Fixing Fuel Pickup Issues on the Bobcat 763 Skid Steer

[MikePhua]

Fuel system problems on heavy equipment, like the Bobcat 763, can lead to significant downtime, frustrating operators, and causing costly delays in projects. One common issue that may arise in these machines is a malfunctioning fuel pickup system. When the fuel pickup becomes clogged, damaged, or fails in any way, it can result in power loss, engine sputtering, or total failure to start.
This article explores the possible causes of fuel pickup issues in the Bobcat 763, how to identify symptoms, and a step-by-step guide on how to fix the problem, along with useful tips for ongoing maintenance to prevent recurrence.
Understanding the Fuel Pickup System
The fuel pickup system in a skid steer like the Bobcat 763 is designed to transport fuel from the tank to the engine. It consists of several components:

• Fuel tank: Holds the fuel used by the engine.
  
• Fuel pickup tube: Positioned at the bottom of the tank to draw fuel into the system.
  
• Fuel filter: Cleans the fuel to prevent debris from entering the engine.
  
• Fuel lines: Carry fuel from the tank to the engine.
  
• Fuel pump: Ensures that fuel is delivered to the engine at the correct pressure.
  

Over time, debris, dirt, or sludge can accumulate in the fuel tank and clog the pickup tube or filter, restricting fuel flow and causing performance issues.
Symptoms of a Malfunctioning Fuel Pickup
There are several signs that may indicate a problem with the fuel pickup system:

• Engine sputtering or stalling: If the engine is not receiving a steady supply of fuel, it may sputter, lose power, or stall, especially under load.
  
• Difficulty starting the machine: If the fuel system is not functioning properly, the engine may have trouble starting or may not start at all.
  
• Poor acceleration: The machine may struggle to accelerate or may operate at reduced power, indicating that the engine is not receiving enough fuel.
  
• Fuel tank shows a full level, but fuel doesn’t seem to reach the engine: In some cases, operators may notice that the fuel tank seems full, but the machine still runs out of fuel, indicating a blockage in the fuel pickup system.
  

If any of these symptoms occur, it’s important to inspect the fuel system and address the issue promptly to avoid further damage to the engine.
Diagnosing the Problem
When diagnosing fuel pickup issues in the Bobcat 763, it's essential to systematically inspect the entire fuel system. Here's a step-by-step guide for troubleshooting:

1. Inspect the Fuel Tank: Ensure that the fuel tank is free of any debris or contaminants. Sometimes dirt or rust can accumulate in the tank, which may clog the pickup tube.
   
2. Check the Fuel Lines: Look for any kinks, cracks, or leaks in the fuel lines that may impede fuel flow. Damaged lines can also introduce air into the system, causing sputtering.
   
3. Examine the Fuel Pickup Tube: The pickup tube is located at the bottom of the fuel tank. If it's clogged with dirt or sludge, it won’t be able to draw fuel properly. In some cases, the tube may become disconnected or damaged.
   
4. Inspect the Fuel Filter: A clogged fuel filter can restrict fuel flow to the engine. If the filter is dirty or clogged, it needs to be replaced.
   
5. Check the Fuel Pump: The fuel pump must maintain the proper pressure to deliver fuel to the engine. If the pump is failing, it can result in poor engine performance or even total failure to start.
   

Fixing the Fuel Pickup System
Once the problem is diagnosed, the following steps will help fix the fuel pickup issue on the Bobcat 763.
Step 1: Clean or Replace the Fuel Pickup Tube

• Remove the fuel tank: The fuel tank may need to be removed to access the pickup tube, depending on the machine's layout.
  
• Clean the pickup tube: If the tube is clogged with debris, clean it using compressed air or a brush. Make sure to remove all dirt and sludge to restore proper fuel flow.
  
• Replace the tube if necessary: If the tube is damaged or excessively clogged, replacement may be necessary.
  

Step 2: Replace the Fuel Filter

• Locate the filter: The fuel filter is typically located along the fuel line. It’s a good idea to replace it if it shows signs of clogging.
  
• Replace the filter: Simply unscrew the old filter and replace it with a new one. Be sure to choose the correct filter for the Bobcat 763, as using an incompatible filter could cause further issues.
  

Step 3: Inspect the Fuel Lines

• Look for cracks and leaks: Examine the entire length of the fuel lines for any visible damage, cracks, or signs of wear. Even small leaks can cause air to enter the fuel system, leading to engine performance issues.
  
• Replace damaged lines: If any lines are cracked or leaking, replace them. Be sure to use the correct diameter and material for the fuel lines.
  

Step 4: Test the Fuel Pump

• Check fuel pump pressure: The fuel pump must deliver fuel at the proper pressure to the engine. A fuel pressure gauge can be used to test the pump’s performance. If the pump fails to deliver the correct pressure, it should be replaced.
  
• Inspect the pump for damage: Look for any signs of wear or leaks around the fuel pump. Replace the pump if necessary.
  

Step 5: Reassemble the System
After cleaning or replacing the necessary components, reassemble the fuel system. Be sure to securely reconnect all fuel lines and fittings to avoid leaks. Reinstall the fuel tank if it was removed during the process.
Tips for Preventing Future Fuel Pickup Issues
To prevent future fuel pickup problems on the Bobcat 763, consider the following maintenance tips:

• Regularly replace fuel filters: Filters should be replaced at regular intervals, as recommended by the manufacturer. A clean fuel filter ensures that debris does not enter the engine.
  
• Use high-quality fuel: Contaminated fuel can quickly clog the fuel system. Always use clean, high-quality fuel from a reliable source.
  
• Keep the fuel tank clean: Periodically inspect and clean the inside of the fuel tank to prevent the buildup of dirt, water, or sludge.
  
• Check fuel lines regularly: Inspect fuel lines and hoses for wear, cracks, or leaks, and replace them as necessary to avoid issues with fuel delivery.
  

Conclusion
Fuel pickup issues in the Bobcat 763 can lead to frustrating performance problems, but with a bit of effort and the right tools, these problems can usually be fixed quickly. By understanding the components of the fuel system and performing regular maintenance, you can ensure that your Bobcat 763 continues to perform optimally, keeping your job site running smoothly. Regular inspections and proper care will prevent costly repairs and downtime, helping to extend the life of your equipment.
Whether you are dealing with clogged fuel lines, a faulty fuel pump, or a blocked pickup tube, addressing fuel system problems promptly will save you both time and money.