Replacing Bobcat Fuel Pickup Tubing: A Step-By-Step Guide

Replacing the fuel pickup tubing on a Bobcat 863 is a challenging task. The tubing is located inside the fuel tank, which is situated in the belly of the machine, under the engine and hydraulic pumps. To access the tubing, you may need to raise the cab and remove the side cover, hydraulic fittings, and/or the engine/pump mounts to create enough space to work. The tubing is held in place by a rubber grommet, which can be difficult to remove and reinstall. When replacing the tubing, it is recommended to use a new seal grommet and fuel tubing from Bobcat, as the original tubing may deteriorate over time. Additionally, some models use a flexible tubing with a strainer screen and check ball, while others use a more rigid plastic tubing without these components. It is important to be aware of the specific configuration of your machine before starting the repair.

Raise the cab and reach over the top of the hyd pumps

To replace the fuel pickup tubing on a Bobcat 863, you will need to raise the cab and reach over the top of the hydraulic pumps. This process can be challenging, but with careful steps, you can successfully access the fuel pickup tubing for replacement. Here is a detailed guide to help you through the process:

Raising the Cab:

• Park your Bobcat 863 on a level surface and engage the parking brake to ensure it doesn't move during the procedure.
• Locate the two nuts at the inside front corners of the cab. These nuts hold the cab in place. Remove them using the appropriate tool, such as a socket wrench.
• Once the nuts are removed, you can start lifting the cab. Place both hands on the cab and lift it upwards, pivoting on the pins located at the back, above the radiator.
• The cab should stay in the lifted position. However, if it feels stuck, you can try standing on the loader arm step and pushing up on the door opening to gain more leverage.
• With the cab raised, locate the hydraulic pumps. These are situated between the engine and the hydrostatic assembly.

Reaching Over the Hydraulic Pumps:

• With the cab raised, you now have access to the fuel pickup tubing. It is located over the top of the hydraulic pumps.
• Depending on the year of your Bobcat 863, there may be a side cover over the rear tires, behind the boom. If so, removing the right-side cover can provide additional access to the fuel pickup tubing.
• Reaching over the hydraulic pumps, locate the fuel pickup tubing. It is positioned between the engine and the hydrostatic assembly.
• The fuel pickup tubing has a rubber grommet that holds it in place. Carefully remove the tubing from the grommet. It may be difficult to get it out, so be patient and use appropriate tools if needed.
• Once the tubing is removed, inspect it for any damage or blockages that may have caused fuel-related issues.
• If you need to replace the tubing, obtain a new one of the same specifications. Install it by feeding it through the grommet and securing it in place. Ensure the tubing is firmly seated and won't come loose during operation.
• Before lowering the cab, take a moment to inspect the area for any debris or dirt that may have accumulated. A clean work area will help prevent future issues.
• Finally, lower the cab by first raising it slightly, depressing the latch release, and then carefully lowering it back into position. Reinstall the nuts at the front inside corners of the cab to secure it in place.

Remember to exercise caution throughout the process and ensure that your Bobcat 863 is securely parked and stabilised before proceeding. Good luck with your fuel pickup tubing replacement!

Remove the right side cover and access the tubing through there

Removing the right side cover on your Bobcat 863 will allow you to access the fuel pickup tubing for replacement. This job can be challenging, but with careful attention to detail, it can be accomplished successfully.

First, you will need to raise the cab of your Bobcat 863. Once the cab is raised, you will have access to the area over your hydraulic pumps, where the fuel pickup tubing is located, between the engine and the hydrostatic assembly.

Next, locate the side cover on the right side of the machine, behind the boom. Depending on the year of your Bobcat 863, there may be a side cover over the rear tires in this area. Remove this right-side cover by unscrewing any fasteners or bolts holding it in place. Be aware that Bobcat machines typically use a strong sealant, rather than gaskets, to secure covers, so you may need to use an air hammer with a chisel bit or a screwdriver and chisel to carefully pry it open.

With the right-side cover removed, you will now have access to the fuel pickup tubing. It is located near the top of the fuel tank, where it connects to the fuel tank grommet. The tubing is held in place by a rubber grommet, which can be difficult to remove and reinstall, so proceed with caution.

Before removing the fuel pickup tubing, clean the surrounding area to ensure that no debris falls into the fuel tank. Once the area is clean, carefully pull the tubing out of the tank. It may be helpful to have an extra set of hands for this step as the tubing can be challenging to remove.

Now that you have accessed and removed the fuel pickup tubing through the right-side cover, you can proceed with installing the new tubing. Remember to exercise caution and patience throughout the process, as some steps can be tricky, and always refer to a qualified mechanic if you need further assistance.

Check the fuel line and strainer in the tank

To check the fuel line and strainer in the tank of your Bobcat 863, you'll need to access the tank, which can be a challenging task. Here's a step-by-step guide to help you through the process:

Step 1: Accessing the Fuel Tank

The fuel tank on the Bobcat 863 is located deep within the machine, and you'll need to find a way to reach it. There are a few different approaches you can take:

• Raise the cab: One option is to raise the cab and reach over the hydraulic pumps. The fuel tank is located between the engine and the hydrostatic assembly.
• Remove the side cover: Depending on the year of your machine, there may be a side cover over the rear tires behind the boom. Removing this cover can provide access to the fuel tank.
• Remove the engine: If you can't reach the fuel tank through the cab or side cover, you may need to remove the engine to access the tank. This is a more involved process and should be considered a last resort.

Step 2: Locating the Fuel Line and Strainer

Once you have accessed the fuel tank, you'll need to locate the fuel line and strainer:

• Fuel line: The fuel line is connected to the fuel tank and runs to the fuel pump. It is usually made of rubber and can deteriorate over time.
• Strainer: The strainer is located at the intake end of the fuel line inside the fuel tank. It is designed to filter out debris and prevent it from entering the fuel line.

Step 3: Inspecting the Fuel Line and Strainer

After locating the fuel line and strainer, carefully inspect them for any signs of damage or clogging:

• Fuel line: Check the condition of the fuel line. Over time, it can deteriorate, collapse, or develop cracks, which can restrict fuel flow.
• Strainer: Pay close attention to the strainer, as it can become clogged with debris, including dirt, algae, or even small creatures like leaves and earthworms. A clogged strainer will block fuel flow and need to be cleaned or replaced.

Step 4: Cleaning or Replacing Components

If you find any issues during your inspection, you may need to clean or replace the fuel line and strainer:

• Cleaning: If the fuel line is clogged or dirty, you can attempt to clear it using compressed air. Remove a connection down the fuel system and blow air through the line to dislodge any debris.
• Replacing: If the fuel line is damaged or deteriorated, it should be replaced. Similarly, if the strainer is severely clogged or damaged, consider installing a new one. You can find replacement parts at Bobcat dealers or online.

Remember to exercise caution when working with fuel systems and refer to your Bobcat 863's manual for detailed specifications and safety guidelines.

Use a straightened-out coat hanger to measure the depth of the fuel tank

To replace the 863 Bobcat fuel pickup tubing, you'll need to access the fuel tank, which can be challenging due to the machine's compact design. Here's a step-by-step guide on how to approach this task using a straightened-out coat hanger:

Step 1: Accessing the Fuel Tank

Before you can measure the depth of the fuel tank with a coat hanger, you'll need to locate and access the tank. Here's how you can do it:

• Raise the cab of your Bobcat.
• Look for the fuel tank, which is located between the engine and the hydrostatic assembly.
• Depending on the year of your Bobcat, there may be a side cover over the rear tires behind the boom. If so, remove the right-side cover to access the fuel tank.
• Alternatively, you can try removing the tire and one of the hydraulic fittings on the right side to create an access point.

Step 2: Measuring the Depth with a Coat Hanger

Now that you have access to the fuel tank, you can use a straightened-out coat hanger to measure its depth:

• Take a metal coat hanger and straighten it out as much as possible to create a long, thin probe.
• Reach into the fuel tank with the coat hanger and carefully lower it down until it touches the bottom of the tank.
• Mark the coat hanger at the fuel tank's depth, and then remove it from the tank.
• Measure the distance from the mark to the end of the coat hanger to determine the depth of your fuel tank.

Step 3: Replacing the Fuel Pickup Tubing

Once you have measured the depth of the fuel tank, you can proceed with replacing the fuel pickup tubing:

• Purchase a new fuel pickup tube that matches the dimensions of your fuel tank.
• Cut the new fuel pickup tube to the appropriate length, ensuring that the fuel strainer will sit approximately half an inch off the bottom of the fuel tank.
• Attach any necessary fittings, such as a 90-degree elbow, to the fuel pickup tube.
• Feed the new fuel pickup tube into the fuel tank through the access point you created earlier.
• Secure the fuel pickup tube in place using the rubber grommet or any other appropriate fastening method.
• Reassemble any components that you removed to access the fuel tank, such as the side cover or hydraulic fittings.

Tips and Considerations:

• This job can be challenging due to the tight spaces and difficult access to the fuel tank. Take your time and work carefully to avoid damaging any other components.
• It is recommended to clean the area around the fuel tank before proceeding with the replacement to prevent debris from falling into the tank.
• Consider extending the vertical drop of the fuel pickup tube by a few inches to prevent fuel starvation if the tube were to break again in the future.
• Always refer to the specific model and year of your Bobcat for the most accurate information, as designs may vary.

Use petroleum jelly to assemble the flexible style pick-up tube

To replace the fuel pickup tube in a Bobcat 863, you'll need to access the fuel tank. This can be done by removing the right rear tire and the side access panel. With the side access panel removed, you'll be able to reach the top of the fuel tank, where you can locate the fuel line and strainer.

Now, for assembling the flexible-style pickup tube, you'll need to have some petroleum jelly on hand. The first step is to measure the distance from the top deck of the fuel tank to its bottom. Cut the new fuel tube accordingly, adding a little extra length to ensure it reaches the bottom of the tank.

Before attaching the end strainer, which has a one-way valve, rub a generous amount of petroleum jelly on the connection point. This will ensure a tight seal and make it easier to connect the two parts. Slide the end strainer onto the tube, making sure it's secure.

Next, attach the new length of fuel hose to the elbow of the tube using a hose clamp. Again, petroleum jelly can be applied to the connection to ensure a tight, leak-proof seal.

With the hose attached, you can now push the grommet down over the tube and onto the elbow. The petroleum jelly can be used again here to ease the process and create a seal.

Finally, push the grommet down into the hole at the top of the fuel tank. You may need to squeeze the lower edge of the grommet inward so that it pops into the hole. Then, push down on the metal elbow to slide it into the grommet and seal the connection.

Make sure that the base of the fuel strainer sits about half an inch off the bottom of the fuel tank. With this setup, even if the tube breaks again, the machine will not suck air until the fuel level is significantly lower.

Frequently asked questions