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| Home / Skid Steer Loaders / Bobcat Skid Steer Loaders / Bobcat 863G |
Bobcat 863 G-Series Troubleshooting
The
Bobcat 863G skid steer loader driveline system components: Deutz BF4M1011F
vertical four-cylinder turbocharged liquid-cooled diesel engine with a rated
power of 73 hp (54 kW), and 1-speed or 2-speed hydrostatic transmission. The
hydraulic system has a pump with a rated capacity of 20 gal/min (76.8 l/min) or
30 gal/min (113.6 l/min). The Bobcat 863 G-Series is equipped with radial-lift
loader boom, 100HS drive chains, and 12.00x16.5 or 33x15.5x16.5 tires. The
loader has a max lift height is 121 inches (3075 mm) to hinge pin, and dump
height is 91.5 inches (2325 mm). The rated operating capacity is 1900 lbs (862
kg), and tipping load is 3800 lbs (1725 kg).
| Engine Troubleshooting |
Engine difficult to start or doesn't start
Air in fuel tank - Bleed fuel tank.
Fuel filter element is clogged - Clean the filter or install new filter element.
Fuel injection nozzles are faulty or clogged - Replace injection nozzles.
Water in the fuel system - Change fuel and repair fuel system.
Improper valve clearance - Have it adjusted.
Fuel injection pump damage - Repair or replace injection pump.
Diesel starts and stops
Air filter is plugged - Clean or change.
Dirty fuel filter - Install new filter element.
Poor fuel injection pump tightness - Look for any leaks of fuel pump, tighten it fast.
Clogged or defective injectors - Clean fuel injectors or change it.
Fuel injection pump malfunctioning - Install a new fuel pump or repair.
Diesel shuts off while driving
Engine is cold - Warm up engine as required.
Dirty fuel filter - Clean or change the filter.
Air in the fuel pipes - Bleed the fuel pipes.
Defective injection nozzle - Replace injection nozzles.
Wrong setting of fuel injection pump timing - Set it up as required.
Engine stops when idle
Low idle speed setting is not correct - Correct low idle adjustment.
Fuel injection pump is damaged - Replacement or repair required.
Damaged or clogged injectors - Clean or replace fuel injectors.
Valve clearance is out of adjustment - Correct valve clearance.
Lack of engine power
Air filter is plugged - Install new air filter element.
Defective or clogged injection nozzle - Change fuel injection nozzles.
Fuel injection pressure is wrong - Adjust pressure to proper level.
Valve clearance is wrong - Adjustment procedure required.
Incorrectly set low idle speed - Adjust the low idle speed.
Restricted fuel hoses or lines - Fuel lines and hoses need to be cleaned.
Cylinder head gasket is worn - Gasket should be replaced.
Leaking or damaged piston rings - Piston rings need to be replaced.
Engine is overheated
Not enough coolant - The cooling system needs to be refilled and checked for faults.
Low engine oil level - Check oil level and add oil as required.
Clogged radiator core or leaking radiator cap - Clean radiator or replace cap.
Loose or damaged fan belt - Change as required.
Engine is under excessive load - Load reducing required.
Oil pressure is low
Engine oil level low - Checking oil level and add if necessary.
Oil filter element is dirty - Change or clean engine oil filter element.
Improper type of engine oil - Use proper viscosity oil.
Crankshaft bearing has incorrect oil clearance - Bearing needs to be changed.
Oil pump failure - Remove and inspect oil pump.
Engine knocks or noises
Engine oil level is insufficient - Checking oil level and add if necessary.
Engine is not fully warmed up - Normalize the temperature by warming up the engine.
Improper setting of fuel injection pump timing - Set it up as required.
Incorrectly set low idle speed - Adjust low idle speed.
Defective fuel injectors - Test and replace fuel injectors if necessary.
Connecting rod is misaligned or defective - Align or replace connecting rod.
Piston wear or scoring - Pistons replacement required.
| Drive System Troubleshooting |
Machine is not moving forward or backward
Hydraulic fluid level low - Check and refill the hydraulic fluid.
Drive chain fault - Check drive chain and change defective components.
Worn or defective relief valve - Relief valve need to be replaced or repair.
Dirty suction line or hydraulic filter - Clean suction line or replace hydraulic filter.
Hand or foot controls malfunction - Inspect and repair if necessary.
Damaged drive pump or motor - Change or repair faulty component.
Loss of power
Clogged hydraulic oil filter - Replace hydraulic filter.
Relief valve is defective or open - Replace or close relief valve.
Transmission parts are worn or defective - Check and change faulty components.
Worn input drive shaft - Change or repair faulty drive shaft.
Air in the hydraulic system - Need to bleed air.
Drive system overheats
Low hydraulic fluid level - Check and refill the hydraulic fluid.
Hydraulic fluid filter is plugged - Replace or clean hydraulic filter.
Relief valve is broken - Change or repair defective relief valve.
Defective drive pump or hydraulic motor - Inspect and change as required.
Clogged hydraulic oil cooler - Cooling fins should be cleaned.
Drive system is overloaded - Reduce loading.
Drive system is noisy
Oil viscosity is incorrect - Drain and refill with correct oil.
Hydraulic system is leaking air - Bleed hydraulic system.
Drive pump or hydraulic motor is damaged - Inspect and change as required.
Mechanical parts of drive system are worn or damaged - Inspect drive system and replace faulty components.
| Hydraulics Troubleshooting |
Hydraulic system overheats
Incorrect hydraulic pressure setting - Correct adjustment is required.
Main relief valve failure or improper setting - Adjust relief valve or change if required.
Hydraulic fluid is dirty - Fill up with fresh hydraulic fluid.
Not enough hydraulic oil in the system - Add oil to the hydraulic system.
Defective hydraulic pump - Replace or repair pump if necessary.
Boom fails to lift or drop
Damaged lift controls - Replace or repair.
Hydraulic pump failure - Repair or install new hydraulic pump.
Hydraulic control valve is defective - Repair or change the valve.
Broken hydraulic cylinder - Repair or install a new lift cylinder.
Low hydraulic oil level - Check and refill the hydraulic oil.
Bucket does not function
Bucket controls are faulty - Repair or change.
Hydraulic pump is broken - Change or repair hydraulic pump if required.
Faulty hydraulic control valve - Repair or change the valve.
Broken bucket cylinder - Install a new cylinder or repair it.
Insufficient hydraulic fluid - Add fluid as required.
Slow boom or bucket operation
Faulty hydraulic oil pump - Flow-rate pump and change pump if necessary.
Oil leaks from hydraulic cylinder - Install new cylinder seals.
Insufficient hydraulic fluid - Fill the system to proper hydraulic fluid level.
Faulty or incorrect setting hydraulic control valve - Repair or adjust properly.
Low hydraulic pressure - Adjust pressure correctly.
Bucket or boom is working jerkily
Air in the hydraulic system - Need to bleed air.
Hydraulic oil filter clogging - Clean or change the filter.
Hydraulic fluid is dirty - The fluid must be changed.
Scored cylinder tube or rod - Change failed component.
Hydraulic pump makes excessive noise
Lack of oil or hydraulic leakage - Top up hydraulic oil or remedy leakage in system.
Clogged hydraulic filter - Clean or change the filter.
Plugged suction line - Clean suction line as required.
Pump sucks air - Bleed air from hydraulics.
Faulty pump parts - Change or rebuild pump.
| Electrical Troubleshooting |
Battery is not charging
Corroded or loose wire connections - Clean or tighten wiring connections.
Battery terminal clamps are defective - Terminal clamps should be changed.
Faulty cell in battery - Replace the battery.
Loose or damaged belt - Adjust belt tension or install a new belt.
Starter motor turns slow
Low battery power - Battery is drained, charge it.
Battery discharges quickly - Battery needs service or replacement.
Battery terminals are corroded or wires are disconnected - Connect wiring correctly or install new terminals.
Starter is not cranking
Battery is discharged or worn - Battery needs to be recharged or replaced.
Disconnected or incorrectly connected wires - Inspect battery wires and connect correctly.
Battery capacity is low - Charge the battery.
Faulty starter motor - Repair or change starter.
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| SKID STEER LOADERS SPECIFICATIONS |