Bobcat T190 Track Loader Troubleshooting

The Bobcat T190 compact track loader is powered by Kubota V2403 diesel engine with a rated power of 61 hp (45.5 kW) or Kubota V2607 diesel engine with a rated power of 66 hp (49.2 kW). The Bobcat T190 is equipped with 1-speed hydrostatic transmission, vertical-lift loader boom, solid-mounted undercarriage, and 12.6" or 15.7" rubber tracks. The hydraulic system has a pump with fluid flow rate of 16.3 gpm (61.6 lpm). The hydraulic pressure is 3350 psi (231 bar). The loader has a rated operating capacity of 1900 lbs (862 kg) and tipping load of 6852 lbs (3108 kg). The boom lifting force is 4700 lbs (2132 kg), and bucket breakout force is 4450 lbs (2018 kg).

Engine Troubleshooting

Engine starts hard or will not start

Air in the fuel pipes - Bleed the fuel pipes.
Fuel filter element clogging - Clean the filter element.
Fuel injection nozzles are clogged or faulty - Test injection nozzles and change if necessary.
Water in the fuel system - Change fuel and repair fuel system.
Valve clearance is not correct - Correct valve clearance needs to be set.
Fuel injection pump malfunction - Replace or repair injection pump.

Engine starts and then shuts off

Air cleaner is clogged - Clean or replace element.
Clogged fuel filter - Install new filter element.
Fuel injection pump leakage - Check the fuel injection pump for leaks and fix it.
Dirty or defective injectors - Test and replace fuel injectors if necessary.
Fuel injection pump is faulty - Replace or rebuild injection pump.

Engine shuts off while running

Engine is cold - Warm up engine as required.
Fuel filter plugging - Service or replace the filter.
Air in the fuel system - Air bleeding.
Fuel injection nozzles are faulty or clogged - Check and replace nozzles if required.
Improper setting of fuel injection pump timing - Adjust according to specifications.

Engine stalls at idle

Low idle speed set incorrectly - Need to adjust idle speed.
Damaged fuel injection pump - Rebuild or replace pump.
Defective fuel injectors - Replace fuel injectors.
Improper valve clearance - Adjustment procedure required.

Engine lacks power

Dirty air cleaner - Install new air cleaner element.
Faulty fuel injection nozzles - Service or change injection nozzles.
Insufficient fuel injection pressure - Adjust pressure to proper level.
Improper valve clearance - Adjustment procedure required.
Low idle speed setting is incorrect - Adjust the low idle speed.
Clogged fuel lines or hoses - Service fuel lines and hoses.
Cylinder head gasket is blown - Gasket should be replaced.
Piston rings are damaged or leaking - Replace piston rings.

Engine is overheated

Not enough coolant - Add coolant fluid to cooling system and also check it for leaks.
Engine oil level is low - Fill up the oil to required level.
Clogged radiator core or damaged radiator cap - Change cap or clean radiator.
Loose or damaged fan belt - Change the fan belt.
Engine is under excessive load - Load reducing is recommended.

Oil pressure too low

Low oil level - Fill crankcase to proper oil level.
Oil filter is dirty - Change or service engine oil filter.
Incorrect oil viscosity - Use proper viscosity oil.
Incorrect oil clearance in crankshaft bearing - Install new bearings.
Oil pump malfunction - Inspect and change as required.

Abnormal engine noise or knocking

Engine oil level is low - Check oil level and add oil as required.
Engine is not preheated - Warm up engine as required.
Timing of fuel injection pump is incorrect - Adjust according to specifications.
Low idle speed set incorrectly - Adjust low idle speed.
Damaged or clogged injectors - Replace fuel injectors.
Connecting rod failure or misalignment - Align or replace connecting rod.
Broken or worn pistons - Replace the pistons.

Drive System Troubleshooting

Drive system will not operate in either direction

Hydraulic fluid level low - Fill up the hydraulic fluid.
Track mechanism is damaged or blocked - Correct blockage or repair tracks.
Relief valve defective or worn - Repair or replace relief valve.
Clogged hydraulic filter or suction line - Change hydraulic filter or service suction line.
Defective hand or foot controls - Repair or change.
Defective drive pump or motor - Replace or repair faulty component.

Machine will not drive straight or drives jerky

Track mechanism is defective or jammed - Fix jamming or repair tracks.
Tracks are sagging or faulty - Correct track sag with tensioning or repair tracks.
Track frame is blocked with debris, dirt, or foreign objects - Clean track frame, remove debris and foreign objects.

Lack of power

Plugged hydraulic oil filter - Change hydraulic filter.
Relief valve is defective or open - Close or change relief valve.
Faulty or damaged transmission components - Inspect and change faulty parts.
Defective input drive shaft - Repair or install a new drive shaft.
There is air in the hydraulic system - Need to bleed air.

Overheated drive system

Insufficient hydraulic fluid - Check and refill the hydraulic fluid.
Plugged hydraulic fluid filter - Replace or clean hydraulic filter.
Relief valve defective or worn - Change or repair relief valve.
Defective drive pump or hydraulic motor - Replace or repair faulty component.
Hydraulic oil cooler is plugged - Cooling fins should be cleaned.
Drive system overloaded continuously - Reduce the load.

Excessive noise

Wrong oil viscosity - Use proper oil viscosity.
There is air in the hydraulic system - Air bleeding is required.
Drive pump or hydraulic motor malfunction - Repair or change faulty component.
Mechanical parts of drive system are worn or damaged - Check the parts for worn or defect and replace if required.

Hydraulics Troubleshooting

Hydraulic system overheats

Hydraulic pressure incorrectly adjusted - Hydraulic pressure must be set correctly.
Defective or misadjusted main relief valve - Replace or set up the relief valve.
Hydraulic fluid is contaminated - The fluid must be changed.
Not enough hydraulic fluid in the system - Check and refill the hydraulic fluid.
Worn hydraulic oil pump - Change or repair hydraulic pump if required.

Lift arm cannot be raised or lowered

Lift controls malfunction - Check and repair as required.
Hydraulic pump malfunction - Repair or install new hydraulic pump.
Hydraulic control valve is defective - Repair or change the valve.
Hydraulic cylinder not working - Change or repair lift cylinder.
Hydraulic fluid is insufficient - Fill up the hydraulic fluid.

Bucket fails to tilt

Bucket controls are faulty - Change or repair.
Hydraulic pump is broken - Repair or change pump if required.
Hydraulic control valve is defective - Install a new hydraulic valve or repair it.
Bucket cylinder is faulty - Repair or install a new cylinder.
Insufficient hydraulic fluid - Add fluid as required.

Boom or bucket functions slowly

Hydraulic pump is worn - Test pump performance and replace pump if necessary.
Leaking hydraulic cylinder - Cylinder seals need to be replaced.
Hydraulic fluid is insufficient - Fill the system to proper hydraulic fluid level.
Hydraulic control valve is defective or set improper - Repair or adjust properly.
Hydraulic pressure loss - Adjust pressure as required.

Bucket or boom is jerky

There is air in the hydraulic system - Need to bleed air.
Hydraulic oil filter is clogged - Change or clean oil filter.
Hydraulic oil contamination - Hydraulic oil change required.
Cylinder tube or rod is scored - Replace defective component.

Excessive hydraulic pump noise

Hydraulic leaks or lack of oil - Correct hydraulic leaks or top up oil as needed.
Plugged hydraulic filter - Clean or install new filter.
Clogged suction line - Clean suction line as required.
Air enters the pump - Bleed air from hydraulics.
Pump parts are damaged - Change or rebuild pump.

Electrical Troubleshooting

Battery cannot be charged

Corroded or loose cable connections - Tighten or clean connections.
Faulty battery terminal clamps - Terminal clamps need to be replaced.
Battery faulty cell - Change the battery.
Defective or loose belt - Replace belt or adjust belt tension.

Starter motor turns slow

Low battery output - Battery needs to be recharged.
Battery won’t hold charge - Service battery or change it.
Battery cables are disconnected or terminals are faulty - Check wire connections and change or service terminals.

Starter motor is not working

Battery is discharged or defective - Change or recharge battery.
Wiring harness is disconnected or improperly connected - Check wiring harness and connect as required.
Low battery power - Battery needs to be recharged.
Starter motor is damaged - Starter needs to be replaced.