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Bobcat M500 Troubleshooting

The Bobcat M500 skid steer loader driveline system components: a 67.2 cu.in (1.1L) Kohler K662 L-head twin-cylinder air-cooled gasoline engine with a rated power of 24 hp (17.9 kW), and variable sheave transmission. The hydraulic system has a pump with a rated capacity of 7.5 gal/min (28.4 l/min). The system relief pressure is 1700 psi (117 bar). The Bobcat M500 is equipped with a radial-lift loader boom, 60H drive chains, and 7.00x15 standard tires. The skid steer loader has a max lift height of 108" (2745 mm) to hinge pin and dump height of 86" (2185 mm). The rated operating capacity is 1000 lbs (454 kg), and tipping load is 2000 lbs (910 kg).

Engine Troubleshooting

Engine doesn't start or hard to start
Empty gas tank - Fill it up.
Low-quality gasoline - Use correct gasoline grade.
Air in the fuel lines - Bleed the fuel lines.
Defective spark plug wire connection - Check the spark plug wire connection, repair or replace.
Spark plug is defective - Replace spark plug.
Clogged fuel filter - Replace fuel filter.
Safety contact for brake pedal defective - Install new part.
Carburetor is not working properly - Inspect and adjust.
Engine has low compression - Check cylinder block and replace defective parts.
Throttle cable is worn or adjusted improperly - Change cable or adjust properly.

Rough engine running
Clogged cooling fins - Need to clean or wash.
Defective ignition system - Check ignition system and replace faulty parts.
Stuck or defective choke cable - Replace or service the cable.
Air filter element is clogged - Change or clean air filter.
Fuel pump is faulty or clogged - Clean or replace fuel pump.

Engine starts and stops immediately
Spark plug is damaged - Spark plug need to be replaced.
Defective or clogged carburetor - Replace or service carburetor.
Ignition coil is not working - Change ignition coil as required.
Weak or damaged valve springs - Change valve springs.
Valves are stuck - Valves must be cleaned.

Engine overheated
Lack of engine oil - Add oil to the engine crankcase.
Engine overload - Load reducing required.
Air intake screen is plugged - Wash or clean as required.
Too lean carburetor mixture - Adjust carburetor correctly.
Bad ignition timing - Adjust ignition timing as required.
Incorrect valve setting - Adjust valves as required.

Abnormal engine noise or knocking
Low octane gasoline - Use proper fuel.
Engine overloaded - Load reducing is recommended.
Engine oil level is low - Fill the crankcase with engine oil.
Too low idle RPM - Adjustment required.
Fuel pump is defective or dirty - Check fuel pump and change if required.
Worn crankshaft or main bearings - Install new parts as as required.
Valve clearance is wrong - Adjust valve clearance.
Damaged piston rings or cylinder bore - Change faulty components.

Engine lacks power
Improperly or clogged carburetor - Service or properly adjust carburetor.
Plugged air filter - Change or clean air filter.
Dirty or defective fuel pump - Service or replace fuel pump.
Ignition system problems - Inspect ignition system and change failed components.
Blown cylinder head gasket - Replace the gasket as required.
Valves are stuck or burned - Replace or clean valves.
Push rod is worn or defective - Change push rod.
Faulty cylinder block components - Replace defective parts.
Oil filter is blocked (if equipped) - Replace or service oil filter.

High fuel consumption
Choke didn't open fully - Adjust or change choke cable.
Carburetor main jet is improperly adjusted - Adjust it correctly.
Loose or defective spark plug - Re-tighten or change the spark plug.
Burned, worn, or stuck valves - Clean or change valves.
Piston, sleeve, or rings are damaged - Replace faulty components.
Excessive valve clearance - Need to adjust valve clearance.

Engine consuming too much oil
Gaskets or seals are excessively worn - Replace defective parts.
Valve guides or stems are damaged - Install new valves.
Stuck or defective piston rings - Change piston rings.
Scored piston or cylinder liner - Inspect piston and liner, fit new components as necessary.
Clogged breather hose or pipe - Replace or clean.

Drive System Troubleshooting

Machine does not move forward or backward
Hydraulic fluid is insufficient - Add fluid as required.
Drive chain is worn - Check drive chain and change defective parts.
Clogged suction line or hydraulic filter - Change hydraulic filter or service suction line.
Foot or hand controls are faulty - Check and repair as required.
Defective or worn transmission parts - Repair or replace faulty component.

Lack of power
Dirty hydraulic oil filter - Replace or service hydraulic filter.
Defective or worn transmission parts - Check and change faulty components.
Worn input drive shaft - Rebuild or change the shaft.
Air in the hydraulic system - Bleed air from hydraulic system.

Drive system overheating
Insufficient hydraulic fluid - Fill the system to proper hydraulic fluid level.
Dirty hydraulic fluid filter - Replace hydraulic filter.
Defective or worn transmission parts - Replace or repair faulty component.
Overloaded drive system - Load should be reduced.

Drive system makes excessive noise
Incorrect oil viscosity - Use the specified type of oil.
Air in the hydraulic system - Bleed hydraulic system.
Transmission parts are defective - Repair or replace faulty components.
Mechanical components of drive system are worn or damaged - Inspect the components for defect or damage and repair as needed.

Hydraulics Troubleshooting

Hydraulic system overheats
Hydraulic pressure incorrectly adjusted - Adjust it correctly.
Main relief valve is defective or unadjusted - Adjust or change relief valve.
Dirty hydraulic fluid - The fluid must be changed.
Not enough hydraulic oil in the system - Add oil to the hydraulic system.
Hydraulic pump is defective - Repair or change pump if required.

Lift arm does not lower or raise
Defective lift controls - Inspect and repair if necessary.
Hydraulic pump malfunction - Repair or replace pump if necessary.
Defective hydraulic control valve - Repair or change hydraulic valve.
Hydraulic cylinder failure - Repair or install a new lift cylinder.
Hydraulic fluid level low - Checking hydraulic fluid level and add if necessary.

Bucket can't tilt
Bucket tilt controls malfunction - Check and repair as required.
Hydraulic pump malfunction - Replace or repair pump if necessary.
Defective hydraulic control valve - Repair or replace the valve.
Broken bucket cylinder - Repair or replace cylinder.
Hydraulic oil is insufficient - Checking hydraulic oil level and add if necessary.

Bucket or lift arm runs slowly
Worn hydraulic oil pump - Check pump flow and change pump if necessary.
Hydraulic cylinder leaking - Correct leakage by changing the seals.
Insufficient hydraulic fluid - Fill the system to proper hydraulic fluid level.
Defective or not adjusted hydraulic control valve - Repair or set correctly.
Hydraulic pressure loss - Adjust pressure as required.

Lift arm or bucket is jerky
Air trapped in hydraulic system - Bleed hydraulic system.
Hydraulic oil filter is dirty - Clean or replace the filter.
Dirty hydraulic fluid - The fluid must be changed.
Cylinder tube or rod scoring - Change worn component.

Hydraulic pump is noisy
Hydraulic leakage or low oil level - Add hydraulic oil or correct system leaks.
Dirty hydraulic filter - Clean or replace the filter.
Suction line clogging - Suction line needs to be cleaned.
Air trapped in hydraulic pump - Bleed air from hydraulics.
Worn pump parts - Replace or rebuild the pump.

Electrical Troubleshooting

Battery cannot be charged
Electrical wire connections are loose or corroded - Clean or tighten connections.
Battery terminal connectors are faulty - Install new terminal connectors.
Battery faulty cell - Battery change required.
Loose or damaged belt - Need to adjust belt tension or replace belt.

Starter turns slowly
Low battery capacity - Battery is drained, charge it.
Battery does not hold charge - Service charging system or install new battery.
Corroded battery terminals or disconnected wires - Connect cables correctly or replace terminals.

Starter motor is not working
Battery is discharged or defective - Battery needs to be recharged or replaced.
Wiring is improperly connected or disconnected - Check wiring and connect properly.
Low battery capacity - Charge the battery.
Starter motor is damaged - Starter needs to be changed.