Bobcat Fuel Pump Replacement: A Step-By-Step Guide For The 863 Model

The Bobcat 863 is a popular skid steer loader used in construction projects and farming applications. One of the most common issues with the Bobcat 863 is fuel problems, which can cause the machine to run poorly or not start at all. Fuel problems can be caused by a variety of issues, including a clogged fuel filter, contaminated fuel, or a faulty fuel pump.

If you are experiencing fuel problems with your Bobcat 863, it is important to properly diagnose the issue before attempting any repairs. This may involve checking the fuel filter, fuel lines, fuel pump, and fuel injectors for any signs of damage, clogs, or leaks.

In some cases, the fuel pickup tube may need to be removed and replaced. This job can be challenging as it requires raising the cab and reaching over the hydraulic pumps to access the tube between the engine and the hydrostatic assembly. Additionally, there may be side covers over the rear tires that can be removed to access the tube from the right side.

By following the proper diagnostic and repair procedures, you can fix fuel-related issues in your Bobcat 863 and ensure that it runs smoothly. Regular maintenance and inspections can also help prevent fuel problems from occurring in the first place.

Removing the fuel pickup tube

Step 1: Raise the Cab

First, you will need to raise the cab of your Bobcat 863 to access the fuel pickup tube. This will provide you with the necessary space to work and locate the tube.

Step 2: Locate the Fuel Pickup Tube

The fuel pickup tube is typically located between the engine and the hydrostatic assembly. It might be easier to access it from the side, so consider removing the right-side cover behind the boom, if your model has one. This will give you better access to the tube.

Step 3: Prepare for Removal

Before removing the fuel pickup tube, make sure you have the necessary tools and materials. You will need a new rubber grommet, petroleum jelly or a similar lubricant, and tools like snap ring pliers, screwdrivers, and wrenches.

Step 4: Remove the Fuel Pickup Tube

The fuel pickup tube is held in place by a rubber grommet. To remove it, carefully pull the tube out of the tank. This can be challenging, as it is in a tight space and may require some maneuvering. Be gentle to avoid damaging any surrounding components.

Step 5: Clean the Area

Once the fuel pickup tube is removed, take the opportunity to clean the area. Make sure there is no debris or dirt around the fuel tank and the tube itself. This will help prevent future clogs and ensure smooth fuel flow.

Step 6: Inspect the Fuel Pickup Tube

Before installing a new fuel pickup tube, inspect the old one. Check for any signs of damage, cracks, or clogs. If the tube is damaged or worn out, replace it with a new one. You can purchase a new fuel pickup tube from Bobcat or an authorized dealer.

Step 7: Install the New Fuel Pickup Tube

When you are ready to install the new fuel pickup tube, follow these steps:

• Lubricate the new rubber grommet with petroleum jelly and slide it onto the tube.
• Apply lubricant to the tube and the elbow barb.
• Gently insert the tube into the grommet until the elbow barb meets the grommet.
• Use a pry bar to gently push the elbow into the grommet.
• Secure the fuel hose to the elbow with a worm gear clamp.

By following these steps, you can successfully remove and replace the fuel pickup tube on your Bobcat 863. Remember to take your time, work carefully, and refer to your machine's specific manual for additional guidance if needed.

Locating the fuel filter

To locate the fuel filter on your Bobcat 863, you'll need to first find the fuel tank. The fuel filter is typically located near the fuel tank or in the engine compartment. Once you've located the fuel tank, you can begin your search for the fuel filter.

The fuel filter on the Bobcat 863 is responsible for removing dirt and impurities from the diesel fuel before it reaches the engine. It is an essential component of the fuel system, ensuring that clean fuel is delivered to the engine for smooth and efficient operation.

On the Bobcat 863, the fuel filter is usually mounted near the fuel tank. To access it, you may need to remove some panels or covers. Look for a cylindrical or rectangular-shaped component with fuel lines connected to it. The fuel filter is typically secured with a mounting bracket and can be unscrewed for replacement.

In some cases, the fuel filter may be located within the engine compartment, closer to the fuel pump and injectors. This placement allows for easier access and maintenance. However, it's important to consult a service manual or seek assistance from a qualified technician if you're unsure about the location or replacement procedure.

Additionally, when working with fuel systems, always exercise caution and refer to safety guidelines to prevent accidents or injuries.

Cleaning fuel injectors

Fuel injectors are responsible for delivering the right amount of fuel to the engine's combustion chamber. Dirty fuel injectors can cause issues such as poor fuel economy, reduced engine power, and rough idling.

Identifying Clogged Fuel Injectors

Clogged fuel injectors can cause a vehicle's engine to idle roughly or stall. If carbon accumulates on the diffusing tip of the injectors, you may also burn more fuel and experience worse fuel economy. Before reaching this point, your vehicle's check engine light will probably turn on.

The best way to clean fuel injectors is to remove them from the engine, as this allows you to thoroughly remove gunk and debris. Here are the general steps:

• Remove the fuel injectors from the engine.
• Disconnect the fuel supply and remove the fuel rails.
• Remove the rubber o-ring from the fuel rail side of the injector.
• Attach a rubber hose to the opening using hose clamps to prevent spills during cleaning.
• Connect one side of an electrical lead to the injectors and the other side to the positive terminal of the vehicle's battery.
• Disconnect the rubber hose from the rail side and attach it to the outflow side to ensure a thorough clean.
• Attach a new o-ring and re-insert the injector.

If you want to clean the fuel injectors without removing them, you can use a gasoline additive that cleans fuel injectors. However, these cleaners are diluted in a full tank of gas, reducing their potency and effectiveness.

A better option is to invest in a fuel injector cleaning kit, which includes a canister for the cleaner and a hose that attaches to the vehicle's fuel injectors. Here are the general steps:

• Pour the fuel injector cleaner into the canister.
• Hang the canister on the underside of the hood to ensure a steady flow of cleaner into the fuel injectors.
• Screw the hose end onto the vehicle's fuel rail at the test port.
• Turn off the fuel pump by removing the fuse from the fuse box.
• Start the vehicle's engine.
• Once the cleaner has emptied from the canister, remove the cleaning kit and re-insert the fuel pump fuse.

Checking and replacing fuel lines

Checking and replacing the fuel lines of your Bobcat 863 is an important part of maintenance, as damaged or clogged fuel lines can cause fuel flow problems, leading to engine stalling or failure. Here is a step-by-step guide to help you through the process:

Step 1: Inspect the Fuel Lines

Before you begin any work, it is important to inspect the fuel lines for any visible signs of damage or wear. Look for any cracks, leaks, or areas of deterioration. If you notice any issues, it is important to replace the fuel lines as soon as possible to prevent further problems.

Step 2: Prepare for Replacement

If you notice any damage or wear on the fuel lines, it is important to replace them with new ones. Purchase new fuel lines that are compatible with your Bobcat 863, ensuring they are of the correct length and diameter. Gather any other necessary tools and materials, such as wrenches, clamps, and fuel line cleaner.

Step 3: Remove the Old Fuel Lines

Before removing the old fuel lines, make sure to relieve the fuel system pressure and disconnect the battery to prevent any accidents. Locate the fuel lines and carefully remove them from the engine and fuel tank. Take note of how they are routed and secured to ensure proper installation of the new fuel lines.

Step 4: Install the New Fuel Lines

Install the new fuel lines, following the same route as the old ones. Secure them in place with appropriate clamps or fittings. Ensure all connections are tight to prevent leaks.

Step 5: Check for Clogs or Obstructions

Before starting the engine, check the fuel lines for any clogs or obstructions. Use a fuel line cleaner to clear any debris or buildup. This step is important even if you are not replacing the fuel lines, as clogs can cause fuel flow problems and affect engine performance.

Step 6: Refill and Restart

Once the new fuel lines are installed and checked, refill the fuel tank and reconnect the battery. Start the engine and check for any leaks or issues. If everything looks good, you have successfully replaced the fuel lines on your Bobcat 863.

Remember to consult a professional mechanic or a qualified technician if you are unsure about any part of the process.

Addressing fuel pump issues

Understanding the Fuel Pump's Role:

The fuel pump in your Bobcat 863 is responsible for pumping diesel fuel from the fuel tank to the engine. It ensures a consistent flow of fuel, enabling the engine to run smoothly.

Signs of Fuel Pump Issues:

There are several signs that indicate fuel pump issues. These can include hard starting or failure to start, stalling or engine misfiring, and decreased engine performance or power. If you notice any of these symptoms, it's important to take action and diagnose the problem.

Diagnosing Fuel Pump Issues:

To diagnose fuel pump issues, start by checking the fuel pump for any visible signs of damage or wear. Use a fuel pressure gauge to measure fuel pressure. If the pressure is too low, it may indicate a faulty fuel pump. Additionally, check the voltage and resistance of electrical circuits related to the fuel system using a multimeter.

Replacing the Fuel Pump:

If you determine that the fuel pump needs to be replaced, follow these steps:

• Purchase a replacement fuel pump specifically designed for your Bobcat 863. Ensure it is compatible with your machine's make and model.
• Raise the cab of your Bobcat 863 to access the fuel pump, which is located between the engine and the hydrostatic assembly. Alternatively, you may be able to access it by removing the side cover over the rear tires behind the boom.
• Remove the old fuel pump by disconnecting it from the fuel lines and any mounting brackets. Pay attention to how it is installed for reference during the reinstallation process.
• Install the new fuel pump by connecting it to the fuel lines and securing it in place with any necessary brackets or fasteners. Ensure all connections are secure and tight.
• Refill the fuel tank and start the engine. Monitor the machine for any leaks or unusual behaviour.

Maintenance and Prevention:

To prevent fuel pump issues and maintain the performance of your Bobcat 863, regular maintenance is key. Here are some tips:

• Perform routine inspections of the fuel system, including the fuel pump, fuel lines, and fuel filters.
• Keep the fuel system clean by using high-quality fuel and fuel additives to prevent contamination and deposits.
• Regularly check fuel pressure and ensure it remains within the recommended levels.
• Replace fuel filters and fuel lines as necessary to avoid clogs and obstructions.
• Store fuel in clean containers and drain the fuel tank periodically to prevent contamination.

By following these steps and staying vigilant about maintenance, you can effectively address fuel pump issues on your Bobcat 863 and ensure its reliable performance for years to come.

Frequently asked questions