Bobcat 863 fuel gauge and lights not working

[Bobcat9]

Hello, I'm new to the forum. I have a 1998 Bobcat 863, purchased new, w/ 910 hours on it. Just recently, two separate problems occurred. 1. First, my fuel gauge was working intermittently, and now has stopped. I spoke with my dealer, and they mentioned the sending unit on the tank as the most likely source of the problem. Is there a manual download somewhere for the process of getting to this area of the Bobcat and also the replacement of the part? I'm very mechanical, but have never needed to do anything to this machine other than the maintenance. Last year, I had Bobcat dealer do a full maintenance on the machine, including hydraulic oil replacement, chains adjusted, etc.....but now I'm broke and need to fix this myself. 2. 3 days ago, unloading a heavy machine out of my truck at night, the Bobcat lights both went down at the same time. Nothing. Any thoughts, and also manual download describing this repair? Any help you can offer is much appreciated. Like many, my business has been hit very, very hard by the economy, so repairing these myself is the only option at this time. JC

 

[OldMachinist]

The first thing I'd check for the lights is the fuse. The fuse block is on the left hand side when you open the engine bay door. If the fuse is good then I'd look for a bad ground connection. Likely the ground wire between the cab and main frame, lift the cab and look for a wire connecting the cab to the body. A bad ground could also be causing the fuel gauge problem. The fuel sending unit is under the engine/pump assembly and may require removing the assembly to service.

 

[Bobcat9]

The first thing I'd check for the lights is the fuse. The fuse block is on the left hand side when you open the engine bay door. If the fuse is good then I'd look for a bad ground connection. Likely the ground wire between the cab and main frame, lift the cab and look for a wire connecting the cab to the body. A bad ground could also be causing the fuel gauge problem. The fuel sending unit is under the engine/pump assembly and may require removing the assembly to service.

Thanks for the reply. Is there a place where I can look at the service manual for this machine. I have no idea how to "open the cab". I know it levers up, as I've seen them that way at the Bobcat dealer, but I'd love to look at the manual to see how these things are done. Thanks, JC

 

[OldMachinist]

Thanks for the reply. Is there a place where I can look at the service manual for this machine. I have no idea how to "open the cab". I know it levers up, as I've seen them that way at the Bobcat dealer, but I'd love to look at the manual to see how these things are done. Thanks, JC

To raise the cab, remove the nuts and washers in the corners where the foward uprights of the cab are, then just lift the cab back on the hinges. I think the 863 has a latch to hold it up so lift until it latches.

 

[donald73d]

Thanks for the reply. Is there a place where I can look at the service manual for this machine. I have no idea how to "open the cab". I know it levers up, as I've seen them that way at the Bobcat dealer, but I'd love to look at the manual to see how these things are done. Thanks, JC

On my 843 you remove two large nuts & washers on the front inside of the cab, one on the left and one on the right. Save them in a container. They tend to get lost. Then standing on the bucket you lift the cab up all the way. Its a bit heavy. If you lift it a foot or two it will not stay, if you lift it all the way it will. (If inside, garage needs to be high). I would pull the gauge cluster and then with a jumper wire and switch on, ground the sender wire on the gauge to ground. It should go full scale. On my 843 its a purple wire. My fuel gauge is flacky also and I have one on order. The problem is sawdust has gotten inside all 3 of my gauges. The voltmeter will not go past 12V. The fuel gauge shows empty when it full. With the fuel gauge in my hand I could see the saw dust float around. I am replacing the temp gauge as its critical and if the engine were to overheat and the gauge not show it, that would be very bad. The gauges from Bobcat are about $25. The gauge cluster on my 843 is held in by 3 bolts on the outside. The wiring diagram is in the operators manual along with the service manual..

 

[bobbie-g]

On my 843 you remove two large nuts & washers on the front inside of the cab, one on the left and one on the right. Save them in a container. They tend to get lost. Then standing on the bucket you lift the cab up all the way. Its a bit heavy. If you lift it a foot or two it will not stay, if you lift it all the way it will. (If inside, garage needs to be high). I would pull the gauge cluster and then with a jumper wire and switch on, ground the sender wire on the gauge to ground. It should go full scale. On my 843 its a purple wire. My fuel gauge is flacky also and I have one on order. The problem is sawdust has gotten inside all 3 of my gauges. The voltmeter will not go past 12V. The fuel gauge shows empty when it full. With the fuel gauge in my hand I could see the saw dust float around. I am replacing the temp gauge as its critical and if the engine were to overheat and the gauge not show it, that would be very bad. The gauges from Bobcat are about $25. The gauge cluster on my 843 is held in by 3 bolts on the outside. The wiring diagram is in the operators manual along with the service manual..

On my 1999 863G the fuses are between the steering levers, right at my heels when I'm seated. Pair of 9/16" bolts secures the bulging cover. There are sometimes problems with moisture seeping into the fuse box, so make sure the seal is good when you replace the cover. Mine has RTV around it, so I'm reluctant to just open it up to have a look. I'll be sorry when I finally blow a fuse. ---Bobbie G.

 

[donald73d]

On my 1999 863G the fuses are between the steering levers, right at my heels when I'm seated. Pair of 9/16" bolts secures the bulging cover. There are sometimes problems with moisture seeping into the fuse box, so make sure the seal is good when you replace the cover. Mine has RTV around it, so I'm reluctant to just open it up to have a look. I'll be sorry when I finally blow a fuse. ---Bobbie G.

I might add some dielectric grease to the fuse ends. While a visual on the fuse should normally be OK, I would check with a DVM if they look good to make sure.