Bobcat 863: Troubleshooting Leaking Hydraulic Hoses

[MikePhua]

The Bobcat 863, a popular skid steer loader, is widely regarded for its reliability and versatility in various construction and agricultural tasks. However, like any heavy equipment, it can experience issues over time. One common problem faced by owners of the Bobcat 863 is the leaking of hydraulic hoses, which can be frustrating and costly if not addressed promptly. This article provides a comprehensive guide on identifying, troubleshooting, and fixing hydraulic hose leaks on the Bobcat 863.
Introduction to the Bobcat 863 Skid Steer Loader
The Bobcat 863 was introduced as part of Bobcat's popular series of skid-steer loaders. Known for its robust construction and powerful performance, the 863 is often used for tasks like excavation, landscaping, and material handling. Its compact size allows it to work in tight spaces, while its hydraulic system provides the lifting power needed for a variety of attachments.
The hydraulic system is a crucial part of the Bobcat 863, powering both the lifting arms and various attachments. When the hydraulic system fails, such as due to leaking hoses, the machine’s performance can be severely compromised. Identifying and repairing these issues quickly can prevent further damage and downtime.
Common Causes of Hydraulic Hose Leaks
Hydraulic hoses are essential for transmitting the pressurized fluid that powers the Bobcat 863’s hydraulic components. However, over time, these hoses can develop leaks due to several factors. Understanding these common causes is key to troubleshooting and solving the problem.

1. Aging and Wear: Over time, hydraulic hoses can degrade due to repeated exposure to heat, pressure, and environmental elements like dirt, UV rays, and moisture. Rubber hoses in particular can dry out and crack, leading to leaks.
   
2. Improper Installation: If hydraulic hoses are installed incorrectly or if they’re routed too tightly, they can rub against other components or surfaces, causing wear and tear. This rubbing can eventually puncture the hose and lead to fluid leaks.
   
3. Pressure Surges: A sudden increase in hydraulic pressure, often caused by a sudden or abrupt operation of the loader or its attachments, can cause hoses to burst. This can happen when attachments like augers or grapples are used under excessive load.
   
4. Contaminants in the System: Dirt, dust, or debris entering the hydraulic system can damage the hoses. Contaminants can cause the inside of the hose to erode, creating weak spots that eventually leak.
   
5. Faulty Fittings or Clamps: Sometimes, the issue isn't with the hose itself but with the fittings or clamps used to secure the hose to the machine. If these components are loose, corroded, or improperly attached, they can cause leaks.
   

Signs of Leaking Hydraulic Hoses
The symptoms of hydraulic hose leaks on the Bobcat 863 are often easy to spot if you know what to look for. Below are some common signs that indicate your skid steer may be suffering from leaking hydraulic hoses:

1. Fluid Puddles or Stains: The most obvious sign of a hydraulic hose leak is the presence of fluid puddles under the machine. If hydraulic fluid is leaking, you'll notice red or amber-colored stains on the ground, especially around the affected hoses.
   
2. Reduced Lifting Capacity: If the loader's hydraulic system isn't working properly due to a hose leak, you may notice a reduction in lifting power. The loader may struggle to lift or move attachments effectively.
   
3. Slow or Jerky Movement: A hose leak can cause air to enter the hydraulic system, leading to erratic or delayed movements when you operate the loader’s arms or attachments.
   
4. Hissing or Squealing Sounds: A leaking hose can cause air to escape from the hydraulic system, creating a high-pitched hissing or squealing sound. If you hear these noises while the machine is operating, it's likely due to a hose leak.
   

Troubleshooting and Fixing Hydraulic Hose Leaks
Once you've identified that the issue is a hydraulic hose leak, the next step is to troubleshoot and fix it. Here's a step-by-step guide on how to do this:
1. Inspect the Hoses

• Visual Inspection: Start by visually inspecting all hydraulic hoses for obvious signs of damage such as cracks, bulges, or abrasions. Look for wet spots where fluid has leaked out.
  
• Check Fittings and Clamps: Inspect the fittings and clamps that secure the hoses to the machine. Ensure that they are tight and free from rust or corrosion. Loose fittings or clamps can often be the cause of leaks.
  

2. Pressurize the System (If Necessary)
If you can’t spot the leak visually, you may need to pressurize the hydraulic system to make the leak more obvious. Operate the Bobcat 863’s hydraulic functions while looking closely at the hoses. The pressure from the hydraulic system will force fluid out of the leak, making it easier to pinpoint the exact location.
3. Check for Contaminants

• Cleanliness: Clean the area around the hose fittings and connections before attempting repairs. This will prevent dirt from entering the hydraulic system when you remove the hose.
  
• Inspect Fluid Quality: Check the quality of the hydraulic fluid. If the fluid is contaminated with dirt or debris, you may need to flush the system and replace the filter.
  

4. Replace or Repair the Hose

• Cut and Replace: If the hose is cracked, worn, or otherwise damaged, the best solution is to replace it entirely. Cut the damaged section of the hose and use the appropriate fittings to attach a new hose. Ensure that you match the new hose's size, pressure rating, and material to the original hose.
  
• Repaired Hose: In some cases, if the damage is minor, you can repair the hose using a hydraulic hose repair kit. These kits typically include fittings, clamps, and seals that allow you to patch up the hose temporarily. However, replacing the hose is often the best long-term solution.
  

5. Test the System
Once the repairs are made, test the system by operating the Bobcat 863. Check for any signs of leaks during operation, and ensure that the hydraulic system is functioning smoothly. If the loader moves properly and no new leaks appear, your repair has been successful.
Preventing Future Hydraulic Hose Leaks
To prevent future leaks and prolong the lifespan of your Bobcat 863’s hydraulic system, here are some maintenance tips:

1. Regular Inspections: Perform regular visual inspections of all hydraulic hoses, fittings, and clamps to catch potential issues early.
   
2. Hydraulic Fluid Maintenance: Keep the hydraulic fluid clean and at the proper level. Regularly change the fluid and replace the filter to maintain system performance.
   
3. Proper Handling: Avoid excessive force or sudden movements that could cause pressure surges in the hydraulic system, as this can stress the hoses and lead to leaks.
   
4. Protect Hoses: Route hoses away from sharp edges, hot surfaces, and moving parts that can cause wear. Use protective sleeves or guards to shield hoses from abrasion.
   

Conclusion
Hydraulic hose leaks are a common issue with older Bobcat 863 skid steer loaders, but with the right tools and knowledge, you can easily troubleshoot and fix them. By inspecting hoses regularly, addressing leaks promptly, and maintaining the hydraulic system properly, you can ensure that your Bobcat 863 continues to perform at its best for years to come.
Being proactive in maintenance and understanding the potential causes of hydraulic hose failure can save both time and money, making your machine more reliable and efficient on the job.