Bobcat 863 Fuel Tank Access and Maintenance Guide

[MikePhua]

Understanding the proper access and maintenance of the fuel tank on a Bobcat 863 skid steer loader is essential for efficient operation and safety. This guide provides a detailed overview of the fuel tank access procedures, common challenges, and practical solutions based on operator experiences, combined with terminology explanations and related anecdotes from the field.
Fuel Tank Location and Design
The Bobcat 863 features a fuel tank located beneath the operator’s seat area, designed to maximize space efficiency while protecting the tank from external damage. The tank is typically constructed from durable steel or reinforced plastic, depending on the model year, ensuring resistance to impact and corrosion.
Terminology:

• Fuel Tank Access Panel: The removable cover or hatch that allows entry to the fuel tank for inspection, cleaning, or repairs.
  
• Drain Plug: A bolt or valve at the bottom of the tank used to drain fuel or water accumulation.
  
• Fuel Gauge Sending Unit: The sensor inside the tank measuring fuel level and sending information to the gauge on the dashboard.
  
• Breather Valve: A small valve allowing air to enter and exit the tank to prevent vacuum or pressure buildup.
  

Accessing the Fuel Tank
To service or inspect the fuel tank on the Bobcat 863, operators typically follow these steps:

1. Raise the Seat Assembly: The operator’s seat is mounted on a hinged frame that can be lifted forward or upward to expose the fuel tank access area.
   
2. Remove the Access Panel: Underneath the seat or adjacent floor panels, a dedicated fuel tank access panel is secured with bolts or clips. Removing this panel provides direct entry to the tank’s top or side components.
   
3. Disconnect Fuel Lines (if necessary): For certain maintenance tasks, such as cleaning or replacing the fuel pump or gauge sender, fuel lines may need to be disconnected carefully to avoid spillage.
   
4. Drain Fuel (if needed): Using the drain plug located at the tank’s bottom, fuel or water sediment can be drained safely into an approved container.
   

Common Issues and Solutions

• Difficult Access Due to Rust or Seized Bolts: Operators report that access panel bolts sometimes seize due to rust. Regular lubrication and use of anti-seize compounds during reassembly help prevent this.
  
• Fuel Contamination: Water or sediment accumulation in the tank can cause engine performance problems. Regular draining through the drain plug and inspection via the access panel mitigate these issues.
  
• Fuel Gauge Malfunction: Faulty sending units inside the tank lead to inaccurate fuel readings. Replacement requires accessing the tank through the panel and careful handling of the electrical connectors.
  

Case Story: Field Experience
A Bobcat 863 owner recounted how ignoring regular fuel tank maintenance led to sudden engine sputtering on a construction site. After lifting the seat and opening the access panel, they found significant water contamination. Draining and cleaning the tank restored performance immediately, highlighting the importance of periodic inspection.
Safety Precautions

• Always ensure the engine is off and cool before accessing the fuel tank to prevent fire hazards.
  
• Work in a well-ventilated area to avoid inhalation of fuel fumes.
  
• Use appropriate tools and protective equipment, including gloves and eye protection.
  
• Dispose of drained fuel and contaminants according to local environmental regulations.
  

Maintenance Tips

• Inspect the fuel tank and related components every 250 operating hours or per the manufacturer’s schedule.
  
• Check and clean the breather valve to prevent vacuum build-up that can restrict fuel flow.
  
• Replace gaskets or seals on the access panel during reassembly to prevent leaks.
  

Fuel Tank Access Summary

• Location: Underneath or behind operator seat.
  
• Tools Needed: Socket wrench set, screwdrivers, lubricant spray, container for draining.
  
• Frequency: Regular inspection every 250 hours or when performance issues arise.
  
• Key Components: Access panel, drain plug, sending unit, breather valve.
  

Industry Insight
The Bobcat 863’s fuel tank design reflects a common trend in skid steer loaders: maximizing compactness without sacrificing serviceability. Other brands like Caterpillar and John Deere have similar setups, though panel designs and access points vary. Proper training on these access methods reduces downtime and extends machine life.
Additional Notes
In colder climates, condensation inside the fuel tank can cause water accumulation faster than usual. Operators often install fuel additives or heaters to mitigate freezing and contamination.
Terminology Recap

• Access Panel: Removable cover to reach fuel tank internals.
  
• Drain Plug: Valve to empty fuel or sediment.
  
• Sending Unit: Sensor measuring fuel level.
  
• Breather Valve: Pressure equalizing valve.
  

This comprehensive guide emphasizes the importance of proper fuel tank access and maintenance on the Bobcat 863. Routine inspections, combined with understanding the fuel system’s components, ensure machine reliability and operator safety.