Bobcat 863 Duetz factory remaned engine lost power and smoking

[Don stanley]

Bobcat is outside sadly. Started tearing it down this AM when it was 19 degrees. Oil is in the intake side and the impeller on the boosted hide is black with soot. It spins freely but didn't notice any side play. Wondering if the oil seal blew hence my symptoms. No snow has ever been in the filter housing due to its design.

 

[stefuel]

You're assuming there's no snow in the filter assembly??? You haven't even checked???
I'm done here.

 

[Vetech63]

Black smoke = Heavy soot. A new turbo isn't going to fix that. The black smoke is what fuel isn't burning, some soot in the exhaust side of the turbo is normal.

Black smoke is either lack of boost pressure due to a leak in the intake system, a failed turbo, leakage in the exhaust system, or lack of sufficient compression in most cases.

Black smoke is also caused by over fueling due to a faulty injector (s), timing being off, or lack of compression, in most cases.

Does the engine black smoke as soon as you start it at idle? Or only when revved up? Engine under load or no load? Is it puffing or rolling?

Until you answer these questions, we are just farting in the wind here.

 

[Don stanley]

Stefuel, sorry for the misunderstanding. The entire intake system (filter, filter housing, intake tube, etc.) Is apart with absolutely no moisture noted. Thanks anyway for your attemps.

 

[Don stanley]

Vetech63, again steady light black smoke at idle then increases under load. New turbo has the wrong oil return fitting but there was oil in the intake side of the turbo and the fins on the exhaust were coated with soot. Appreciate your patience as I am not a mechanic and doing the best I can to get this POS up and running again.

 

[ozarkag]

Sorry to say. . . but I don't feel it's a turbo. Light black smoke at idle is not a boost issue, for the simple reason there is normally no boost at idle. Oil in the turbo intake, suction side, comes from the breather/crankcase ventilation and is normal.
I'm leaning towards timing, either belt that jumped a tooth, or slipped cam gear.

 

[Simon C]

There is usually soot on the exhaust impeller. Borrow timing pins from someone or have someone check it for you before spending the big money. Breather vent will put some oil into intake side as Ozarkag said in his above post. And yes no boost at idle unless under load like stalling out.
Simon C

 

[Don stanley]

Want to thank all of you for your help! I finally got the right turbo and injectors for the 863 and after many swear words, got them installed. Runs like new. Thank you all!

 

[Chad Almond]

Want to thank all of you for your help! I finally got the right turbo and injectors for the 863 and after many swear words, got them installed. Runs like new. Thank you all!

Ive also got a 863 g series three months ago I pulled the motor out to replace motor mounts and the oil pan that rubbed a hole through the bottom thanks to the mounts, changed timing belt and some other stuff. Ran like a champ for the begining of the concrete construction season, then out of the blue it started rolling out the smoke, like light grey smoke. Just swapped out the injectors yesterday and there has been no change in the smoke so guessing the turbo will be next. Super sucks. Will have dumped about 10 grand into this machine within the last 6 months so reading about you issues definitely relates to mines issues. Next up target practice with the 45-70 perhaps ?

 

[Simon C]

$10000 is a bit of money, but that size machine is going for 100 - 120 thousand in Canada. Fixing might be cheaper. New ones break down also.
Simon C

 

[ozarkag]

Well. .. . . a new 90 hp compact track loader is, yes. A decent used Bobcat 863, a 20 to 30 year old machine- is probably only worth about 15,000 USD.

Chad, while turbo is definitely on the list of possible failures, headgasket failures are quite common on the Deutz as well. A quick physical check for wobble on the turbo shaft would be the next step.

 

[Simon C]

Well. .. . . a new 90 hp compact track loader is, yes. A decent used Bobcat 863, a 20 to 30 year old machine- is probably only worth about 15,000 USD.

Chad, while turbo is definitely on the list of possible failures, headgasket failures are quite common on the Deutz as well. A quick physical check for wobble on the turbo shaft would be the next step.

Suggest as ozarkag posted about checking the turbo and head gaskets. And yes used machines cost only a fraction of new and are good for people who use only few hours a year. Not every one can afford a $3000 payment per month. I just finished paying for a Deere 332G and yes if used enough worth it otherwise cheaper fixer upper is way to go.
Simon C