Fuel System Troubleshooting for Bobcat 863 Skid-Steer Loaders

[MikePhua]

Introduction
The Bobcat 863 skid-steer loader, equipped with a Deutz 1011F engine, is renowned for its versatility and durability in various construction and landscaping applications. However, like all machinery, it is susceptible to fuel system issues that can impede performance. Addressing these problems promptly is crucial to maintain the loader's efficiency and longevity.
Common Fuel System Issues

1. Fuel Starvation
   Fuel starvation occurs when the engine is deprived of adequate fuel, leading to stalling or difficulty starting. This can be caused by several factors:
   • Clogged Fuel Filters: Over time, fuel filters can become clogged with debris and contaminants, restricting fuel flow. Regular inspection and replacement are essential.
     
   • Faulty Fuel Lift Pump: The lift pump is responsible for drawing fuel from the tank to the engine. A malfunctioning pump can result in insufficient fuel delivery.
     
   • Air Leaks in Fuel Lines: Even minor leaks can introduce air into the fuel system, disrupting the fuel flow and causing the engine to run erratically.
     
2. Injector Issues
   If fuel reaches the injectors but the engine still fails to run properly, the injectors themselves may be clogged or malfunctioning. Cleaning or replacing the injectors can resolve this issue.
   
3. Fuel Contamination
   Water or other contaminants in the fuel can cause corrosion and damage to the fuel system components. Using clean, high-quality fuel and installing water separators can mitigate this risk.
   

Troubleshooting Steps

1. Inspect and Replace Fuel Filters
   Start by checking the fuel filters for signs of clogging or contamination. For the Bobcat 863, the fuel filter part number is 6667352. Replace the filter if it appears dirty or damaged. After replacement, bleed the fuel system to remove any air pockets:
   • Loosen the bleeder screw on top of the filter housing.
     
   • Use the primer bulb to pump fuel until a steady stream flows from the bleeder screw.
     
   • Tighten the bleeder screw and pump the primer bulb a few more times to ensure proper priming.
     
2. Check the Fuel Lift Pump
   The lift pump should provide consistent fuel pressure. If the engine cranks but doesn't start, or starts and then stalls, the lift pump may be faulty. Testing the pump's pressure output can help diagnose this issue.
   
3. Inspect Fuel Lines for Leaks
   Examine all fuel lines for signs of wear, cracks, or leaks. Even small leaks can introduce air into the system, leading to performance issues. Replace any damaged lines promptly.
   
4. Test the Injectors
   If fuel reaches the injectors but the engine still doesn't run properly, the injectors may be clogged or malfunctioning. Remove and inspect the injectors for signs of wear or blockage. Cleaning or replacing them can restore proper engine function.
   
5. Check for Fuel Contamination
   Drain a small amount of fuel from the tank and inspect it for signs of water or debris. If contamination is present, clean the tank and replace the fuel with fresh, clean fuel.
   

Preventive Maintenance Tips

• Regularly Replace Fuel Filters: Establish a routine for inspecting and replacing fuel filters to prevent clogging and ensure optimal fuel flow.
  
• Use High-Quality Fuel: Always use clean, high-quality fuel to minimize the risk of contamination and damage to the fuel system.
  
• Install Water Separators: Consider installing water separators to remove any water present in the fuel before it reaches the engine.
  
• Inspect Fuel Lines Periodically: Regularly check fuel lines for signs of wear or damage and replace them as necessary.
  

Conclusion
Addressing fuel system issues in the Bobcat 863 promptly can prevent prolonged downtime and costly repairs. By following the troubleshooting steps and preventive maintenance tips outlined above, operators can ensure their equipment remains in optimal working condition. Always consult the manufacturer's manual for specific maintenance procedures and specifications.