Bobcat T190 Engine Help

[Black71gp]

Hello, I recently aquired a 2003 bobcat t190 with the V2003-TE engine. Has 3700 Hrs. I have been using it but, its been giving me some issues, major issue is Hard starting, and excessive black smoke and engine lugging. When starting it puffs a bunch of white smoke while cranking, then when it fires its all black. constant haze when just running, and heavier black when under load. I took it into the local Bobcat Dealer, To have them check out the fuel system. (which they never did) After they "looked" it over and charged me 6 hours of labor at $90 and hr, they decided it needed a new engine, and it would cost $9000 to have them put a new reman engine in. I said no way and brought it home. I can not get them to give me much of what they did to it. The said it needs a new engine because it is low compression. And that is why it doesnt start wel, and why it smokes. After talking to the mechanic who was doing the work, all he said he did was test the glow plugs, then checked compression, and thats it. somehow that took 6 hrs. whatever. Compression is as follows 380-390-390-380. New spec is 412-420, according to info I found from Kubota, minimum allowable spec is 355 with no more than 10% difference in cylinders. So that seems to me like the compression is still within specs, and for 3700 hr bobcat probably ok? Its been a while since i had my diesel ASE certs, but hard start and black smoke, I would look at fuel first? I already checked air filters and turbo condition, all are ok. My questions are do you think I need a whole new engine based off those compression numbers? How should I go about testing fuel injection system? Can i pull the pump and have a local injector place bench test the injection pump? would they be able to find out what they need to from a bench test. Anything else I can do to get this machine up and running properly again? Thanks.

 

[Bobcatdan]

Did you change the fuel filter? 99% of running issue is plugged fuel filter. If that is not it. Pull the injectors and have a diesel shop test them.

 

[7LBSSMALLIE]

Did you change the fuel filter? 99% of running issue is plugged fuel filter. If that is not it. Pull the injectors and have a diesel shop test them.

ive been following this. have been reluctant to reply. not wanting to trash dealership svc. what I need to properly diagnose. is A. code sheet, first and foremost gives a history of unit. takes two minutes to do, what it shows is a proper path to further eng diagonistics. ( for example. a. 86 dirty air filter warnings. 12 shut downs . indicates eng ate dirt.b if it got by the air filter it got into turbo and got into cyl;s. 1/2 teaspoon of dirt will wipe an eng in 8 hrs. (FACT) another indicator is eng oil low pressure codes? as in warnings and shut downs. that is first diagnostic tool of eng failure. 2 . pull inlet hose visual inspection of turbo. have blades contacted housing ? will see shiny marks 3 put finger on turbo shaft nut should have zero radial run out. 4 compression check wet and dry will tell us if . its upper or lower. yea sound like joe Friday but its true the facts and nothining but the facts. cannot do further diagonastics without them. its a process . A; codes b visual c physical tests.

 

[mmsllc]

ive been following this. have been reluctant to reply. not wanting to trash dealership svc. what I need to properly diagnose. is A. code sheet, first and foremost gives a history of unit. takes two minutes to do, what it shows is a proper path to further eng diagonistics. ( for example. a. 86 dirty air filter warnings. 12 shut downs . indicates eng ate dirt.b if it got by the air filter it got into turbo and got into cyl;s. 1/2 teaspoon of dirt will wipe an eng in 8 hrs. (FACT) another indicator is eng oil low pressure codes? as in warnings and shut downs. that is first diagnostic tool of eng failure. 2 . pull inlet hose visual inspection of turbo. have blades contacted housing ? will see shiny marks 3 put finger on turbo shaft nut should have zero radial run out. 4 compression check wet and dry will tell us if . its upper or lower. yea sound like joe Friday but its true the facts and nothining but the facts. cannot do further diagonastics without them. its a process . A; codes b visual c physical tests.

Would change / check fuel filter FIRST off. Then, I would review all fuel hoses for any signs of cracking / leaking (pulling air) into the fuel system. White smoke on start up is normal to a certain degree, but should go away soon after start up. Black smoke under a load is an engine needing more air, or less fuel = as it is running too rich. Has your air filter been changed lately? Is / was it clogged? Check the turbo. Are there any signs of dirt on any of the impeller blades? Any movement, other than simple rotation? However, when you combine these (white & black smoke) two issues, it does sound like a weak injection pump or worn injector nozzles. I would remove the injectors & have them tested / rebuilt. I would suggest using a diesel fuel additive (I use "POWER-SERVICE" from Advance Auto Parts) every so often. It is just a cheap reassurance to keeping the fuel system lubricated.

 

[Black71gp]

Would change / check fuel filter FIRST off. Then, I would review all fuel hoses for any signs of cracking / leaking (pulling air) into the fuel system. White smoke on start up is normal to a certain degree, but should go away soon after start up. Black smoke under a load is an engine needing more air, or less fuel = as it is running too rich. Has your air filter been changed lately? Is / was it clogged? Check the turbo. Are there any signs of dirt on any of the impeller blades? Any movement, other than simple rotation? However, when you combine these (white & black smoke) two issues, it does sound like a weak injection pump or worn injector nozzles. I would remove the injectors & have them tested / rebuilt. I would suggest using a diesel fuel additive (I use "POWER-SERVICE" from Advance Auto Parts) every so often. It is just a cheap reassurance to keeping the fuel system lubricated.

Sorry for the Delay, missed the notifications. Ok here is the updates. Took four injectors and injection pump to the local service center, injectors tested good, injection pump had some bad seals/leaks, so they rebuilt it. Still no change in performance. Fuel filter is changed, intake is clear, turbo works properly, no binding, and plenty of boost when running. remember there is a hard start with white smoke, that turns to black when it starts and excessive black when loaded. I adjusted the valves as they were .025 instead of .008. no change. The dealer gave NO information to me other than compression of the engine, 380-390-390-380. were the four cylinders. No codes, they didnt scan, they didnt test anything else other than the glow plugs were good. that was a 520$ compression test. after finding a manual on the v2003t engine, I checked the injection timing, according to my test it is firing well after TDC mark on the flywheel for compression stroke cylinder #1. the front cover on the machine still looks to be factory painted so I am not sure if anyone has been in there or not and perhaps re attached the gears improperly. So I am still trying to figure out what up. Its more than simple filters, or injectors at this point.

 

[theonlyrussell]

Sorry for the Delay, missed the notifications. Ok here is the updates. Took four injectors and injection pump to the local service center, injectors tested good, injection pump had some bad seals/leaks, so they rebuilt it. Still no change in performance. Fuel filter is changed, intake is clear, turbo works properly, no binding, and plenty of boost when running. remember there is a hard start with white smoke, that turns to black when it starts and excessive black when loaded. I adjusted the valves as they were .025 instead of .008. no change. The dealer gave NO information to me other than compression of the engine, 380-390-390-380. were the four cylinders. No codes, they didnt scan, they didnt test anything else other than the glow plugs were good. that was a 520$ compression test. after finding a manual on the v2003t engine, I checked the injection timing, according to my test it is firing well after TDC mark on the flywheel for compression stroke cylinder #1. the front cover on the machine still looks to be factory painted so I am not sure if anyone has been in there or not and perhaps re attached the gears improperly. So I am still trying to figure out what up. Its more than simple filters, or injectors at this point.

I have the exact same problems as you describe. I have done compression test on mine and it is at 420psi and has just been rebuilt. Head was cracked and motor got rebuild at the same time. But same problem afterwards. Now I have narrowed it down to timing, injection pump or governor. What did you end up finding?!

 

[Bswwood]

I have the exact same problems as you describe. I have done compression test on mine and it is at 420psi and has just been rebuilt. Head was cracked and motor got rebuild at the same time. But same problem afterwards. Now I have narrowed it down to timing, injection pump or governor. What did you end up finding?!

Have you checked your turbo? Black smoke is from to much fuel or not enough air. Pull the intake hose off the intake manifold and see if you are getting forced air from the turbo while running.

 

[theonlyrussell]

Have you checked your turbo? Black smoke is from to much fuel or not enough air. Pull the intake hose off the intake manifold and see if you are getting forced air from the turbo while running.

Yeah I have inspected the turbo. Seems fine, spools easy with touch of air blown intake. No play and fins look fine in both sides. I teed in a pressure gauge and I'm only getting 7psi underload and high idle. This seems low does anyone know the spec? I cannot find it. Removed wastegate line and plugged it off. It now runs at 10-12psi underload. Smoke is gone and it has power. Most likely the wastegate or the turbo is my problem. Just would like to know what it is suppose to be running at.