____________________________________________________________________________________
| Home / Skid Steer Loaders / Bobcat Skid Steer Loaders / Bobcat 863H |
Bobcat 863H Troubleshooting
The
Bobcat 863H skid steer loader is powered by 166.7 cu.in (2.7L) Deutz BF4M1011
4-cylinder direct injection turbocharged diesel engine with a rated power of
73.5 hp (54.8 kW). The Bobcat 863H is equipped with a single-speed hydrostatic
transmission, radial-lift loader boom, 100HS drive chains, and 12.00x16.5 tires.
The hydraulic system has a pump with fluid flow rate of 18 gpm (68 lpm) or 28
gpm (106 lpm). The hydraulic pressure is 3000 psi (206 bar). The skid steer has
a rated operating capacity of 2000 lbs (907 kg) and tipping load of 4000 lbs
(1815 kg). The maximum lift height is 121 inches (3075 mm) to hinge pin, and
dump height is 91.5 inches (2325 mm).
| Engine Troubleshooting |
Engine hard to start or won't start
There is air in the fuel system - Bleed the system.
Fuel filter element is dirty - Clean the filter or install new filter element.
Burnt or defective injection nozzle - Check injection nozzles and replace if required.
Water or dirt in fuel system - Drain, flush, and service the system.
Incorrect valve clearance - Have it adjusted.
Fuel injection pump is not working correctly - Repair or replace injection pump.
Engine starts and stalls suddenly
Clogged air filter - Clean or replace element.
Fuel filter plugging - Change or clean the filter element.
Fuel injection pump has loose connections - Tighten the connections.
Clogged or defective injectors - Inspect fuel injectors and change as required.
Fuel injection pump is defective - Replace injection pump or repair it.
Engine shuts off while running
Engine not warmed up - Warm up to required temperature.
Clogged fuel filter - Change filter element.
Air in fuel tank - Bleed fuel tank.
Defective or clogged injection nozzle - Service or change injection nozzles.
Improper fuel injection timing - Use the correct fuel injection pump timing adjustment.
Engine stops while idle
Too low idle RPM - Correct the settings.
Defective fuel injection pump - Repair or install new pump.
Fuel injectors are faulty or clogged - Change or clean fuel injectors.
Improper valve clearance - Adjust valve clearance according to specifications.
Diesel power loss
Dirty air cleaner - Clean or replace element.
Fuel injection nozzles are faulty or clogged - Replace injection nozzles.
Improper fuel injection pressure - Adjust to proper pressure.
Valve clearance is not correct - Correct valve clearance needs to be set.
Low idle speed set incorrectly - Adjust low idling as recommended.
Dirt in the fuel lines or hoses - Clean fuel system lines and hoses.
Cylinder-head gasket is broken - Install new cylinder head gasket.
Leaking or damaged piston rings - Piston rings need to be replaced.
Engine overheats
Not enough coolant - Add coolant and check the components of cooling system.
Not enough engine oil - Check and refill engine oil.
Damaged radiator cap or dirty radiator core - Clean radiator or install new cap.
Damaged or worn fan belt - Change the fan belt.
Engine overloaded - Reduce engine load.
Oil pressure too low
Oil level is insufficient - Add oil as required.
Engine oil filter is plugged - Replace or service engine oil filter.
Different type of engine oil - Use the specified type of engine oil.
Crankshaft bearing has excessive oil clearance - Replace bearings.
Oil pump is worn or damaged - Repair or change.
Abnormal engine knocking or noise
Low engine oil level - Checking oil level and add if necessary.
Engine is cold -Warm up the engine as required.
Fuel injection pump timing is wrong - Set up as recommended.
Low idle speed setting is incorrect - Test and adjust.
Clogged or defective injectors - Clean or replace fuel injectors.
Connecting rod misalignment or failure - Alignment procedure or replacement is required.
Broken or worn pistons - Have pistons replaced.
| Drive System Troubleshooting |
Machine does not move forward or backward
Hydraulic oil level is low - Need to add oil.
Faulty drive chain - Check drive chain and change defective components.
Relief valve worn or defective - Service or change relief valve.
Hydraulic filter or suction line is dirty - Replace hydraulic filter or clean suction line.
Defective foot or hand controls - Replace or repair.
Drive motor or pump is defective - Repair or replace faulty component.
Reduced power
Clogged hydraulic oil filter - Change or service hydraulic filter.
Open or faulty relief valve - Close or replace relief valve.
Worn or defective transmission parts - Check and replace faulty components.
Input drive shaft is damaged - Repair or replace drive shaft.
Air trapped in hydraulic system - Bleed hydraulic system.
Drive system overheating
Insufficient hydraulic oil - Fill the system to proper hydraulic oil level.
Plugged hydraulic fluid filter - Change hydraulic filter.
Relief valve malfunction - Change or repair defective relief valve.
Drive pump or hydraulic motor is damaged - Repair or replace faulty component.
Hydraulic oil cooler is dirty - Clean the cooling fins.
Transmission overloading - Reduce the load.
Excessive noise
Improper oil viscosity - Use correct oil viscosity.
Air in hydraulic system - Bleed hydraulic system.
Hydraulic motor or drive pump failure - Change or repair faulty component.
Mechanical components of drive system are worn or damaged - Inspect drive system and replace faulty components.
| Hydraulics Troubleshooting |
Hydraulic system is overheated
Hydraulic pressure is not adjusted correctly - Adjust pressure as required.
Main relief valve is defective or unadjusted - Replace or set up the relief valve.
Contaminated hydraulic oil - The oil must be changed.
Not enough hydraulic oil in the system - Add oil to the hydraulic system.
Worn hydraulic oil pump - Install new pump or repair it.
Boom can't lift or drop
Lift controls malfunction - Change or repair.
Defective hydraulic pump - Repair or install new hydraulic pump.
Defective hydraulic control valve - Repair or replace hydraulic valve.
Defective hydraulic cylinder - Install a new boom cylinder or repair it.
Hydraulic fluid is insufficient - Add fluid as required.
Bucket does not function
Bucket controls failure - Repair or replace.
Hydraulic pump is broken - Repair or change pump if required.
Defective hydraulic control valve - Repair or replace hydraulic valve.
Bucket cylinder malfunction - Repair or replace cylinder.
Insufficient hydraulic fluid - Add fluid as required.
Boom or bucket functions slowly
Hydraulic pump is faulty - Flow-rate pump and change pump if necessary.
Hydraulic cylinder oil leakage - Cylinder seals need to be replaced.
Hydraulic fluid is insufficient - Fill up the hydraulic fluid.
Defective or not adjusted hydraulic control valve - Repair or set correctly.
Low hydraulic pressure - Adjust it correctly.
Lift arm or bucket is jerky
Hydraulic system is leaking air - Air bleeding is required.
Hydraulic oil filter clogging - Replace or clean the filter.
Hydraulic oil is dirty - Fill up with fresh hydraulic oil.
Cylinder tube or rod is scored - Replace damaged component.
Hydraulic pump makes excessive noise
Insufficient oil level or leaking hydraulic system - Top up hydraulic oil or remedy leakage in system.
Plugged hydraulic filter - Change or clean oil filter.
Plugged suction line - Need to clean the suction line.
Pump sucks air - Bleed air.
Pump components are worn out - Install new hydraulic pump or rebuild it.
| Electrical Troubleshooting |
Battery is not charging
Corroded or loose electrical wire connections - Service or tighten cable connections.
Battery terminal clamps are defective - Change terminal clamps.
Defective battery - Install a new battery.
Worn or loose belt - Install a new belt or adjust belt tension.
Starter cranks slow
Low battery voltage - Low battery charging, charge as required.
Battery runs out quickly - Service charging system or install new battery.
Terminals are faulty or battery cables are disconnected - Connect wiring correctly or install new terminals.
Starter is not cranking
Battery is drained or defective - Recharge or replace battery.
Disconnected or improperly connected wiring harness - Inspect battery wiring harness and connect as required.
Battery voltage is low - Charge the battery.
Starter motor failing - Repair or install a new starter.
____________________________________________________________________________________
____________________________________________________________________________________
| SKID STEER LOADERS SPECIFICATIONS |