Bobcat 863 Electrical Troubleshooting Guide

[MikePhua]

The Bobcat 863, a compact skid-steer loader introduced in the late 1990s, has been a staple in construction and landscaping due to its versatility and durability. However, like all machinery, it is susceptible to electrical issues that can hinder performance. Understanding common electrical problems and their solutions is crucial for maintaining the 863's efficiency.
Common Electrical Issues in the Bobcat 863

1. No Start Condition
   • Symptoms: The engine turns over when the starter is jumped, but the machine fails to start.
     
   • Potential Causes:
     • Faulty fuel shutoff solenoid not receiving 12V from the control panel.
       
     • Malfunctioning ignition switch or wiring issues.
       
     • Blown fuses or relays.
       
   • Diagnostic Steps:
     • Verify the presence of 12V at the fuel shutoff solenoid.
       
     • Inspect the ignition switch and associated wiring for continuity.
       
     • Check all fuses and relays related to the starting circuit.
       
     • Test the main 100A fuse for continuity.
       
2. Electrical Components Not Receiving Power
   • Symptoms: Certain electrical components, like the right-side control panel, fail to receive power.
     
   • Potential Causes:
     • Blown fuses or damaged relays.
       
     • Corroded or loose wiring connections.
       
     • Faulty ground connections.
       
   • Diagnostic Steps:
     • Inspect all relevant fuses and relays for integrity.
       
     • Clean and secure all wiring connections.
       
     • Ensure all ground points are clean and properly connected.
       
3. Intermittent Power Loss
   • Symptoms: Electrical systems function sporadically, with some components losing power unexpectedly.
     
   • Potential Causes:
     • Loose or corroded battery terminals.
       
     • Faulty alternator not charging the battery properly.
       
     • Worn or damaged wiring harnesses.
       
   • Diagnostic Steps:
     • Inspect battery terminals for tightness and cleanliness.
       
     • Test the alternator output to ensure proper charging.
       
     • Examine wiring harnesses for signs of wear or damage.
       

Preventative Maintenance Tips

• Regularly Inspect Electrical Components: Routine checks of fuses, relays, and wiring can help identify potential issues before they become major problems.
  
• Maintain Clean Battery Terminals: Corrosion can impede electrical flow, leading to power loss.
  
• Ensure Proper Grounding: A poor ground connection can cause erratic electrical behavior.
  
• Use Quality Replacement Parts: Always replace faulty components with high-quality parts to ensure longevity and reliability.
  

Conclusion
The Bobcat 863 is a robust machine, but like all equipment, it requires regular maintenance to ensure optimal performance. By understanding common electrical issues and following proper diagnostic and maintenance procedures, operators can keep their 863 running smoothly and efficiently. Always refer to the Bobcat 863 service manual for detailed specifications and procedures.