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Bobcat S62 Troubleshooting

The Bobcat S62 skid steer loader driveline system components: a 146.5 cu.in (2.4L) Bobcat Doosan D24 4-cylinder turbocharged diesel engine with a rated power of 68 hp (50.7 kW), and 1-speed or 2-speed hydro transmission. The hydraulic system has a pump with a rated capacity of 17.6 gal/min (66.5 l/min). The system relief pressure is 3500 psi (241 bar). The Bobcat S62 is equipped with radial-lift loader boom, 80 HSOC roller chains, and 10x16.5 or 31-12x16.5 tires. The skid steer has a boom lifting force of 4186 lbs (1900 kg) and bucket breakout force of 5093 lbs (2310 kg). The rated operating capacity is 2100 lbs (953 kg), and tipping load is 4200 lbs (1906 kg).

Engine Troubleshooting

Engine starts hard or doesn't start
Air in the fuel system - Air bleeding.
Fuel filter element is clogged - Filter maintenance required.
Clogged or burnt injection nozzle - Change fuel injection nozzles.
Water or dirt in fuel system - Drain, flush, and service the system.
Valve out of adjustment - Need to adjust valve clearance.
Fuel injection pump malfunctioning - Repair or replace injection pump.

Engine starts and stalls suddenly
Air filter is clogged - Install new air filter element.
Fuel filter element is dirty - Replace filter element.
Poor fuel injection pump tightness - Look for any leaks of fuel pump, tighten it fast.
Damaged or clogged injectors - Replace or clean fuel injectors.
Fuel injection pump is broken - Rebuild or replace pump.

Diesel shuts off while driving
Low coolant temperature - Warm up the engine.
Dirty fuel filter - Install new filter element.
There is air in the fuel system - Bleed the system.
Dirty or faulty injection nozzles - Clean or replace injection nozzles.
Wrong setting of fuel injection pump timing - Use the correct fuel injection pump timing adjustment.

Engine stalls at low idle speed
Too low idle RPM - Adjust low idling as recommended.
Fuel injection pump damage - Rebuild or change fuel pump.
Dirty or defective injectors - Clean or replace fuel injectors.
Valve clearance is wrong - Correct valve clearance.

Engine power loss
Air cleaner is dirty - Clean or change cleaner.
Faulty fuel injection nozzles - Replace injection nozzles.
Fuel injection pressure is wrong - Adjust pressure to proper level.
Excessive valve clearance - Adjustment procedure required.
Low idle speed adjustment is incorrect - Correct the settings.
Clogged fuel hoses or lines - Service fuel hoses and lines.
Blown cylinder head gasket - Install new cylinder head gasket.
Leaking or damaged piston rings - Piston rings need to be replaced.

Engine overheated
Coolant level is low - Fill the cooling system and check components for leaks or other faults.
Not enough engine oil - Check oil level and add oil as required.
Clogged radiator fins or damaged radiator cap - Install new cap or clean radiator.
Fan belt is broken or worn - Install new fan belt.
Engine overload - Reduce load on the engine.

Insufficient oil pressure
Insufficient engine oil - Fill crankcase to proper oil level.
Oil filter is clogged - Change or clean engine oil filter element.
Oil grade or viscosity is wrong - Drain and refill with oil of correct grade and viscosity.
Excessive oil clearance of crankshaft bearing - Replace bearings.
Oil pump failure - Repair or replace.

Abnormal engine noise or knocking
Lack of engine oil - Fill up the engine oil.
Low coolant temperature - Warm up the engine.
Incorrect adjustment of fuel injection pump timing - Adjust the pump as required.
Too low idle RPM - Test and adjust.
Fuel injectors are dirty or defective - Clean or replace fuel injectors.
Connecting rod is not aligned or defective - Connecting rod must be aligned or replaced.
Worn or broken pistons - Pistons replacement required.

Drive System Troubleshooting

Drive system won't operate in either direction
Insufficient hydraulic fluid - Fill the system to proper hydraulic fluid level.
Drive chain is damaged - Inspect drive chain and replace defective parts.
Input drive shaft malfunctioning - Replace drive shaft.
Relief valve failure - Rebuild or install a new relief valve.
Dirty hydraulic filter or suction line - Clean suction line or replace hydraulic filter.
Foot or hand controls are damaged - Replace or repair.
Worn drive motor or pump - Repair or change faulty component.

Loss of power
Hydraulic oil filter is clogged - Replace hydraulic filter.
Open or damaged relief valve - Close or replace relief valve.
Worn or faulty transmission components - Inspect and change defective parts.
Input drive shaft is damaged - Repair or replace faulty drive shaft.
Air leaks in hydraulic system - Bleed air from system.

Overheated drive system
Hydraulic oil level is low - Need to add oil.
Hydraulic fluid filter is clogged - Check, clean, or replace as required.
Relief valve is stuck - Repair or replace relief valve.
Damaged drive pump or hydraulic motor - Replace or repair faulty component.
Dirty oil cooler - Cooling fins should be cleaned.
Transmission overloading - Load needs to be reduced.

Drive system makes excessive noise
Oil viscosity is incorrect - Use proper oil viscosity.
Air in hydraulic system - Bleed air from hydraulic system.
Defective drive pump or hydraulic motor - Inspect and replace as necessary.
Worn or defective mechanical parts of drive system - Inspect the parts for worn or defect and repair as needed.

Hydraulics Troubleshooting

Hydraulic system is overheated
Hydraulic pressure incorrectly adjusted - Set pressure correctly.
Main relief valve is damaged or adjusted improperly - Adjust the valve or replace if necessary.
Hydraulic oil is dirty - Hydraulic oil change required.
Hydraulic fluid level is insufficient - Add fluid to the hydraulic system.
Faulty hydraulic oil pump - Install new pump or repair it.

Boom does not raise or lower
Lift controls failure - Replace or repair.
Hydraulic pump not working - Repair or replace pump if necessary.
Hydraulic control valve is defective - Install a new valve or repair it.
Defective hydraulic cylinder - Install a new boom cylinder or repair it.
Low hydraulic fluid level - Fill the system to proper hydraulic fluid level.

Bucket does not function
Damaged bucket controls - Repair or replace.
Damaged hydraulic oil pump - Repair or replace pump if necessary.
Hydraulic control valve is defective - Repair or change hydraulic valve.
Hydraulic bucket cylinder is defective - Change or repair cylinder.
Hydraulic oil is insufficient - Need to add oil.

Boom or bucket moves slowly
Hydraulic pump is worn - Check hydraulic pump flow and replace pump if necessary.
Hydraulic cylinder oil leakage - Cylinder seals need to be replaced.
Hydraulic fluid is insufficient - Checking hydraulic fluid level and add if necessary.
Hydraulic control valve is unadjusted or worn - Adjust properly or repair.
Hydraulic pressure has dropped - Adjust it correctly.

Lift arm or bucket is jerky
There is air in the hydraulic system - Bleed hydraulic system.
Hydraulic oil filter element is dirty - Replace or clean the filter.
Contaminated hydraulic oil - Change hydraulic oil.
Cylinder rod or tube is scratched - Replace damaged component.

Hydraulic pump makes excessive noise
Leaking hydraulic system or insufficient oil level - Repair hydraulic leaks or add oil as required.
Dirty hydraulic filter - Service or replace hydraulic filter.
Suction line clogging - Suction line needs to be cleaned.
Pump sucks air - Bleed air from hydraulics.
Worn pump parts - Rebuild or change hydraulic pump.

Electrical Troubleshooting

Battery won’t charge
Loose or corroded cable connections - Clean or tighten connections.
Electrical terminal connectors are faulty - Terminal connectors need to be changed.
Battery faulty cell - Replace the battery.
Belt is loose or defective - Adjust belt tension or install a new belt.

Starter cranks slow
Low battery voltage - Battery is drained, charge it.
Battery runs out quickly - Service charging system or change battery.
Disconnected wires or corroded battery terminals - Connect wiring correctly or install new terminals.

Starter motor won't turn
Battery is low or faulty - Replace or charge as required.
Wiring is improperly connected or disconnected - Check wiring and connect properly.
Battery capacity is low - Battery needs to be recharged.
Starter motor failure - Starter should be changed.