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| Home / Skid Steer Loaders / Bobcat Skid Steer Loaders / Bobcat 863 |
Bobcat 863 Troubleshooting
The
Bobcat 863 skid steer loader driveline system components: a 166.7 cu.in (2.7L)
Deutz BF4M1011 four-cylinder turbocharged liquid-cooled diesel engine
with a rated power of 73.5 hp (54.8 kW), and 1-speed hydrostatic transmission.
The hydraulic system has a pump with a rated capacity of 18 gal/min (68 l/min).
The system relief pressure is 3000 psi (206 bar). The Bobcat 863 is equipped
with a radial-lift loader boom, 100HS drive chains, and 12.00x16.5 tires. The
skid steer has a max lift height of 121" (3075 mm) to hinge pin and
dump height of 91.5" (2325 mm). The rated operating capacity is 2000 lbs (907
kg), and tipping load is 4000 lbs (1815 kg).
| Engine Troubleshooting |
Diesel hard to start or doesn't start
Air trapped in fuel system - Bleed air.
Fuel filter element is dirty - Service or replace the filter.
Defective or clogged injection nozzle - Change fuel injection nozzles.
Water or dirt in fuel system - Drain, flush, and service the system.
The valve clearance is not adjusted - Adjust valve clearance.
Fuel injection pump is not working correctly - Rebuild or replace pump.
Engine stalls after starting
Clogged air filter - Clean or replace element.
Dirty fuel filter - Service or replace the filter.
Fuel injection pump leakage - Check the fuel injection pump for leaks and fix it.
Defective or clogged fuel injectors - Replace fuel injectors.
Damaged fuel injection pump - Rebuild or change fuel pump.
Engine shuts off suddenly while running
Engine is not fully warmed up - Warm up engine as required.
Dirty fuel filter - Replace filter element.
Air trapped in fuel system - Bleed air.
Fuel injection nozzles are damaged - Test injection nozzles and change if necessary.
Fuel injection pump timing is not adjusted - Set up as recommended.
Engine stalls when idle
Incorrect low idle setting - Correct the settings.
Fuel injection pump is defective - Replace injection pump or repair it.
Fuel injector fault - Clean fuel injectors or change it.
Valve clearance is wrong - Correct valve clearance.
Engine power is insufficient
Clogged air cleaner - Clean or change.
Dirty or faulty injection nozzles - Replace injection nozzles.
Improper fuel injection pressure - Correct the pressure settings.
Valve out of adjustment - Adjustment procedure required.
Wrong adjustment of low idle speed - Correct the settings.
Fuel lines or hoses clogging - Clean fuel system hoses and lines.
Cylinder head gasket is defective - Replace the gasket as required.
Piston rings are damaged or leaking - Install new piston rings.
Engine overheating
Engine has a lack of coolant - Fill the cooling system and check components for leaks or other faults.
Engine oil level low - Need to add engine oil.
Dirty radiator core or defective radiator cap - Install new cap or clean radiator.
Broken or loose fan belt - Change as required.
Diesel engine is overloaded - Load reducing required.
Oil pressure is low
Not enough oil in the engine - Checking oil level and add if necessary.
Oil filter is dirty - Replace or service engine oil filter.
Different type of engine oil - Use oil of proper viscosity.
Crankshaft bearing has excessive oil clearance - Bearing needs to be changed.
Oil pump malfunction - Replace as required.
Abnormal engine noise or knocking
Lack of engine oil - Fill up the oil to required level.
Engine not warmed up - Warm up the engine.
Fuel injection pump timing is not adjusted - Use the correct fuel injection pump timing adjustment.
Too low idle RPM - Adjust as required.
Fuel injector fault - Test and replace fuel injectors if necessary.
Misaligned or faulty connecting rod - Alignment procedure or replacement is required.
Worn or broken pistons - Have pistons replaced.
| Drive System Troubleshooting |
Drive system doesn't function in one direction or either direction
Hydraulic fluid level low - Add fluid as required.
Worn drive chain - Inspect drive chain and replace faulty components.
Worn or damaged relief valve - Rebuild or install a new relief valve.
Hydraulic filter or suction line is clogged - Clean suction line or change hydraulic filter.
Worn or damaged foot or hand controls - Repair or change.
Damaged drive pump or motor - Repair or replace faulty component.
Reduced power
Plugged hydraulic oil filter - Replace hydraulic filter.
Relief valve is defective or open - Replace or close relief valve.
Faulty or damaged transmission components - Inspect and change faulty parts.
Input drive shaft is defective - Repair or replace drive shaft.
Air leaks in hydraulic system - Bleed air from system.
Overheated drive system
Hydraulic oil is insufficient - Fill the system to proper hydraulic oil level.
Clogged hydraulic fluid filter - Change hydraulic filter.
Worn or damaged relief valve - Service or change relief valve.
Hydraulic motor or drive pump is defective - Change or repair faulty component.
Hydraulic oil cooler is plugged - Cooling fins should be cleaned.
Drive system is overloaded - Load needs to be reduced.
Excessive noise
Wrong oil viscosity - Use proper oil viscosity.
Hydraulic system is leaking air - Bleed air from hydraulic system.
Hydraulic motor or drive pump is defective - Check and repair if required.
Worn or defective mechanical components of drive system - Inspect the parts for defect or damage and repair as required.
| Hydraulics Troubleshooting |
Hydraulic system overheated
Incorrect hydraulic pressure setting - Correct setting is required.
Defective or misadjusted main relief valve - Adjust or change relief valve.
Hydraulic fluid is contaminated - The fluid must be changed.
Hydraulic oil level is low - Check oil level and add hydraulic oil as required.
Faulty hydraulic oil pump - Replace or repair pump if necessary.
Lift arm fails to drop or lift
Lift controls failure - Repair or change.
Defective hydraulic pump - Replace or repair pump if necessary.
Hydraulic control valve malfunction - Replace or repair the valve.
Hydraulic cylinder malfunction - Install a new boom cylinder or repair it.
Hydraulic fluid level low - Fill the system to proper hydraulic fluid level.
Bucket can't tilt
Bucket tilt controls are defective - Repair or replace.
Defective hydraulic pump - Replace or repair pump if necessary.
Damaged hydraulic control valve - Repair or replace the valve.
Hydraulic bucket cylinder not working - Repair or change cylinder.
Low hydraulic fluid level - Checking hydraulic fluid level and add if necessary.
Bucket or lift arm functions slowly
Worn hydraulic oil pump - Test the pump performance and change pump if required.
Oil leaks from hydraulic cylinder - Replace cylinder piston seals.
Insufficient hydraulic oil - Need to add oil.
Faulty or incorrect setting hydraulic control valve - Repair or adjust properly.
Low hydraulic pressure - Correct adjustment is required.
Lift arm or bucket jerks when working
There is air in the hydraulic system - Bleed air from hydraulic system.
Hydraulic oil filter element is clogged - Clean or install new filter.
Dirty hydraulic fluid - Change hydraulic fluid.
Scored cylinder tube or rod - Change worn component.
Hydraulic pump is noisy
Leaking hydraulic system or insufficient oil level - Correct hydraulic leaks or top up oil as needed.
Hydraulic filter is clogged - Clean or replace the filter.
Clogged suction line - Clean suction line as required.
Air in hydraulic pump - Need to bleed air.
Damaged pump parts - Replace or rebuild the pump.
| Electrical Troubleshooting |
Battery will not charge
Electrical cable connections are loose or corroded - Tighten or service cable connections.
Defective battery terminal connectors - Change terminal connectors.
Defective battery - Replace the battery.
Loose or worn belt - Adjust belt tension or change the belt.
Starter turning slow
Battery voltage is low - Recharge the battery.
Battery is not holding charge - Service charging system or replace battery.
Battery terminals are corroded or wires are disconnected - Check wire connections and change or service terminals.
Starter motor won't turn
Battery is low or faulty - Battery needs to be recharged or replaced.
Disconnected or incorrectly connected wires - Inspect battery wires and connect correctly.
Battery power is low - Low battery charging, charge as required.
Starter motor is damaged - Replace or repair starter.
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| SKID STEER LOADERS SPECIFICATIONS |