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Bobcat 3400 3400XL Utility Vehicle Service Manual 7255691 (02-20) – PDF DOWNLOAD
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Bobcat 3400 3400XL Utility Vehicle Service Manual 7255691 (02-20) – PDF DOWNLOAD
S/N B3FL11001 & Above
S/N B3FN11001 & Above
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Description
Bobcat 3400 3400XL Utility Vehicle Service Manual 7255691 (02-20) – PDF DOWNLOAD
FILE DETAILS:
Bobcat 3400 3400XL Utility Vehicle Service Manual 7255691 (02-20) – PDF DOWNLOAD
Language : English
Pages : 519
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat 3400 3400XL Utility Vehicle Service Manual 7255691 (02-20) – PDF DOWNLOAD
S/N B3FL11001 & Above
S/N B3FN11001 & Above
FOREWORD
This manual is for the Utility Vehicle mechanic. It provides necessary servicing and adjustment procedures for the Utility Vehicle and its component parts and systems. Refer to the for operating instructions, starting procedure, daily checks, etc
SAFETY INSTRUCTIONS
Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death.
IMPORTANT
This notice identifies procedures which must be followed to avoid damage to the machine
The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments / implements:
- The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.
- The Operation & Maintenance Manual delivered with the machine or attachment / implement contains operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.
- Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment / implement. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.
- An Operator’s Handbook fastened to the operator cab. It’s brief instructions are convenient to the operator. The handbook is available from your dealer in an English edition or one of many other languages. See your Bobcat dealer for more information on translated versions.
- The Service Manual and Parts Manual are available from your dealer for use by mechanics to do shoptype service and repair work.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Bobcat 3400 3400XL Utility Vehicle Service Manual 7255691 (02-20) – PDF DOWNLOAD
MAINTENANCE SAFETY.......................................................... 3 CONTENTS.................................................................... 5 FOREWORD.................................................................... 7 FOREWORD................................................................ 9 SAFETY INSTRUCTIONS..................................................... 11 FIRE PREVENTION......................................................... 13 Maintenance......................................................... 13 Operation........................................................... 13 Electrical.......................................................... 13 Fueling............................................................. 13 Starting............................................................ 13 Spark Arrester Exhaust System....................................... 13 Welding And Grinding................................................ 13 Fire Extinguishers.................................................. 14 SERIAL NUMBER LOCATIONS................................................. 15 Utility Vehicle Serial Number....................................... 15 Engine Serial Number................................................ 15 DELIVERY REPORT......................................................... 16 UTILITY VEHICLE IDENTIFICATION (3400)................................... 17 UTILITY VEHICLE IDENTIFICATION (3400XL)................................. 18 SAFETY & MAINTENANCE........................................................ 19 LIFTING AND BLOCKING THE UTILITY VEHICLE................................ 21 Procedure........................................................... 21 ROLLOVER PROTECTIVE STRUCTURE (ROPS).................................... 23 Description......................................................... 23 TRANSPORTING THE UTILITY VEHICLE ON A TRAILER........................... 25 Loading And Unloading............................................... 25 Fastening........................................................... 26 TOWING THE UTILITY VEHICLE.............................................. 27 Procedure........................................................... 27 SERVICE SCHEDULE........................................................ 29 Maintenance Intervals............................................... 29 AIR CLEANER SERVICE..................................................... 31 Pre-Filter Element.................................................. 31 Replacing Filter Element............................................ 32 ENGINE COOLING SYSTEM................................................... 33 Checking Level...................................................... 33 Cleaning............................................................ 34 Removing And Replacing Coolant...................................... 35 FUEL SYSTEM............................................................. 37 Fuel Specifications................................................. 37 Filling The Fuel Tank............................................... 38 Filling A Portable Fuel Container................................... 38 ENGINE LUBRICATION SYSTEM............................................... 39 Checking And Adding Engine Oil...................................... 39 Engine Oil.......................................................... 39 Removing And Replacing Oil And Filter............................... 40 CONTINUOUS VARIABLE TRANSMISSION (CVT).................................. 43 CVT Drying.......................................................... 43 CVT Filter.......................................................... 44 GEARCASE................................................................ 45 Checking Transmission Fluid......................................... 45 Transmission Fluid.................................................. 46 Adding Transmission Fluid........................................... 46 Removing And Replacing Transmission Fluid........................... 46 Checking Front Gearcase Fluid....................................... 46 Front Gearcase Fluid................................................ 47 Adding Front Gearcase Fluid......................................... 47 Removing And Replacing Front Gearcase Fluid......................... 47 TIRE MAINTENANCE........................................................ 49 Tires............................................................... 49 Tire Tread Depth.................................................... 49 Axle And Wheel Nut Torque........................................... 49 Wheel Removal And Installation...................................... 50 Mounting............................................................ 50 Tire Pressure....................................................... 50 SPARK ARRESTER MUFFLER.................................................. 51 Cleaning Procedure.................................................. 51 UTILITY VEHICLE STORAGE AND RETURN TO SERVICE........................... 53 Storage............................................................. 53 Return To Service................................................... 53 STOPPING THE ENGINE AND LEAVING THE UTILITY VEHICLE..................... 55 Procedure........................................................... 55 SEAT BELT............................................................... 57 Inspection And Maintenance.......................................... 57 LUBRICATING THE UTILITY VEHICLE......................................... 59 Lubrication Locations............................................... 59 DRIVE SYSTEM................................................................ 61 BRAKE................................................................... 65 General Specifications.............................................. 65 Torque Specifications............................................... 65 System Service Notes................................................ 66 Noise Troubleshooting............................................... 67 System Troubleshooting.............................................. 68 Hydraulic Brake System Operation.................................... 69 System Parts Identification......................................... 70 Master Cylinder Removal And Installation............................ 71 Foot Brake Pedal Removal And Installation........................... 72 Bleeding / Fluid Removal And Installation........................... 73 Brake Inspection.................................................... 75 Brake Pad Inspection................................................ 75 Burnishing.......................................................... 76 BRAKE (FRONT)........................................................... 77 Pad Removal......................................................... 77 Pad Inspection...................................................... 78 Pad Assembly / Installation......................................... 79 Caliper Removal..................................................... 80 Caliper Parts Identification........................................ 81 Caliper Disassembly................................................. 82 Caliper Inspection.................................................. 83 Caliper Assembly.................................................... 84 Caliper Installation................................................ 84 Disc Runout......................................................... 85 Disc Inspection..................................................... 85 Disc Removal And Installation....................................... 86 BRAKE (REAR)............................................................ 87 Caliper Removal..................................................... 87 Pad Removal......................................................... 87 Pad Inspection...................................................... 88 Pad Installation.................................................... 88 Caliper Parts Identification........................................ 89 Caliper Disassembly................................................. 90 Caliper Inspection.................................................. 91 Caliper Assembly.................................................... 92 Caliper Installation................................................ 92 Disc Runout......................................................... 93 Disc Inspection..................................................... 93 Disc Removal And Installation....................................... 94 TRANSMISSION............................................................ 95 General Operation................................................... 95 System Troubleshooting.............................................. 96 Shift Lever Removal And Installation................................ 97 Shift Cable Inspecting.............................................. 99 Shift Cable Adjustment..............................................100 Shift Cable Removal And Installation................................100 Removal And Installation............................................102 Parts Identification................................................109 Transmission Disassembly............................................111 Gear Cluster Disassembly............................................114 Snorkel Shaft Removal / Disassembly.................................115 Planetary Differential Disassembly..................................117 Planetary Differential Assembly.....................................120 Snorkel Gear Backlash...............................................121 Transmission Assembly...............................................124 DRIVE BELT..............................................................129 Removal.............................................................129 Installation........................................................131 Belt Inspection.....................................................131 Belt Damage.........................................................132 CONTINUOUS VARIABLE TRANSMISSION (CVT)..................................135 CVT System Overview.................................................135 Drive Clutch Operation..............................................135 Driven Clutch Operation.............................................136 CVT Break-In (Drive Belt / Clutches)................................136 Maintenance And Inspection..........................................136 Overheating Troubleshooting.........................................137 System Troubleshooting..............................................138 CVT Sealing, Guard And Ducting Components Parts Identification......140 CVT (Outer) Cover Removal And Installation..........................141 CVT (Inner) Cover Removal And Installation..........................142 CONTINUOUS VARIABLE TRANSMISSION (CVT) (DRIVE CLUTCH)...................143 Removal And Installation............................................143 Spring Specifications...............................................144 Parts Identification................................................145 Disassembly.........................................................146 Assembly............................................................157 CONTINUOUS VARIABLE TRANSMISSION (CVT) (DRIVEN CLUTCH)..................161 Removal And Installation............................................161 Parts Identification................................................162 Disassembly.........................................................163 Assembly............................................................164 FINAL DRIVE.............................................................165 Description.........................................................165 Bearing Carrier Removal.............................................165 Bearing Removal And Installation....................................167 Bearing Carrier Installation........................................168 Front Drive Shaft Removal And Installation..........................171 Rear Drive Shaft Removal And Installation...........................172 Drive Shaft / CV Joint Handling.....................................175 Outer CV Joint And Boot Removal And Installation....................175 Inner Plunging Joint And Boot Removal And Installation..............178 Propshaft Removal And Installation..................................181 Propshaft U-Joint Disassembly.......................................182 Propshaft U-Joint Assembly..........................................184 Front Gearcase Operation............................................187 Front Gearcase Removal And Installation.............................190 Front Gearcase Parts Identification.................................192 Front Gearcase Disassembly / Inspection.............................193 Front Gearcase Assembly.............................................197 MAINFRAME...................................................................201 ROLL OVER PROTECTIVE STRUCTURE (ROPS)...................................203 Removal And Installation............................................203 OPERATOR SEAT...........................................................217 Seat Back Removal And Installation..................................217 Seat Base Removal And Installation..................................219 Seat Belt Removal And Installation..................................220 DASH....................................................................223 Front Access Cover Removal And Installation.........................223 Upper Dash Panel Removal And Installation...........................223 Lower Dash Panel Removal And Installation...........................224 Storage Panel Removal And Installation..............................227 BUMPER COVER............................................................229 Removal And Installation............................................229 REAR SUSPENSION LINK AND AXLE BRACE.....................................231 Upper Suspension Link Removal And Installation......................231 Lower Suspension Link Removal And Installation......................232 Axle Brace Removal And Installation.................................233 Rear Axle Bearing Replacement.......................................235 STEERING COLUMN.........................................................237 Description.........................................................237 Tilt Steering Shock Removal And Installation........................237 Parts Identification................................................238 Steering Wheel Removal And Installation.............................239 Steering Wheel / Upper Steering Shaft Removal And Installation......240 Steering Shaft Bearing Replacement..................................241 Power Steering Unit Removal.........................................242 Power Steering Unit Installation....................................243 STEERING BOX............................................................245 Removal And Installation............................................245 FUEL TANK...............................................................247 Removal And Installation............................................247 SHOCKS..................................................................249 Rear Shock Removal And Installation.................................249 Front Shock Removal And Installation................................250 Shock Spring Removal And Installation...............................251 A-ARMS..................................................................253 Lower A-Arm Removal And Installation................................253 Upper A-Arm Removal.................................................254 Upper A-Arm Installation............................................256 Inspection..........................................................258 Ball Joint Removal And Installation.................................259 TIE ROD.................................................................261 Description.........................................................261 Removal And Installation............................................261 Toe Adjustment Procedure............................................262 TAILGATE................................................................263 Removal And Installation............................................263 Latch Removal And Installation......................................264 CARGO BOX...............................................................265 Removal And Installation............................................265 FENDER..................................................................267 Removal And Installation (Front)....................................267 Removal And Installation (Rear).....................................267 Flare Removal And Installation......................................269 FRONT WINDOW............................................................271 Removal And Installation............................................271 DOOR....................................................................273 Removal And Installation............................................273 DOOR LATCH..............................................................275 Removal And Installation............................................275 Adjustment..........................................................275 REAR PANEL..............................................................277 Removal And Installation............................................277 ELECTRICAL SYSTEM & ANALYSIS................................................279 ELECTRICAL SCHEMATICS...................................................283 ELECTRICAL SYSTEM INFORMATION...........................................284 Glossary Of Electrical Symbols......................................284 Troubleshooting.....................................................287 Description.........................................................288 Fuse And Relay Location.............................................288 BATTERY.................................................................290 Removal And Installation............................................290 Servicing...........................................................291 Using A Booster Battery (Jump Starting).............................292 Battery Terminal Blocks.............................................294 CHARGING SYSTEM.........................................................296 Current Draw - Key OFF..............................................296 Break Even Test.....................................................297 Stator Testing......................................................298 Stator Removal......................................................299 Stator Installation.................................................300 Testing Flow Chart..................................................302 STARTER SYSTEM..........................................................304 Testing.............................................................304 Removal And Installation............................................305 Parts Identification................................................306 Starting Testing Flow Chart.........................................307 REGULATOR / RECTIFIER...................................................308 Location............................................................308 Removal And Installation............................................308 Testing.............................................................311 LIGHTS..................................................................312 Headlight Removal And Installation..................................312 Headlight Adjustment................................................313 Taillight / Brake Light Removal And Installation....................314 ELECTRONIC CONTROL MODULE (ECU).........................................316 Description.........................................................316 Removal And Installation............................................316 IGNITION COIL...........................................................318 Description.........................................................318 Testing.............................................................318 Ignition Coil Test..................................................318 Removal And Installation............................................319 ELECTRONIC FUEL INJECTION SENSORS.......................................320 Crank Position Sensor (CPS).........................................320 Temp / Manifold Absolute Pressure Sensor (T-MAP)....................321 Engine Coolant Temperature Sensor (ECT).............................322 Pedal Position Sensor (PPS).........................................323 SWITCH (HEADLIGHT)......................................................326 Location............................................................326 Removal And Installation............................................326 Testing.............................................................327 SWITCH (BRAKE LIGHT)....................................................328 Location............................................................328 Removal And Installation............................................328 Testing.............................................................329 SWITCH (AWD / 2WD / TURF)...............................................330 Location............................................................330 Removal And Installation............................................330 Testing.............................................................331 SWITCH (KEY)............................................................332 Location............................................................332 Removal And Installation............................................332 Ignition Key Switch Testing.........................................333 SWITCH (GEAR SELECTOR)..................................................334 Location............................................................334 Removal And Installation............................................334 Testing.............................................................335 TEMPERATURE SENSOR......................................................336 Description.........................................................336 Testing.............................................................336 Removal And Installation............................................337 DIFFERENTIAL SOLENOID...................................................338 Description.........................................................338 Removal And Installation............................................338 DIFFERENTIAL SOLENOID (REAR RELAY)......................................340 Description.........................................................340 Removal And Installation............................................340 BACK-UP ALARM SYSTEM....................................................342 Description.........................................................342 Inspection..........................................................342 Removal And Installation............................................343 ELECTRONIC THROTTLE CONTROL (ETC).......................................344 Description.........................................................344 Testing.............................................................344 Removal And Installation............................................345 INSTRUMENT CLUSTER......................................................348 Information Display.................................................348 Pinouts.............................................................350 Information Display Area............................................350 Diagnostic Trouble Codes............................................355 Removal And Installation............................................358 FUEL SENDER.............................................................360 Testing.............................................................360 DIAGNOSTIC TESTING......................................................362 Digital Wrench™ Diagnostic Software.................................362 Digital Wrench™ Diagnostic Connector................................363 Digital Wrench™ SmartLink Module Kit - MEL1721......................363 Serial Number Location..............................................364 Version And Update ID...............................................364 Updates.............................................................365 Digital Wrench™ Feature Map.........................................367 Engine Controller Reprograming (Reflash)............................368 ELECTRONIC POWER STEERING (EPS).........................................372 EPS Operation.......................................................372 Power Steering 30A Fuse.............................................372 System Diagnosing...................................................372 EPS Troubleshooting (Power Steering Non-Functional with MIL ON).....373 EPS Troubleshooting (Power Steering Non-Functional with MIL OFF)....374 EPS Troubleshooting (Using Digital Wrench™).........................375 ENGINE SERVICE..............................................................376 ENGINE INFORMATION......................................................380 Description.........................................................380 Specifications......................................................381 Torque Values.......................................................385 Troubleshooting.....................................................386 Accessible Engine Components........................................389 Engine Removal And Installation.....................................390 Engine Installation Notes...........................................396 Engine Mount Replacement............................................397 Compression - Checking..............................................398 THROTTLE SYSTEM.........................................................400 Description.........................................................400 Testing.............................................................400 Removal And Installation............................................401 MUFFLER.................................................................402 Removal And Installation............................................402 AIR CLEANER.............................................................404 Housing Removal And Installation....................................404 ENGINE COOLING SYSTEM...................................................406 Cooling System Pressure Test........................................406 Radiator Cap Pressure Test..........................................406 System Bleeding.....................................................407 Radiator Cleaning...................................................408 Radiator Removal And Installation...................................409 Cooling Fan Removal And Installation................................411 Thermostat Removal And Installation.................................412 Water Pump Cover And Impeller Service...............................413 Water Pump Mechanical Seal / Oil Seal Removal.......................414 Water Pump Mechanical Seal / Oil Seal Installation..................416 LUBRICATION SYSTEM......................................................420 Engine Oil Pressure - Testing.......................................420 FUEL SYSTEM.............................................................422 Fuel System Operation...............................................422 System Trouble Shooting.............................................423 Relieving Fuel Pressure.............................................424 Initial Priming / Starting Procedure................................425 Fuel Line (Quick Connect) Removal And Installation..................425 Fuel Pump Test......................................................426 Fuel Pressure Regulator Description.................................427 Fuel Pressure Regulator Test........................................427 Fuel Pressure Regulator Replacement.................................427 Fuel Pump Removal And Installation..................................428 Fuel Injector Description...........................................431 Fuel Injector Troubleshooting.......................................432 Fuel Injector Test..................................................432 Fuel Injector Removal And Installation..............................433 FUEL SYSTEMS DIAGNOSTICS................................................436 Instrument Cluster Trouble Code Display.............................436 ENGINE DISASSEMBLY / INSPECTION.........................................438 Setting Top-Dead-Center (TDC).......................................439 Valve Cover Removal.................................................440 Camshaft / Carrier Removal..........................................440 Camshaft Sprocket Inspection........................................442 Camshaft Inspection.................................................442 Exhaust Camshaft Decompression Mechanism............................443 Cam Chain And Guide Service.........................................443 Cylinder Head Removal...............................................444 Cylinder Head Disassembly...........................................444 Cylinder Head Inspection............................................446 Cylinder Head Warp Inspection.......................................446 Valve Inspection....................................................447 Combustion Chamber Cleaning.........................................448 Valve Seat Reconditioning...........................................448 Cylinder Removal....................................................451 Cylinder Inspection.................................................451 Piston Removal......................................................452 Piston-To-Cylinder Clearance........................................453 Piston / Rod Inspection.............................................453 Piston Ring Installed Gap...........................................455 Honing to Oversize..................................................455 Crankcase Disassembly...............................................456 Starter One-Way Clutch Removal / Inspection.........................458 Stator Removal......................................................459 Oil Pump Removal....................................................460 Oil Pump Assembly...................................................462 Crankcase Breather Service..........................................462 Crankcase Separation................................................463 Balance Shaft Removal / Inspection..................................464 Crankshaft Removal..................................................465 Crankshaft Inspection...............................................466 PTO Side Crankcase Bearing Service..................................467 MAG Side Crankcase Bearing Service..................................468 Oil Pickup Assembly Inspection......................................468 Oil Pressure Regulator (Bypass) Valve Inspection....................469 Crankcase Inspection................................................469 ENGINE ASSEMBLY.........................................................470 Crankcase Assembly - PTO Side.......................................470 Balance Shaft Installation / Timing.................................472 Final Crankcase Assembly............................................473 Piston Ring Installation............................................474 Piston / Connecting Rod Assembly....................................475 Cylinder Installation...............................................475 Cylinder Head Assembly..............................................476 Valve Sealing Test..................................................478 Cylinder Head Installation..........................................479 Valve Clearance Check / Adjustment..................................480 Intake Valve Lash - Tappet Selection Matrix.........................482 Exhaust Valve Lash - Tappet Selection Matrix........................483 Camshaft Installation / Timing......................................484 Valve Cover Installation............................................486 Starter One-Way Clutch Installation.................................487 Flywheel Installation...............................................487 Stator And Stator Cover Installation................................489 SPECIFICATIONS..............................................................490 3400 UTILITY VEHICLE SPECIFICATIONS.....................................492 Dimensions (B3FL16999 & Below)......................................492 Dimensions (B3FL17001 & Above)......................................493 (3400XL) Dimensions (B3FN16999 & Below).............................494 (3400XL) Dimensions (B3FN17001 & Above).............................495 Performance.........................................................496 Controls............................................................496 Engine..............................................................497 Electrical..........................................................497 Drive System........................................................498 Fluid And Capacities................................................498 Tires...............................................................499 TECHNICAL SERVICE GUIDE SPECIFICATIONS..................................500 Engine..............................................................500 Engine Torques......................................................500 Cooling System......................................................500 TORQUE SPECIFICATIONS FOR BOLTS.........................................502 Torque For General SAE Bolts........................................502 Torque For General Metric Bolts.....................................503 CONVERSIONS.............................................................504 Decimal And Millimeter Equivalent Chart.............................504 U.S. To Metric Conversion Chart.....................................505 SERVICE TOOLS REQUIRED..................................................506 Hydraulic Tools.....................................................506 Transmission / Clutch / Drive Tools.................................507 Engine Tools........................................................511 HVAC Tools..........................................................515 ALPHABETICAL INDEX..........................................................516
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PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
S.M
