In need of assistance: I have a 2001 Bobcat 864 G Series with triangle headlights. The machine was operating smoothly until a main hose burst. While waiting for parts and performing maintenance on the foot controls during the repair, the cage was up for a few weeks. After replacing the hoses and trying to start the machine, we discovered there was no voltage to the panel with the key switch. Despite being able to start the machine by jumping the starter, there are no lights or indication of power to the key. We have checked for corrosion or moisture in the gauge panel and key switch panel, but found nothing out of the ordinary. We also tested the key switch and it was fine. The service manual with wiring diagram was not very helpful in identifying the issue. We have tried swapping relays in the fuse panel, but still no luck. When turning the key, one relay can be heard moving, but there is no power going to the panel. Any suggestions on which wire to trace or possible causes for this issue would be greatly appreciated. We have exhausted all troubleshooting ideas. Thank you!
Begin troubleshooting by locating the key switch and identifying the wire that is constantly energized. If there isn't a hot wire connected to the switch, check for a fuse or circuit breaker. Once you've identified the hot wire, switch the key to the ON position and track the wire that just became energized.
One of the most common areas to check for electrical issues is where the cab harness connects to the main harness under the cab, often located near the hydraulic tank. Disconnect the harness at the LH panel and look for the red or red/white wires, as well as the black ground wire. Ensure the wire is still receiving power even with the key off by checking for battery voltage between the wires and between the red wire and a solid chassis ground. It is crucial to confirm you have both voltage and ground. If there is no voltage, try disconnecting the cab/mainframe harness connector and test for unswitched power on the mainframe side. Keep in mind that the harness connector may not have strong seals and could have been damaged when the cab was raised. Look for any signs of wire breakage, even if the insulation appears intact.
I am truly impressed by these fantastic responses. Thank you for the valuable advice.
crewchief888 recommended checking for unswitched power on the mainframe side of the cab/mainframe harness connector. Due to the possibility of twisted or pulled harnesses when the cab is raised, wires may have broken without obvious signs of damage. It is crucial to inspect the wire strands for internal breakage. A similar issue was resolved on a T300 by examining the mainframe/cab harness connector and discovering a wire break at the crimp. By bypassing the broken wire with a jumper, the problem was successfully fixed. Welcome to HEF VinceHay! Cheers!
In a forum thread, user willie59 shared an experience with a T300 where they encountered a connectivity issue. Despite inspecting the mainframe/cab harness connector and finding no visible damage to wires, the problem persisted. It was only after testing the unswitched power wire on both sides of the connector that they discovered a broken wire inside the connector itself. By bypassing the damaged wire with a jumper, the issue was resolved. This incident highlights the frustration commonly experienced with faulty connectors in heavy machinery. On separate occasions, users have encountered similar issues with newer square connectors, leaving them puzzled about the cause of the problem.
Answer: Answer: Possible causes for this issue could include a faulty relay, wiring problem, or a malfunction in the electrical system components. It is recommended to check for any damaged wires, loose connections, or faulty relays that may be affecting the flow of power to the panel.
Answer: Answer: To troubleshoot the issue of no power to the key panel, you can start by checking the wiring connections, fuses, relays, and the key switch itself. Ensure that all connections are secure and free of corrosion, and test the components with a multimeter to identify any faulty parts that may be causing the problem.
Answer: Answer: Begin by systematically checking the wiring, relays, fuses, and key switch for any signs of damage or malfunction. Use a wiring diagram from the service manual to trace the relevant wires and components. If swapping relays did not resolve the issue, focus on checking for continuity in the wiring and testing each component for proper functionality.
Join hundreds of satisfied customers who have transformed their maintenance processes.
Sign up today and start optimizing your workflow.