BOBCAT MT52 MT55 SERVICE MANUAL S/N A3WR11001 A3WT11001 A3WS1100 A3WU11001 & ABOVE

This bobcat MT52 MT55  service manual is for the Bobcat loader mechanic. It provides necessary servicing and adjustment procedures for the Bobcat Mini loader and its component parts and systems. Refer to the Operation & Maintenance manual for operating instructions, Starting procedure, daily checks, etc.

CONTENTS
FOREWORD. . . . . . . . . . .. . . . . . . . . . . . III
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . V
SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . .IX
DELIVERY REPORT. . . . . . . . . . . . . . . . . . . . . . . .IX
BOBCAT LOADER IDENTIFICATION. . . . . . . . . . . . . . X
SAFETY AND MAINTENANCE. . . . . . . . . 10-01
HYDRAULIC SYSTEM . . . . . . . . . 20-01
HYDROSTATIC SYSTEM . . . . . . .  . . . . . . 30-01
DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . 40-01
MAIN FRAME . . . . . . . . . . . . . . . . . 50-01
ELECTRICAL SYSTEM & ANALYSIS. . . . . . . . . . 60-01
ENGINE SERVICE . . . . . . . . . . . . . . . . 70-01
SPECIFICATIONS. . . . . . .. . . . . . . . SPEC-01

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HYDRAULIC SYSTEM INFORMATION  Troubleshooting

• No drive function
• No drive on one side in both directions
• No drive on one side in one direction
• Machine does not drive in reverse
• Machine does not move in straight line
• Hydrostatic system overheating
• Hydraulic/Hydrostatic warning light comes on.

KEY TO CORRECT THE CAUSE

1. Belt slippage.
2. Low or no charge pressure.
3. Sheared key on drive motor and/or loose castle bolt.
4. Hydrostatic system has fluid leak.
5. Steering linkage loose, damaged or needs adjustment.
6. Hydrostatic pressure relief valve is defective.
7. Hydrostatic pump has defect.
8. Hydrostatic motor has defect.
9. Hydrostatic fluid not at correct level.
10. Drive relief on hydrostatic pump is stuck open.
11. Inspect reverse speed adjustment.
12. Reverse stop linkage mechanism failure.
13. Steering lever is obstructed.
14. Restricted oil cooler.
15. Plugged case drain.
16. Hydraulic cooling fan not operable (Refer to Electrical Troubleshooting).
17. Electrical defect.
18. Hydraulic oil temp too high.

ELECTRICAL SYSTEM INFORMATION  Troubleshooting

Battery looses charge.
Alternator will not charge.
Starter will not turn the engine.
Auxiliary blower fan will not run when auxiliaries are engaged.
Lift arm does not lower with the engine running and activation of the lift lever.
Electric fan not operating with engine running.

KEY TO CORRECT THE CAUSE

1. Alternator belt is loose or damaged.
2. Battery connections are dirty or loose.
3. Battery is weak or failed.
4. The ground is not correct in the electrical system.
5. The alternator has a failure.
6. Engine seizure.
7. Starter has a failure.
8. Neutral start circuit failure. (wiring, relay, solenoid, connectors)
9. Fuse had a failure.
10. Auxiliary lever engaged.
11. Left or right drive lever engaged.
12. Starter relay has a failure.
13. Electric fan circuitry failure.
14. Electric fan motor.
15. Lift arm circuit has a failure. (fuse, relay, solenoid)
16. Engine oil pressure circuit has a failure. (fuse, relay, solenoid, switch)
17. Low engine oil pressure.
18. Loose, disconnected or damaged wiring.
19. Lift control lever, not in neutral position.
20. Continuous auxiliary hydraulic shutoff lever is engaged.

ENGINE INFORMATION Troubleshooting

Slow cranking speed.
Engine will not start.
Difficult to start.
No power from the engine.
Engine is mis-firing.
Too much fuel consumption.
Black exhaust.
Blue/White exhaust.
Low oil pressure.
Engine knocking.
Engine running rough.
Vibration.
High oil pressure.
Engine Overheating.
Too much crankcase pressure.
Poor compression.
Engine starts but does not stay running.
Engine does not shut off.

KEY TO CORRECT THE CAUSE

1. Battery capacity low. 31. Worn valves and seats.
2. Bad electrical connection. 32. Broken, worn or sticking piston rings.
3. Faulty starter motor. 33. Worn valve stems and guides.
4. Incorrect grade of oil. 34. Overly full air cleaner.
5. Low cranking speed. 35. Worn or damaged bearings.
6. Fuel tank empty. 36. Not enough oil in the oil pan.
7. Faulty stop control operation. 37. Gauge is not correct.
8. Plugged fuel line. 38. Oil pump worn.
9. Faulty fuel lift pump. 39. Pressure relief valve is open.
10. Plugged fuel filter. 40. Pressure relief valve is sticking closed.
11. Restriction in the air cleaner. 41. Broken relief valve spring.
12. Air in the fuel system. 42. Faulty suction pipe.
13. Faulty fuel injection pump. 43. Plugged oil filter.
14. Faulty fuel injectors. 44. Piston seizure.
15. Incorrect use of the glow plugs 45. Incorrect piston height.
16. Glow plugs not working. 46. Damaged fan.
17. Broken fuel injection pump drive. 47. Faulty engine mounting or loose mounting.
18. Incorrect fuel pump timing. 48. Faulty thermostat.
19. Incorrect valve timing. 49. Restriction in the water jacket.
20. Poor compression. 50. Loose fan belt.
21. Plugged fuel tank vent. 51. Plugged radiator.
22. Incorrect type or grade of fuel. 52. Faulty water pump.
23. Exhaust pipe restriction. 53. Plugged breather pipe.
24. Cylinder head gasket leaking. 54. Valve stem seals damaged.
25. Overheating. 55. Coolant level low.
26. Cold running. 56. Plugged oil pump pipe strainer.
27. Incorrect valve tappet adjustment. 57. Broken valve spring.
28. Sticking valves. 58. Hydraulics in Detent position or drive engaged.
29. Incorrect high pressure tubelines. 59. Faulty shut-down circuit. (See Troubleshooting on Page
60-10-5)
30. Worn engine cylinder bores