front opening on the operator cab and rear window provide exits. Pull on the tag (Item 1) [Figure 10-30-6] at the top of the rear window to remove the rubber cord. Push the rear window out of the rear of the operator cab.
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463 Bobcat Loader Service Manual
TRANSPORTING THE LOADER
Adjusting The Bumper
Procedure
Figure 10-40-2
WARNING Adequately designed ramps of sufficient strength are needed to support the weight of the machine when loading onto a transport vehicle. Wood ramps can break and cause personal injury. W-2058-0494 P-19457
Figure 10-40-1
P-9926
P-9927
Use the following procedure to fasten the Bobcat loader to the transport vehicle to prevent the loader from moving during sudden stops or when going up or down slopes [Figure 10-40-2]. SUPPORT
B-6198
Be sure the transport and towing vehicles are of adequate size and capacity. A loader with an empty bucket or no attachment must be loaded backward onto the transport vehicle [Figure 1040-1]. The rear of the trailer must be locked or supported [Figure 10-40-1] when loading or unloading the loader to prevent the front end of the trailer from raising up.
Fully lower any bucket or attachment. Stop the engine. Engage the parking brake. Fasten chains at the front using the slots in the axle gussets [Figure 10-40-2]. The counterweight is removed (Inset) to show clarity. DO NOT operate the loader with counterweight removed. Figure 10-40-3
P-9924
Fasten the rear of the loader as shown with a loop of chain through the tie down provided [Figure 10-40-3]. 10-40-1
463 Bobcat Loader Service Manual
Figure 10-50-2
TOWING THE LOADER Procedure
IMPORTANT Do not push or pull the machine at more than 2 MPH (3,2 km/h) or for a distance of more than 25 feet (7,6 meters) with the towing tool in place. I-2017-0389
Be sure the transport and towing vehicles are of adequate size and capacity. To prevent damage to the loaders hydrostatic system, a tow valve is available for towing the loader short distances at slow speeds. (Example: Moving the loader onto a transport vehicle.)
P-21493 P-21495
Install the tow valves in the fitting holes [Figure 10-50-2]. Figure 10-50-3
A tow valve is available from your dealer and must be installed before towing the loader. Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Clean the area around the hydrostatic pumps.
1
Figure 10-50-1
P-21497
Tighten the jam nut (Item 1) [Figure 10-50-3] to 20-25 ft.lbs. (27-34 Nm) torque while the tow valve flats are in the horizontal position.
1
P-21492
Remove the charge pressure tubeline and fittings (Item 1) [Figure 10-50-1] from the front side of the hydrostatic pumps.
10-50-1
463 Bobcat Loader Service Manual
TOWING THE LOADER (CONT’D) Procedure (Cont’d) Figure 10-50-4 When flats are vertical loader can be towed
1
P-21496
Turning the tow valves so the flats are vertical as shown (Item 1) [Figure 10-50-4] will release the relief valves and the check valves in the hydrostatic pumps and allow the loader to be moved. The towing chain (or cable) must be rated at 1-1/2 times the weight of the loader. (See Machine Specifications on Page SPEC-10-1.) Turn the key switch to ON and press the traction lock override button. If the electrical system is not functioning, contact your Bobcat loader dealer. (Part of the brake system must be disassembled to move the loader.) Remove the tow valves and install the fittings and charge tubelines before operating the loader.
10-50-2
463 Bobcat Loader Service Manual
Figure 10-60-1
REMOTE START SWITCH Procedure The tool listed will be needed to do the following procedure: MEL1429-B- Remote Start Switch Kit Kit Includes: MEL1429-1 Adapter MEL1429- 2 Start Switch MEL1429-3 Adapter
1
The Remote Start Switch is required when the operator cab is in the raised position for service and the service technician needs to start the engine. The operator cab wire harness connectors must be separated from the engine wiring harness connector under the cab. The remote start switch is required when the service technician is adjusting the steering linkage and checking the hydraulic/hydrostatic system.
WARNING Put jackstands under the front axles and rear corners of the frame before running the engine for service. Failure to use jackstands can allow the machine to fall or move and cause injury or death. W-2017-0286
P-7523
Connect the remote start switch to the connectors (Item 1) [Figure 10-60-1]. Replace the inner filter every third time the outer filter is replaced or as indicated by the Service Schedule.
WARNING Never work on a machine with the lift arms up unless the lift arms are secured by an approved lift arm support device. Failure to use an approved lift arm support device can allow the lift arms or attachment to fall and cause injury or death. W-2059-0598
Lift and block the loader. (See LIFTING AND BLOCKING THE LOADER on Page 10-10-1.) Raise the lift arms and install the lift arm support device. (See Engaging The Lift Arm Support Device on Page 1020-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)
10-60-1
463 Bocat Loader Service Manual
Figure 10-60-4
REMOTE START SWITCH (CONT’D) Procedure (Cont’d) Figure 10-60-2
1
P-4714
Move the traction lock override switch (Item 1) [Figure 10-60-4] to the OFF position so the traction function is unlocked. The wheels are now able to turn.
1 P-7101
NOTE: On late model loaders, the connector on the BICS™ harness is a round 7-pin connector, NOT a rectangular 8-pin connector. Use the adapter (Item 1) [Figure 10-60-2] if your loader has a round 7-pin BICS harness connector. Figure 10-60-3
1
P-4713
Put the traction lock override switch (Item 1) [Figure 1060-3] in the ON position so the traction function is locked. The wheels are not able to turn. Turn the key to the right and start the engine.
10-60-2
463 Bobcat Loader Service Manual
SERVICE SCHEDULE Chart Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The service schedule is a guide for correct maintenance of the Bobcat loader.
WARNING
Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death.
W-2003-1285
SERVICE SCHEDULE ITEM
Engine Air Cleaner
HOURS
SERVICE REQUIRED
8-10
50
100
250
500
■1000
Empty the dust cup & replace the filter as needed.
Engine Oil
Check the engine oil level and add oil as needed.
Engine Cooling System
Clean debris from oil cooler, radiator and grill. Check coolant level in recovery tank. Add coolant as needed.
Tires
Check for damaged tires and correct air pressure.
Indicators, Gauges, & Lights (Opt.)
Check for correct operation of all indicators, gauges & lights (Opt.).
Seat Belt, Seat Bar
Check the condition of the seat belt. Check the seat bar & pedal interlocks for correct operation. Clean dirt and debris from moving parts.
Safety Signs (Decals) and Safety Tread
Check for damaged sign (decals) and safety treads. Replace any signs or safety treads that are damaged or worn.
Lift Arms and BobTach Pivot Pins and Wedges
Lubricate with multi-purpose lithium based grease.
Engine Fuel Filter
Remove the water from the filter.
Hydraulic Fluid, Hoses and Tubelines
Check fluid level and add as needed. Check for damage and leaks. Repair or replace as needed.
Bobcat Interlock Control System (BICS™)
Check BICS™ System Controller functions. Clean dirt, debris or objects from under or behind seat as required.
Battery
Check cables, connections and electrolyte level. Add distilled water as needed.
Control Pedals & Steering
Check for correct operation. Repair or adjust as needed.
Bob-Tach
Check locking levers & wedges for condition & operation.
Wheel Nuts
❑Check for loose wheel nuts & tighten to 40-45 ft.-lbs. (54-61 Nm) torque.
Parking Brake
Check operation.
Alternator Belt
Check belt tension and adjust as needed.
Engine Oil and Filter
Replace oil and filter. (See Oil Chart on Page 10-110-1.)
Hydraulic Filter Element
Replace Filter Element.
Spark Arrestor Muffler
Clean the spark chamber.
Drive Belt
Clean the spark chamber.
Steering Lever Pivots
Lubricate grease fittings and oil hole in the steering shaft.
Engine Fuel Filter
Replace the filter element.
Hydraulic Reservoir Breather
Replace the breather cap.
Final Drive Trans (Chaincase)
Replace the fluid.
Hydraulic/Hydrostatic Reservoir
•Replace the fluid.
❑ Check wheel nut torque every 8 hours for the first 24 hours. • Also replace hydraulic/hydrostatic filter element when the transmission warning
light stays on for five minutes after the hydraulic fluid is at operating
temperature.
■ Or every 12 months.
10-70-1
463 Bobcat Loader Service Manual
Figure 10-80-2
AIR CLEANER SERVICE Replacing Filter Element (See SERVICE SCHEDULE on Page 10-70-1.) for the interval to service the air cleaner system. Check the air intake hose for damage. Check the air cleaner housing for damage. Check to make sure all connections are tight.
1
Figure 10-80-1
3
P-19450
Figure 10-80-3 2 1
P-19452
P-19453
NOTE: Before replacing the filter element, push the button on the condition indicator (Item 1) [Figure 10-80-1]. Start the engine, then stop the engine. If the red ring does not show, do not replace the filter element.
1
Replace the outer filter element only when the red ring shows in the window of the condition indicator (Item 2) [Figure 10-80-1].
P-19451
Replace the inner filter every third time the outer filter is replaced or when the red ring still shows in the indicator window after the outer filter has been replaced.
Remove the outer filter element (Item 1) [Figure 10-80-2] and if required, remove the inner filter element (Item 1) [Figure 10-80-3].
Release the two fasteners (Item 3) [Figure 10-80-1] to remove the cover. Clean any debris or dust from the cover.
Clean the inside of the filter housing. Install the inner element, if required. Install the outer element. Install the cover and engage the two fasteners.
10-80-1
463 Bobcat Loader Service Manual
Cleaning The Cooling System
ENGINE COOLING SYSTEM Check the cooling system every day to prevent overheating, loss of performance or engine damage.
WARNING
Checking The Coolant Level
Use safety goggles when using air or water under pressure. Do not use cold water to clean a hot engine. Failure to obey warnings can cause serious injury.
Figure 10-10-1
W-2064-1285
Open the rear door. Use air pressure or water pressure to remove the debris in the area of the radiator and oil cooler.
1
If debris is a problem, check with your dealer about the special debris screens.
P-9816
Open the rear door. The coolant recover tank (Item 1) [Figure 10-10-1] is located between the radiator and the right upright. The coolant level in the recovery tank must be between the maximum and minimum mark when engine is cool. NOTE: the loader is factory filled with propylene glycol coolant. DO NOT mix propylene glycol with ethylene glycol. Add premixed coolant; 47% water and 53% propylene glycol to the recovery tank if the coolant level is low. One gallon and one pint of propylenen glycol mixed with one gallon of water is the correct mixture of coolant to provide a -34° F (-37° C) freeze protection. Use a refractometer to check the condition of propylene glycol in your cooling system. NOTE: Coolant testing strips are available for checking the coolant condition. (See your Bobcat loader dealer.)
10-90-1
463 Bobcat Loader Service Manual
Figure 10-90-4
ENGINE COOLING SYSTEM (CONT’D) Replacing The Coolant Figure 10-90-2
1
1 P-9806
Open the drain valve (Item 1) [Figure 10-90-4]. Located on the front engine by the fuel lift pump. Turn the valve counterclockwise to open.
P-9881
Open the rear door. Place the drain hose (Item 1) [Figure 10-90-2] into a clean container. Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Figure 10-90-3
1
P-19402
Remove the radiator cap (Item 1) [Figure 10-90-3].
10-90-2
463 Bobcat Loader Service Manual
Filling The Fuel Tank
FUEL SYSTEM Fuel Specification
WARNING
Use only clean, high quality diesel fuel, Grade No. 2 or Grade No. 1. The following is a suggested blending guideline which should prevent fuel gelling problems: Temp. F°/ C° +15° (-9° ) Down to -20° / (-29° ) Below -20° / (-29° )
No. 2 100% 50% 0%
No.1 0% 50% 100%
Stop and cool the engine before adding fuel. NO SMOKING! Failure to obey warnings can cause an explosion or fire. W-2063-0887
Figure 10-100-2
We recommend an operator contact their fuel supplier for local recommendations. Figure 10-100-1
1 2 1
P-9830
Remove the fuel fill cap (Item 1) [Figure 10-100-2]. Use a clean, approved safety container to add fuel of the correct specifications. Add fuel only in an area that has free movement of air and no open flames or sparks. NO SMOKING .[Figure 10-100-2]
P-9831
The fuel gauge (Item 1) [Figure 10-100-1] and the fuel shut off valve (Item 2) [Figure 10-100-1] are located on the right side of the loader.
Install and tighten the fuel fill cap (Item 1) [Figure 10100-2].
10-100-1
463 Bobcat Loader Service Manual
FUEL SYSTEM (CONT’D) Filling The Fuel Tank (Cont’d)
WARNING Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death. W-2103-1285
Figure 10-100-3 WRONG
B-6108
10-100-2
463 Bobcat Loader Service Manual
FUEL SYSTEM (CONT’D)
Figure 10-100-5
Fuel Filter
WARNING Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death. W-2103-1285
Drain Water:
1
(See SERVICE SCHEDULE on Page 10-70-1.) for the service interval when to remove the water from the fuel filter. Figure 10-100-4
P-9880
Loosen the drain (Item 1) [Figure 10-100-5] at the bottom of the filter element to drain water from the filter. Close the drain.
OFF
Open the shut-off valve (Item 1) [Figure 10-100-4] to turn on the fuel supply. Replace Fuel Filter:
1
(See SERVICE SCHEDULE on Page 10-70-1.) for the service interval when to replace the fuel filter. Clean the area around the fuel filter.
ON
Close the shut-off valve (Item 1) [Figure 10-100-4]. Remove the fuel filter [Figure 10-100-5]. NOTE: Be sure the filter gasket is removed with the old fuel filter.
P-9831
Turn the fuel shut-off valve (Item 1) [Figure 10-100-4] clockwise to shut off the fuel supply.
Install the new filter element and hand tight. Open the shut-off valve (Item 1) [Figure 10-100-4].
10-100-3
463 Bobcat Loader Service Manual
Figure 10-100-7
FUEL SYSTEM (CONT’D) Removing Air From The Fuel System Figure 10-100-6
1
1
2
P-19025
Open the valve (Item 1) [Figure 10-100-7] on the injector pump and squeeze the hand pump several times until fuel flows from the valve.
P-9880
After replacing the fuel filter element or when the fuel tank has run out of fuel, air must be removed from the fuel system before starting the engine.
Close the valve (Item 1) [Figure 10-100-7]. Lower the operator cab. (See Lowering The Operator Cab on Page 10-30-2.)
Open the rear door. The engine must be cool. Start the engine. Open the vent plug (Item 1) [Figure 10-100-6]. Operate the hand pump (priming bulb) (Item 2) [Figure 10-100-6] until fuel flows from the vent plug with no air bubbles. Close the vent plug. With the operator in the seat, seat belt fastened, seat bar lowered, and parking brake engaged, start the engine.
WARNING Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire which can result in injury or death. W-2103-1285
NOTE: If engine fails to start, remove air from the fuel injection pump as follows: Put jackstands under the rear of the frame. (See LIFTING AND BLOCKING THE LOADER on Page 10-10-1.) Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.)
10-100-4
463 Bobcat Loader Service Manual
ENGINE LUBRICATION SYSTEM
Replacing Oil And Filter
Checking Engine Oil
Figure 10-110-2
Figure 10-110-1
2 1
P-9882 P-9892
(See SERVICE SCHEDULE on Page 10-70-1.) for the service interval for replacing the engine oil filter. Check the oil every day. Stop the engine and remove the dipstick (Item 1) [Figure 10-110-1].
Open the rear door and remove the cap from the end of the hose. Drain the oil into a container [Figure 10-1102].
Keep the oil level between the marks on the dipstick. Use a good quality motor oil that meets API Service Classification of CD or better. (See Oil Chart below.) Oil Chart RECOMMENDED SAE VISCOSITY NUMBER
Run the engine until it its at operating temperature. Stop the engine.
Remove the filter (Item 2) [Figure 10-110-1]. Clean the filter housing surface. Put clean oil on the gasket of the new filter. Install the filter and hand tighten.
(LUBRICATION OILS FOR DIESEL ENGINE CRANKCASE)
Install and tighten the cap on the drain hose.
C°
F°
TEMPERATURE RANGE ANTICIPATED BEFORE NEXT OIL CHANGE (DIESEL ENGINES MUST USE API CLASSIFICATION CD, CF4, CG4) *Can be used ONLY when available with appropriate diesel rating.
10-110-1
463 Bobcat Loader Service Manual
ENGINE LUBRICATION SYSTEM (CONT’D) Replacing Oil And Filter (Cont’d) Figure 10-110-3
1
P-9874
Turn the oil fill cap (Item 1) [Figure 10-110-3] counter clockwise the remove the cap. Fill to capacity. (See Capacities on Page SPEC-10-4.) Start the engine and let it run for about 5 minutes. Check for leaks ant the filter. Check the oil level. Add oil until the level is at the FULL mark on the dipstick. Install the oil fill cap (Item 1) [Figure 10-110-3]. NOTE: DO NOT overfill the crankcase.
10-110-2
463 Bobcat Loader Service Manual
Figure 10-120-1
HYDRAULIC/HYDROSTATIC SYSTEM
WARNING Diesel fuel or hydraulic fluid under pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician familiar with this injury.
1
W-2072-0496 P-19414
Checking And Adding Fluid Use only recommended fluid in the hydraulic system. (See HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS on Page SPEC-50-1.) Stop the loader on a level surface. Lower the lift arms and tilt the Bob-Tach fully back. Stop the engine.
Open the rear door. [Figure 10-120-1].
Remove the dipstick (Item 1)
The fluid level is correct if the fluid is between the marks on the dipstick. NOTE: The dipstick may indicate an incorrect level of fluid when first removed because of expansion or contraction of oil in the fill tube. Always (1) remove the dipstick, (2) wipe the dipstick, (3) insert the dipstick again and (4) re-check the fluid level. If fluid is needed, remove the dipstick (Item 1) [Figure 10-120-1] and add fluid to the reservoir until the level is correct.
10-120-1
463 Bobcat Loader Service Manual
Replacing The Hydraulic/Hydrostatic Fluid
HYDRAULIC/HYDROSTATIC SYSTEM (CONT’D)
(See SERVICE SCHEDULE on Page 10-70-1.) for the service interval to replace the fluid. The fluid must also be replaced if it becomes contaminated and after any major repairs.
IMPORTANT Fluid such as engine oil, hydraulic fluid, coolants, grease, etc. must be deposed of in an environmentally safe manner. Some regulations require that certain spills and leaks on the ground must be cleaned in a specific manner. See local, state and federal regulations for the correct disposal.
Stop the engine. Open the rear door. Remove the fill cap/dipstick. Figure 10-120-3
I-2067-0499
Hydraulic/Hydrostatic Filter Replacement (See SERVICE SCHEDULE on Page 10-70-1.) for the correct service interval. Stop the engine. Open the rear door. Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Clean the area around the filter housing. 1 Figure 10-120-2 P-9863
Loosen the nut (Item 1) [Figure 10-120-3] which fastens the fill tube to the loader frame.
1
Loosen the clamp at the fill tube, turn the fill tube down to drain the fluid from the reservoir [Figure 10-120-3]. After the fluid is removed, put the fill tube in the correct position, tighten the hose clamp and tighten the bolt. Replace the hydraulic filter element. P-7527
Add Hydraulic/Hydrostatic fluid to the reservoir. (See HYDRAULIC/HYDROSTATIC FLUID SPECIFICATIONS on Page SPEC-50-1.)
Remove the filter element (Item 1) [Figure 10-120-2]. Clean the surface of the filter housing where the filter element seal contacts the filter housing.
Do Not over fill the reservoir.
Put grease on the seal of the filter element, install the element and hand tighten only. Lower the operator cab. Start the engine and operate the loader through the hydraulic and hydrostatic functions. Stop the engine. Check the fluid level and add fluid the the reservoir as needed.
10-120-2
463 Bobcat Loader Service Manual
FINAL DRIVE TRANSMISSION (CHAINCASE) The chaincase contains the final drive sprockets and the chains and is filled with the same type of fluid as is used in the hydraulic system. (See HYDRAULIC/ HYDROSTATIC FLUID SPECIFICATIONS on Page SPEC-50-1.) Checking And Adding Oil Figure 10-130-1
1
P-7561
Put the loader on a level surface. Remove the plug at the front of the chaincase (Item 1) [Figure 10-130-1]. If the fluid can be reached with the tip of your finger through the hole, the level is correct. Add fluid through the check plug hole until the fluid flows from the hole. Install and tighten the plug.
10-130-1
463 Bobcat Loader Service Manual
AUXILIARY CONTROL LOCKBOLT Procedure Figure 10-140-1
1
P-19415
The Auxiliary control has a lockbolt (Item 1) [Figure 10140-1] that must be removed to use the optional auxiliary hydraulics. Raise the operator cab. (See Raising The Operator Cab on Page 10-30-1.) Remove the nut and bolt (Item 1) [Figure 10-140-1] from the right hand steering lever.
10-140-1
463 Bobcat Loader Service Manual
Figure 10-150-2
BOB-TACH Inspection And Maintenance
WARNING
1
Bob-Tach wedges must extend through the holes in attachment. Levers must be fully down and locked. Failure to secure wedges can allow attachment to come off and cause injury or death. W-2102-0588
Figure 10-150-1
P-19495
The wedges must extend through the holes in the attachment mounting frame (Item 1) [Figure 10-150-2].
1
Inspect the mounting frame on the attachment and the Bob-Tach, linkages and wedges for excessive wear or damage. Replace any parts that are damaged, bent, or missing. Keep all fasteners tight. Look for cracked welds. Contact your Bobcat dealer for repair or replacement parts. Lubricate the wedges. (See SERVICE SCHEDULE on Page 10-70-1 and See LUBRICATING THE LOADER on Page 10-160-1)
P-19494
Move the Bob-Tach lever (Item 1) [Figure 10-150-1] to engage the wedges. The levers and wedges must move freely.
10-150-1
463 Bobcat Loader Service Manual
Figure 10-160-3
LUBRICATING THE LOADER Procedure Lubricate the loader as specified in the SERVICE SCHEDULE Contents, Page 10-01 for the best performance of the loader.
1 Record the operating hours each time you lubricate the Bobcat loader. Always use a good quality lithium based multi-purpose grease when you lubricate the loader. Apply the lubricant until extra grease shows. Lubricate the following locations on the loader:
P-19456
Figure 10-160-1 Lift Arm Pivot Pin (Item 1-Both sides) [Figure 10-160-3]. Figure 10-160-4
1
1 P-7548
Base End Lift Cylinder (Item 1-Both sides) [Figure 10160-1].
P-19466
Rod End Tilt Cylinder (Item 1) [Figure 10-160-4].
Figure 10-160-2
1 P-19455
Rod End Lift Cylinder (Item 1-Both sides) [Figure 10160-2].
10-160-1
463 Bobcat Loader Service Manual
Figure 10-160-7
LUBRICATING THE LOADER (CONT’D) Procedure (Cont’d) Figure 10-160-5
1
1
P-19035
Steering shaft pivot bearings (Item 1) [Figure 10-160-7] (Both sides).
P-7552
NOTE: If the steering levers do not move freely, (See Lever Disassembly And Assembly on Page 30-30-3.) to disassemble and lubricate the mechanism.
Base End Tilt Cylinder (Item 1) [Figure 10-160-5]. Figure 10-160-6
1
P-19417
Bob-Tach pivot pins (Item 1) [Figure 10-160-6] (Both sides).
10-160-2
463 Bobcat Loader Service Manual
Tire Inflation
TIRE MAINTENANCE Wheel Nuts
WARNING
(See SERVICE SCHEDULE on Page 10-70-1.) for the service interval to check the wheel nuts. The correct torque is 40-50 ft.-lbs. (54-61 Nm) torque.
Do not inflate tires above specified pressure. Failure to use correct tire mounting procedure can cause an explosion which can result in injury or death.
Tire Rotation
W-2078-1285
Figure 10-170-1
IMPORTANT Inflate tires to the MAXIMUM pressure shown on the sidewall of the tire. DO NOT mix brands of tires used on the same loader. I-2057-0794
Tires are to be repaired only by an authorized person using the proper procedures and safety equipment. Tires and rims must always be checked for correct size before mounting. Check rim and tire bead for damage.
B-9976
Check the tires regularly for wear, damage and pressure. (See Tires on Page SPEC-10-4.) Rear tires usually wear faster than front tires. To keep tire wear even, move the front tires to the rear and rear tires to the front [Figure 10-170-1].
The rim flange must be cleaned and free of rust. The tire bead and rim flange must be lubricated with a rubber lubricant before mounting the tire, avoid excessive pressure which can rupture the tire and cause serious injury or death. During inflation of the tire, check the tire pressure frequently to avoid over inflation.
It is important to keep the same size tires on each side of the loader. If different sizes are used, each tire will be turning at a different rate and cause excessive wear. The tread bars of all the tires must face the same direction. Recommended tire pressure must be maintained to avoid excessive tire wear and loss of stability and handling capability. Check for the correct pressure before operating the loader.
10-170-1
463 Bobcat Loader Service Manual
SPARK ARRESTOR MUFFLER
WARNING
(See SERVICE SCHEDULE on Page 10-70-1.) for correct service interval. Do not operate the loader with a defective exhaust system.
Never use machine in atmosphere with explosive dust or gases or where exhaust can contact flammable material. Failure to obey warnings can cause injury or death.
Cleaning Procedure
W-2068-1285
WARNING Stop engine and allow the muffler to cool before cleaning the spark chamber. Wear safety goggles. Failure to obey can cause serious injury. W-2011-1285
WARNING
WARNING When the engine is running during service, the steering levers must be in neutral and the parking brake engaged. Failure to do so can cause injury or death. W-2006-0284
When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust outside. Exhaust fumes contain odorless, invisible gases which can kill without warning. W-2050-1285
Start the engine. Have a second person (wearing safety goggles) hold a block of wood over the outlet of the muffler (with the engine running) for about 10 seconds. Stop the engine and install the plug. Close the rear door.
Figure 10-180-1
IMPORTANT This loader is factory equipped with a U.S.D.A. Forestry Service approved spark arrestor muffler. It is necessary to do maintenance on this spark arrestor muffler to keep it in working condition. The spark arrestor muffler must be serviced by dumping the spark chamber every 100 hours of operation. If this machine is operated on flammable forest, brush or grass covered land, it must be equipped with a spark arrestor attached to the exhaust system and maintained in working order. Failure to do so will be in violation of California State Law, Section 4442 PRC.
1 P-9764
Stop the engine. Open the rear door. Remove the plug (Item 1) [Figure 10-180-1] from the bottom of the muffler.
Make reference to local laws and regulations for spark arrestor requirements.
10-180-1
I-2022-0595
463 Bobcat Loader Service Manual
PIVOT PINS Figure 10-190-1
1
P-19288
Figure 10-190-2
1
P-19291
All pivot pins, lift arms, and cylinders have a large pin held in position with lockbolts and retainer (Item 1) [Figure 10-190-1] & [Figure 10-190-2]. Check that the lockbolts are tightened to 8-10 ft.-lbs. (1113 Nm) torque. Do not over-tighten.
10-190-1
463 Bobcat Loader Service Manual
SEAT BAR RESTRAINT SYSTEM
Seat Bar Maintenance
The seat bar restraint system has a pivoting seat bar with arm rests and has spring loaded interlocks for the loft and tilt control pedals. The operator controls the use of the seat bar. The seat bar in the down position helps to keep the operator in the seat. The interlocks require the operator to lower the seat bar in order to operate the foot pedal controls. When the seat bar is up, the lift and tilt pedals are locked when returned to the neutral position.
(See SERVICE SCHEDULE on Page 10-70-1.) and on the loader for correct service interval. Figure 10-200-1
WARNING AVOID INJURY OR DEATH The Seat Bar System must lock the lift and tilt foot pedals or hand controls in neutral when the Seat Bar is up. Service the system if controls do not lock correctly. W-2263-0597
Seat Bar Inspection Sit in the seat and fasten the seat belt. Engage the parking brake. Pull the seat bar all the way down. Start the engine. Press the green PRESS TO OPERATE Button. Operate each foot pedal to check both the lift and tilt functions. raise the lift arms until the bucket is about 2 feet (600 mm) off the ground. Raise the seat bar, try to move each pedal. The pedals must be firmly locked in neutral position. There must be no motion of the tilt (bucket) or the lift arms when the pedals are pushed.
P-9790
Figure 10-200-2
Pull the seat bar down, press the green PRESS TO OPERATE Button and lower the lift arms. Operate the lift pedal. While the lift arms are going up, raise the seat bar and the lift arms should stop. Lower the seat bar, Press the green PRESS TO OPERATE Button, lower the lift arms and put the bucket flat on the ground. Stop the engine. Raise the seat bar and operate the foot pedals to be sure that the pedals are firmly locked in the neutral position. Unbuckle the seat belt. P-4400
Clean any debris or dirt from the moving parts [Figure 10-200-1] & [Figure 10-200-2]. Inspect the linkage bolts and nuts for tightness. correct torque is 25-28 ft.-lbs. (34-38 Nm).
10-200-1
The
463 Bobcat Loader Service Manual
SEAT BAR RESTRAINT SYSTEM (CONT’D) Seat Bar Maintenance (Cont’d) If the seat bar system does not function correctly, check for free movement of each linkage part. Check for excessive wear. Adjust pedal control linkage. Replace parts that are worn or damaged. Use only genuine Bobcat replacement parts. Foot Pedal Clean Out Figure 10-200-3
1
P-7528
Clean any debris from around the foot pedals. Debris will fall out through the holes under the pedals (Item 1) [Figure 10-200-3].
10-200-2
463 Bobcat Loader Service Manual
HYDRAULIC SYSTEM BICSâ„¢ BLOCK VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-50-1 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 20-50-2 CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Pedals Removal And Installation. . . . . . . . . . . . . . Pedal Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pedal Interlock Linkage Removal And Installation. . . . . . .
20-90-1 20-90-2 20-90-2 20-90-1
CYLINDER (LIFT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking The Lift Cylinder(s). . . . . . . . . . . . . . . . . . . . . . . Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
20-20-1 20-20-1 20-20-5 20-20-4 20-20-2
CYLINDER (TILT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking The Tilt Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
20-21-1 20-21-1 20-21-4 20-21-3 20-21-1
HYDRAULIC CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . 20-40-1 Auxiliary Spool Detent . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11 Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . 20-40-3 Identification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-3 Lift Spool Detent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-6 Load Check Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-4 Main Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-4 Port Relief Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5 Port Relief/Anti-Cavitation Valve . . . . . . . . . . . . . . . . . . . . 20-40-5 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1 Rubber Boot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-6 Spool Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-12 Tilt Centering Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-11
SAFETY & MAINTENANCE
HYDRAULIC SYSTEM
DRIVE SYSTEM
ELECTRICAL SYSTEM & ANALYSIS ENGINE SERVICE
SPECIFICATIONS
HYDRAULIC FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-70-1 Block Disassembly And Assembly. . . . . . . . . . . . . . . . . . . 20-70-2 Block Removal And Installation . . . . . . . . . . . . . . . . . . . . . 20-70-1 HYDRAULIC PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking The Output Of The Pump. . . . . . . . . . . . . . . . . . Disassembly And Assembly. . . . . . . . . . . . . . . . . . . . . . . . Parts Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
20-60-1 20-60-1 20-60-6 20-60-5 20-60-2
HYDRAULIC RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 20-80-1 Continued On Next Page 20-01-1
463 Bobcat Loader Service Manual
HYDRAULIC SYSTEM (CONT’D) HYDRAULIC SYSTEM INFORMATION . . . . . . . . . . . . . . . . . 20-10-1 Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-5 MAIN RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking The Main Relief Valve Without Auxiliaries . . . . . Checking The Main Relief Valve With Auxiliaries. . . . . . . . Main Relief Valve Adjustment . . . . . . . . . . . . . . . . . . . . . . Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . .
20-01-2
20-30-1 20-30-1 20-30-2 20-30-3 20-30-3
463 Bobcat Loader Service Manual
463 HYDRAULIC/HYDROSTATIC SCHEMATIC S/N 520011001 AND ABOVE S/N 519911001 AND ABOVE (PRINTED APRIL 2001) V-0050legend
LEGEND 1
RESERVOIR: Capacity . . . . . . . . . 5.3 Qts. (5,0 L)
2
FILTER - HYDRAULIC/HYDROSTATIC (CANISTER)
3 4
5
CHARGE PRESSURE SWITCH: 17-21 PSI (118-144 kPa) TEMPERATURE SWITCH 225-232 degrees F. (108-111 degrees C.) RELIEF VALVE - CHARGE: 85 PSI (586 kPa)
17 RELIEF/ANTICAVITATION VALVE PORT . . . . . . . . 1700 PSI (11720 kPa) at Full Speed 18 FILTER - BICS CONTROL VALVE 19
CHECK VALVE - BICS CONTROL VALVE
20
SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BICS CONTROL
21
PULL BUTTON ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT ARM BY PASS CHECK VALVE - BICS CONTROL VALVE
6
BY PASS VALVE - COOLER: 625 PSI (4308 kPa)
22
7
FIXED CAPACITY DISPLACEMENT BIDIRECTIONAL HYDRAULIC/ HYDROSTATIC MOTOR
23 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - LIFT CONTROL
8
VARIABLE CAPACITY DISPLACEMENT BIDIRECTIONAL HYDRAULIC/ HYDROSTATIC PUMP
24 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - TILT CONTROL
9
HYDRAULIC PUMP: Gear Type . . . 10.0 GPM (37,85 L/min.) at 3100 RPM
25 SOLENOID ACTIVATED DIRECTIONAL CONTROL VALVE - BUCKET POSITION VALVE (ON/OFF)
10
RELIEF VALVE - HIGH PRESSURE: 3000 PSI (20682 kPa)
26
11
REPLENISHING VALVE
12 RELIEF VALVE - MAIN: 2450 PSI (16890 kPa) at Front Quick Couplers 13 LOAD CHECK VALVE 14 RELIEF/ANTICAVITATION VALVE PORT . . . . . . . . . 1700 PSI (11720 kPa) at Full Speed 15 RELIEF VALVE - PORT: 1700 PSI (11720 kPa) at Full Speed 16 RELIEF VALVE - PORT: 1700 PSI (11720 kPa) at Full Speed
Printed in U.S.A.
FLOW DIVIDER ADJUSTMENT VALVE
27 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - FLOW CONTROL SPOOL 28 CHECK VALVE - BUCKET POSITION VALVE 29 PILOTED ACTIVATED DIRECTIONAL CONTROL VALVE - UNLOADING SPOOL
NOTE: Unless otherwise specified springs have NO significant pressure value.
V-0050legend (3-26-01)
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