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Bobcat 3400 3400XL Utility Vehicle Service Manual – PDF DOWNLOAD
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Bobcat 3400 3400XL Utility Vehicle Service Manual – PDF DOWNLOAD
S/N B3FK11001 & Above
S/N B3FM11001 & Above
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Description
Bobcat 3400 3400XL Utility Vehicle Service Manual – PDF DOWNLOAD
FILE DETAILS:
Bobcat 3400 3400XL Utility Vehicle Service Manual – PDF DOWNLOAD
Language : English
Pages : 487
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat 3400 3400XL Utility Vehicle Service Manual – PDF DOWNLOAD
S/N B3FK11001 & Above
S/N B3FM11001 & 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 – 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..................................................... 33 Pre-Filter Element.................................................. 33 Replacing Filter Element............................................ 34 ENGINE COOLING SYSTEM................................................... 35 Checking Level...................................................... 35 Cleaning............................................................ 36 Removing And Replacing Coolant...................................... 37 FUEL SYSTEM............................................................. 39 Fuel Specifications................................................. 39 Biodiesel Blend Fuel................................................ 39 Filling The Fuel Tank............................................... 40 Fuel Filter......................................................... 40 Removing Air From The Fuel System................................... 41 Filling A Portable Fuel Container................................... 41 ENGINE LUBRICATION SYSTEM............................................... 43 Checking And Adding Engine Oil...................................... 43 Engine Oil Chart.................................................... 43 Removing And Replacing Oil And Filter............................... 44 CONTINUOUS VARIABLE TRANSMISSION (CVT).................................. 47 CVT Drying.......................................................... 47 CVT Filter.......................................................... 48 GEARCASE................................................................ 49 Checking Transmission Fluid......................................... 49 Transmission Fluid.................................................. 50 Adding Transmission Fluid........................................... 50 Removing And Replacing Transmission Fluid........................... 50 Checking Front Gearcase Fluid....................................... 51 Front Gearcase Fluid................................................ 51 Adding Front Gearcase Fluid......................................... 51 Removing And Replacing Front Gearcase Fluid......................... 52 TIRE MAINTENANCE........................................................ 53 Tires............................................................... 53 Tire Tread Depth.................................................... 53 Axle And Wheel Nut Torque........................................... 53 Wheel Removal And Installation...................................... 54 Mounting............................................................ 55 Tire Pressure....................................................... 55 SPARK ARRESTER MUFFLER.................................................. 57 Cleaning Procedure.................................................. 57 UTILITY VEHICLE STORAGE AND RETURN TO SERVICE........................... 59 Storage............................................................. 59 Return To Service................................................... 59 STOPPING THE ENGINE AND LEAVING THE UTILITY VEHICLE..................... 61 Procedure........................................................... 61 SEAT BELT............................................................... 63 Inspection And Maintenance.......................................... 63 LUBRICATING THE UTILITY VEHICLE......................................... 65 Lubrication Locations............................................... 65 DRIVE SYSTEM................................................................ 67 BRAKE................................................................... 71 General Specifications.............................................. 71 Torque Specifications............................................... 71 System Service Notes................................................ 72 Noise Troubleshooting............................................... 73 System Troubleshooting.............................................. 74 Hydraulic Brake System Operation.................................... 75 System Parts Identification......................................... 76 Master Cylinder Removal And Installation............................ 77 Foot Brake Pedal Removal And Installation........................... 78 Bleeding / Fluid Removal And Installation........................... 79 Brake Inspection.................................................... 81 Brake Pad Inspection................................................ 81 Burnishing.......................................................... 82 BRAKE (FRONT)........................................................... 83 Pad Removal......................................................... 83 Pad Inspection...................................................... 84 Pad Assembly / Installation......................................... 85 Caliper Removal..................................................... 86 Caliper Parts Identification........................................ 87 Caliper Disassembly................................................. 88 Caliper Inspection.................................................. 89 Caliper Assembly.................................................... 90 Caliper Installation................................................ 90 Disc Runout......................................................... 91 Disc Inspection..................................................... 91 Disc Removal And Installation....................................... 92 BRAKE (REAR)............................................................ 93 Caliper Removal..................................................... 93 Pad Removal......................................................... 93 Pad Inspection...................................................... 94 Pad Installation.................................................... 94 Caliper Parts Identification........................................ 95 Caliper Disassembly................................................. 96 Caliper Inspection.................................................. 97 Caliper Assembly.................................................... 98 Caliper Installation................................................ 98 Disc Runout......................................................... 99 Disc Inspection..................................................... 99 Disc Removal And Installation.......................................100 TRANSMISSION............................................................101 General Operation...................................................101 System Troubleshooting..............................................102 Shift Lever Removal And Installation................................103 Shift Cable Inspecting..............................................105 Shift Cable Adjustment..............................................106 Shift Cable Removal And Installation................................106 Removal.............................................................108 Installation........................................................112 Parts Identification................................................116 Transmission Disassembly............................................119 Gear Cluster Disassembly............................................122 Snorkel Shaft Removal / Disassembly.................................123 Planetary Differential Disassembly..................................125 Planetary Differential Assembly.....................................128 Snorkel Gear Backlash...............................................129 Transmission Assembly...............................................131 DRIVE BELT..............................................................137 Removal.............................................................137 Installation........................................................139 Belt Inspection.....................................................139 Belt Damage.........................................................140 CONTINUOUS VARIABLE TRANSMISSION (CVT)..................................143 CVT System Overview.................................................143 Drive Clutch Operation..............................................143 Driven Clutch Operation.............................................144 CVT Break-In (Drive Belt / Clutches)................................144 Maintenance And Inspection..........................................144 Overheating Troubleshooting.........................................145 System Troubleshooting..............................................146 CVT Sealing, Guard And Ducting Components Parts Identification......148 CVT (Outer) Cover Removal And Installation..........................149 CVT (Inner) Cover Removal And Installation..........................150 CONTINUOUS VARIABLE TRANSMISSION (CVT) (DRIVE CLUTCH)...................151 Removal And Installation............................................151 Spring Specifications...............................................152 Parts Identification................................................153 Disassembly.........................................................154 Assembly............................................................165 CONTINUOUS VARIABLE TRANSMISSION (CVT) (DRIVEN CLUTCH)..................169 Removal And Installation............................................169 Parts Identification................................................170 Disassembly.........................................................171 Assembly............................................................172 FINAL DRIVE.............................................................173 Description.........................................................173 Bearing Carrier Removal.............................................173 Bearing Removal And Installation....................................175 Bearing Carrier Installation........................................176 Front Drive Shaft Removal And Installation..........................179 Rear Drive Shaft Removal And Installation...........................180 Drive Shaft / CV Joint Handling.....................................182 Outer CV Joint And Boot Removal And Installation....................183 Inner Plunging Joint And Boot Removal And Installation..............186 Propshaft Removal And Installation..................................189 Propshaft U-Joint Disassembly.......................................190 Propshaft U-Joint Assembly..........................................192 Front Gearcase Operation............................................195 Front Gearcase Removal And Installation.............................198 Front Gearcase Parts Identification.................................200 Front Gearcase Disassembly / Inspection.............................201 Front Gearcase Assembly.............................................205 MAINFRAME...................................................................209 ROLL OVER PROTECTIVE STRUCTURE (ROPS)...................................211 Removal And Installation............................................211 OPERATOR SEAT...........................................................225 Seat Back Removal And Installation..................................225 Seat Base Removal And Installation..................................226 Seat Belt Removal And Installation..................................227 DASH....................................................................231 Front Access Cover Removal And Installation.........................231 Upper Dash Panel Removal And Installation...........................231 Lower Dash Panel Removal And Installation...........................232 Storage Panel Removal And Installation..............................235 BUMPER COVER............................................................237 Removal And Installation............................................237 REAR SUSPENSION LINK AND AXLE BRACE.....................................239 Upper Suspension Link Removal And Installation......................239 Lower Suspension Link Removal And Installation......................240 Axle Brace Removal And Installation.................................241 Rear Axle Bearing Replacement.......................................243 STEERING COLUMN.........................................................245 Description.........................................................245 Tilt Steering Shock Removal And Installation........................245 Parts Identification................................................246 Steering Wheel Removal And Installation.............................247 Steering Wheel / Upper Steering Shaft Removal And Installation......248 Steering Shaft Bearing Replacement..................................249 Power Steering Unit Removal.........................................250 Power Steering Unit Installation....................................251 STEERING BOX............................................................253 Removal And Installation............................................253 FUEL TANK...............................................................255 Removal And Installation............................................255 SHOCKS..................................................................257 Rear Shock Removal And Installation.................................257 Front Shock Removal And Installation................................258 Shock Spring Removal And Installation...............................259 A-ARMS..................................................................261 Lower A-Arm Removal And Installation................................261 Upper A-Arm Removal.................................................262 Upper A-Arm Installation............................................264 Inspection..........................................................266 Ball Joint Removal And Installation.................................267 TIE ROD.................................................................269 Description.........................................................269 Removal And Installation............................................269 Toe Adjustment Procedure............................................270 TAILGATE................................................................271 Removal And Installation............................................271 Latch Removal And Installation......................................272 CARGO BOX...............................................................273 Removal And Installation............................................273 FENDER..................................................................275 Removal And Installation (Front)....................................275 Removal And Installation (Rear).....................................275 Flare 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 CHARGING SYSTEM.........................................................294 Current Draw - Key OFF..............................................294 Break Even Test.....................................................295 Alternator Removal And Installation.................................296 Belt Adjustment.....................................................296 Belt Replacement....................................................297 STARTER SYSTEM..........................................................298 Operation...........................................................298 Testing.............................................................298 Removal And Installation............................................299 FUEL SOLENOID...........................................................300 Location............................................................300 Removal And Installation............................................300 Testing.............................................................301 LIGHTS..................................................................302 Headlight Removal And Installation..................................302 Headlight Adjustment................................................303 Taillight / Brake Light Removal And Installation....................304 ELECTRONIC CONTROL MODULE (ECU).........................................306 Description.........................................................306 Removal And Installation............................................306 VEHICLE SPEED SENSOR....................................................308 Location............................................................308 Testing.............................................................308 SWITCH (HEADLIGHT)......................................................310 Location............................................................310 Removal And Installation............................................310 Testing.............................................................311 SWITCH (BRAKE LIGHT)....................................................312 Description.........................................................312 Location............................................................312 Removal And Installation............................................313 Testing.............................................................313 SWITCH (AWD / 2WD / TURF)...............................................314 Location............................................................314 Removal And Installation............................................314 Testing.............................................................315 SWITCH (KEY)............................................................316 Location............................................................316 Removal And Installation............................................316 Ignition Key Switch Testing.........................................317 SWITCH (GEAR SELECTOR)..................................................318 Location............................................................318 Removal And Installation............................................318 Testing.............................................................319 GLOWPLUGS...............................................................320 Location............................................................320 Removal And Installation............................................320 Testing.............................................................321 DIFFERENTIAL SOLENOID...................................................322 Description.........................................................322 Removal And Installation............................................322 DIFFERENTIAL SOLENOID (REAR RELAY)......................................324 Description.........................................................324 Removal And Installation............................................324 BACK-UP ALARM SYSTEM (IF EQUIPPED)......................................326 Description.........................................................326 Inspecting..........................................................326 Removal And Installation............................................327 TEMPERATURE SENSOR......................................................328 Description.........................................................328 Testing.............................................................328 Removal And Installation............................................329 Fan Control Circuit Operation / Testing.............................329 Fan Control Circuit Bypass Test.....................................329 INSTRUMENT CLUSTER......................................................330 Information Display.................................................330 Pinouts.............................................................332 Information Display Area............................................333 Diagnostic Trouble Codes............................................338 Removal And Installation............................................340 FUEL SENDER.............................................................342 Testing.............................................................342 DIAGNOSTIC TESTING......................................................344 Digital Wrench™ Diagnostic Software.................................344 Digital Wrench™ Diagnostic Connector................................345 Digital Wrench™ SmartLink Module Kit - MEL1721......................345 Serial Number Location..............................................346 Version And Update ID...............................................346 Updates.............................................................347 Digital Wrench™ Feature Map.........................................349 Engine Controller Reprograming (Reflash)............................350 ELECTRONIC POWER STEERING (EPS).........................................354 EPS Operation.......................................................354 Power Steering 30A Fuse.............................................354 System Diagnosing...................................................354 EPS Troubleshooting (Power Steering Non-Functional with MIL ON).....355 EPS Troubleshooting (Power Steering Non-Functional with MIL OFF)....356 EPS Troubleshooting (Using Digital Wrench™).........................357 ENGINE SERVICE..............................................................358 ENGINE INFORMATION......................................................362 Description.........................................................362 Specifications......................................................363 Torque Values.......................................................367 Troubleshooting.....................................................368 Accessible Engine Components........................................375 Engine Removal And Installation.....................................376 Engine Installation Notes...........................................382 Engine Mount Replacement............................................383 Compression And Leakage Test........................................384 Cylinder Head Diagnostics...........................................385 Fuel Limiter........................................................385 Idle Speed Setting..................................................386 Timing Belt Inspection..............................................387 THROTTLE SYSTEM.........................................................388 Throttle Pedal Removal And Installation.............................388 Throttle Cable Removal And Installation.............................389 Throttle Freeplay...................................................391 Inspection And Maintenance..........................................391 Throttle Freeplay Adjustment........................................391 MUFFLER.................................................................392 Removal And Installation............................................392 AIR CLEANER.............................................................394 Housing Removal And Installation....................................394 ENGINE COOLING SYSTEM...................................................396 Cooling System Pressure Test........................................396 Radiator Cap Pressure Test..........................................396 System Bleeding.....................................................397 Radiator Cleaning...................................................398 Radiator Removal And Installation...................................399 Cooling Fan Removal And Installation................................401 Thermostat Removal And Installation.................................402 Water Pump Removal And Installation.................................403 LUBRICATION SYSTEM......................................................404 Oil Pan Removal And Installation....................................404 Oil Pump Removal....................................................405 Oil Pump Inspection.................................................406 Oil Pump Installation...............................................406 Engine Oil Pressure - Testing.......................................407 FUEL SYSTEM.............................................................408 Service Notes.......................................................408 Operation...........................................................408 Initial Priming / Starting Procedure................................408 Fuel Line Removal / Installation....................................409 Fuel Tank Removal...................................................409 Fuel Tank Installation..............................................410 Fuel Pump...........................................................411 Fuel Sender.........................................................413 Injector Timing.....................................................415 ENGINE DISASSEMBLY AND INSPECTION.......................................416 Crankcase Vacuum Regulator Valve Removal............................416 Intake Manifold Removal.............................................416 Exhaust Manifold Removal............................................417 Drive Pulley Removal................................................417 Flywheel Removal....................................................418 Timing Belt Removal.................................................419 Timing Pulleys Removal..............................................420 Water Pump Removal..................................................421 Speed Governor Removal..............................................421 Rocker Arm Cover Removal............................................422 Fuel Rail Removal...................................................423 Unit Injector Removal...............................................423 Rocker Arm Assembly Removal.........................................424 Camshaft Removal....................................................425 Camshaft Inspection.................................................426 Cylinder Head Removal...............................................427 Valve Removal.......................................................427 Valve And Spring Inspection.........................................428 Pre-Combustion Chamber Removal......................................430 Piston And Connecting Rod Removal...................................431 Piston And Piston Ring Inspection...................................432 Connecting Rod Inspection...........................................433 Cylinder Inspection.................................................434 Crankshaft Removal..................................................435 Crankshaft Inspection...............................................436 ENGINE ASSEMBLY.........................................................438 Crankshaft Installation.............................................438 Piston And Connecting Rod Installation..............................439 Oil Pan Installation................................................440 Pre-Combustion Chamber Installation.................................441 Valve Installation..................................................441 Cylinder Head Installation..........................................442 Camshaft Installation...............................................443 Rocker Arm Assembly Installation....................................444 Valve / Rocker Arm Clearance........................................444 Speed Governor Installation.........................................445 Unit Injector Installation..........................................446 Fuel Rail Installation..............................................447 Rocker Arm Cover Installation.......................................447 Oil Pump Installation...............................................448 Water Pump Installation.............................................449 Timing Pulleys Installation.........................................449 Timing Belt Installation............................................450 Flywheel Installation...............................................453 Drive Pulley Installation...........................................453 Starter Installation................................................454 Exhaust Manifold Installation.......................................455 Intake Manifold Installation........................................455 Crankcase Vacuum Regulator Valve Installation.......................456 SPECIFICATIONS..............................................................458 3400 UTILITY VEHICLE SPECIFICATIONS.....................................460 Dimensions (S/N B3FK16999 & Below)..................................460 Dimensions (S/N B3FK17001 & Above)..................................461 (3400XL) Dimensions (S/N B3FM16999 & Below).........................462 (3400XL) Dimensions (S/N B3FM17001 & Above).........................463 Performance.........................................................464 Controls............................................................464 Engine..............................................................465 Electrical..........................................................465 Drive System........................................................466 Fluid And Capacities................................................466 Tires...............................................................467 TECHNICAL SERVICE GUIDE SPECIFICATIONS..................................468 Engine..............................................................468 Engine Torques......................................................468 Cooling System......................................................468 TORQUE SPECIFICATIONS FOR BOLTS.........................................470 Torque For General SAE Bolts........................................470 Torque For General Metric Bolts.....................................471 CONVERSIONS.............................................................472 Decimal And Millimeter Equivalent Chart.............................472 U.S. To Metric Conversion Chart.....................................473 SERVICE TOOLS REQUIRED..................................................474 Hydraulic Tools.....................................................474 Transmission / Clutch / Drive Tools.................................475 Engine Tools........................................................479 HVAC Tools..........................................................483 ALPHABETICAL INDEX..........................................................484
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