Bobcat 3400 Utility Vehicle 3400 3400XL Operation & Maintenance Manual – PDF DOWNLOAD

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Bobcat 3400 Utility Vehicle 3400 3400XL Operation & Maintenance Manual – PDF DOWNLOAD

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Bobcat 3400 Utility Vehicle 3400 3400XL Operation & Maintenance Manual – PDF DOWNLOAD

Language : English
Pages : 150
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat 3400 Utility Vehicle 3400 3400XL Operation & Maintenance Manual – PDF DOWNLOAD

(3400) S/N B3FL12001 & Above
(3400XL) S/N B3FN12001 & Above

FOREWORD

This Operation & Maintenance Manual was written to give the owner / operator instructions on the safe operation and maintenance of the Bobcat utility vehicle. READ AND UNDERSTAND THIS OPERATION & MAINTENANCE MANUAL BEFORE OPERATING YOUR BOBCAT UTILITY VEHICLE. If you have any questions, see your Bobcat dealer. This manual may illustrate options and accessories not installed on your Bobcat utility vehicle

SAFETY INSTRUCTIONS
Before Operation

• Carefully follow the operating and maintenance instructions in this manual. The Bobcat utility vehicle is highly maneuverable and compact. It is rugged and useful under a wide variety of conditions.
• This presents an operator with hazards associated with off road, rough terrain applications, common with Bobcat utility vehicle usage. This vehicle handles differently than other vehicles, such as motorcycles, golf cars or cars. If you fail to take proper precautions, a collision or rollover can occur quickly, even during routine maneuvers like turning, braking, driving over rough terrain and up and down hills or over obstacles.
• This can result in severe injury or death. This vehicle is intended for off road use only and should not be operated on public roads. Driving this vehicle in an aggressive manner can increase the risk of head injury and requires head protection. For these aggressive driving conditions, Bobcat Company recommends that all occupants wear a properly fitting Department of Transportation (D.O.T.) approved helmet

Always follow these instructions:

•  Fasten seat belts for occupant restraint before operating.
• Keep hands and feet inside the vehicle at all times.
• Travel at appropriate vehicle speeds depending on the type of terrain, visibility conditions, operating conditions and your operating experience.
• Wear eye protection.
• Wear other personal protective equipment such as a helmet or hard hat, face protection, hearing protection, safety boots or shoes, chemical suit, respirators and gloves as needed by work location and vehicle operation.
• NEVER attempt jumps or other stunts with the vehicle.

This vehicle is an ADULT VEHICLE ONLY. NEVER operate this vehicle if you are under age 16 and NEVER operate without a valid drivers license. No person under the age of 12 may ride as a passenger in this vehicle.

• Any passenger must be able to comfortably reach the floor and hand holds. Never permit a guest to operate this vehicle unless the guest has read this manual and all safety signs (decals). Always inspect the vehicle before each use to make sure it is in safe operating condition. Always follow the inspection procedures described in this manual.
• The Bobcat utility vehicle has an internal combustion engine with resultant heat and exhaust. All exhaust gases can kill or cause illness so use the utility vehicle with adequate ventilation. The dealer explains the capabilities and restrictions of the Bobcat utility vehicle, attachment and accessories for each application. The dealer demonstrates the safe operation according to Bobcat instructional materials, which are also available to operators.
• The dealer can also identify unsafe modifications or use of unapproved attachments and accessories. The attachments and buckets are designed for an attachment arm Rated Capacity. They are designed for secure fastening to the Bobcat utility vehicle. The user must check with the dealer, or Bobcat literature, to determine safe loads of materials of specified densities for the vehicle – attachment combination.

The following publications and training materials provide information on the safe use and maintenance of the Bobcat utility vehicle and attachments and accessories:

• • The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine and attachment is in safe operating condition.
• The Operation & Maintenance Manual delivered with the machine or attachment gives 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. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.
• An Operator’s Handbook is fastened to the operator cab of the machine. 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 Toolcat Utility Work Machine Operating Training Course is available through your Bobcat dealer. This course is intended to provide rules and practices of correct operation of the Toolcat utility work machine. The course is available in English and Spanish versions.

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Bobcat 3400 Utility Vehicle 3400 3400XL Operation & Maintenance Manual – PDF DOWNLOAD

OPERATOR SAFETY WARNINGS.................................................................................................................................................................................................................................................  3
CONTENTS.................................................................................................................................................................................................................................................................  5
FOREWORD.................................................................................................................................................................................................................................................................  7
	BOBCAT COMPANY IS IS0 9001 CERTIFIED.................................................................................................................................................................................................................................  9
	REGULAR MAINTENANCE ITEMS............................................................................................................................................................................................................................................  9
	SERIAL NUMBER LOCATIONS.............................................................................................................................................................................................................................................. 10
		Utility Vehicle Serial Number.................................................................................................................................................................................................................................... 10
		Engine Serial Number............................................................................................................................................................................................................................................. 10
	DELIVERY REPORT...................................................................................................................................................................................................................................................... 10
	EMISSION CONTROL SYSTEMS............................................................................................................................................................................................................................................. 11
		Noise Emission Control System.................................................................................................................................................................................................................................... 11
		Operating On Public Lands In The U.S.A........................................................................................................................................................................................................................... 11
		Crankcase Emission Control System................................................................................................................................................................................................................................ 11
	(3400) UTILITY VEHICLE IDENTIFICATION................................................................................................................................................................................................................................ 12
	(3400XL) UTILITY VEHICLE IDENTIFICATION.............................................................................................................................................................................................................................. 13
	FEATURES, ACCESSORIES AND ATTACHMENTS................................................................................................................................................................................................................................ 14
		Standard Items................................................................................................................................................................................................................................................... 14
		Options And Accessories.......................................................................................................................................................................................................................................... 14
		Attachment....................................................................................................................................................................................................................................................... 14
SAFETY AND TRAINING RESOURCES............................................................................................................................................................................................................................................ 15
	SAFETY INSTRUCTIONS.................................................................................................................................................................................................................................................. 17
		Before Operation................................................................................................................................................................................................................................................. 17
		Safe Operation Is The Operator’s Responsibility.................................................................................................................................................................................................................. 18
		Safe Operation Needs A Qualified Operator........................................................................................................................................................................................................................ 18
		Equipment Modifications.......................................................................................................................................................................................................................................... 19
		Avoid Silica Dust................................................................................................................................................................................................................................................ 19
	FIRE PREVENTION...................................................................................................................................................................................................................................................... 19
		Maintenance...................................................................................................................................................................................................................................................... 19
		Operation........................................................................................................................................................................................................................................................ 19
		Electrical....................................................................................................................................................................................................................................................... 19
		Fueling.......................................................................................................................................................................................................................................................... 20
		Starting......................................................................................................................................................................................................................................................... 20
		Spark Arrester Exhaust System.................................................................................................................................................................................................................................... 20
		Welding And Grinding............................................................................................................................................................................................................................................. 20
		Fire Extinguishers............................................................................................................................................................................................................................................... 20
	UTILITY VEHICLE SIGNS (DECALS)....................................................................................................................................................................................................................................... 21
	PUBLICATIONS AND TRAINING RESOURCES.................................................................................................................................................................................................................................. 23
OPERATING INSTRUCTIONS................................................................................................................................................................................................................................................... 25
	OPERATOR CONTROLS AND INSTRUMENT PANELS.............................................................................................................................................................................................................................. 27
		Overview......................................................................................................................................................................................................................................................... 27
		Instrument Panel................................................................................................................................................................................................................................................. 28
		Tilt Steering Column Adjustment.................................................................................................................................................................................................................................. 30
		Gear Selector.................................................................................................................................................................................................................................................... 31
		Control Panel.................................................................................................................................................................................................................................................... 32
		Raising And Lowering The Cargo Box - With Power Lift Assist Switch (Optional).................................................................................................................................................................................... 32
		Key - Start / Stop............................................................................................................................................................................................................................................... 33
		Storage Compartment.............................................................................................................................................................................................................................................. 34
		Storage Bins..................................................................................................................................................................................................................................................... 34
		Winch............................................................................................................................................................................................................................................................ 35
		Radio............................................................................................................................................................................................................................................................ 36
	BRAKE PEDAL.......................................................................................................................................................................................................................................................... 38
		Operation........................................................................................................................................................................................................................................................ 38
	THROTTLE PEDAL....................................................................................................................................................................................................................................................... 38
		Operation........................................................................................................................................................................................................................................................ 38
	BACK-UP ALARM SYSTEM................................................................................................................................................................................................................................................. 39
		Description...................................................................................................................................................................................................................................................... 39
		Operation........................................................................................................................................................................................................................................................ 39
	ROLL-OVER PROTECTIVE STRUCTURE (ROPS) / OCCUPANT PROTECTIVE STRUCTURE (OPS).......................................................................................................................................................................................... 40
		Description...................................................................................................................................................................................................................................................... 40
	OPERATOR CAB (ROPS) / (OPS).......................................................................................................................................................................................................................................... 40
		Description...................................................................................................................................................................................................................................................... 40
		Cab Door......................................................................................................................................................................................................................................................... 41
		Front Wiper...................................................................................................................................................................................................................................................... 41
		Window Washer Reservoir.......................................................................................................................................................................................................................................... 41
		Side Windows..................................................................................................................................................................................................................................................... 42
	NEW VEHICLE BREAK-IN................................................................................................................................................................................................................................................. 43
		Break-In Period.................................................................................................................................................................................................................................................. 43
		Engine And Drivetrain Break-In................................................................................................................................................................................................................................... 43
		Clutches / Belt Break-In......................................................................................................................................................................................................................................... 43
	DAILY INSPECTION..................................................................................................................................................................................................................................................... 44
		Daily Inspection And Maintenance................................................................................................................................................................................................................................. 44
	PRE-STARTING PROCEDURE............................................................................................................................................................................................................................................... 45
		Entering The Utility Vehicle..................................................................................................................................................................................................................................... 45
		Seat Belt Adjustment............................................................................................................................................................................................................................................. 46
		Securing The Side Nets........................................................................................................................................................................................................................................... 47
	STARTING THE ENGINE.................................................................................................................................................................................................................................................. 48
		Key Switch....................................................................................................................................................................................................................................................... 48
		Warming The Engine............................................................................................................................................................................................................................................... 48
	STOPPING THE ENGINE AND LEAVING THE UTILITY VEHICLE.................................................................................................................................................................................................................. 49
		Procedure........................................................................................................................................................................................................................................................ 49
		Emergency Exit (When Equipped With Cab).......................................................................................................................................................................................................................... 50
	VEHICLE LOAD CAPACITY................................................................................................................................................................................................................................................ 51
		Vehicle Load Capacities (Model 3400)............................................................................................................................................................................................................................. 51
		Vehicle Load Capacities (Model 3400XL)........................................................................................................................................................................................................................... 52
	OPERATING PROCEDURE.................................................................................................................................................................................................................................................. 53
		Inspect The Work Area............................................................................................................................................................................................................................................ 53
		Basic Operating Instructions..................................................................................................................................................................................................................................... 53
		Driving Procedure................................................................................................................................................................................................................................................ 54
		Operating On Public Roads........................................................................................................................................................................................................................................ 55
		Operating On Pavement............................................................................................................................................................................................................................................ 55
		Turning Improperly............................................................................................................................................................................................................................................... 55
		Jumps And Stunts................................................................................................................................................................................................................................................. 55
		Operating In Unfamiliar Terrain.................................................................................................................................................................................................................................. 55
		Improper Tire Maintenance........................................................................................................................................................................................................................................ 55
		Operating On Frozen Bodies Of Water.............................................................................................................................................................................................................................. 55
		Unauthorized Use Of The Vehicle.................................................................................................................................................................................................................................. 55
		Driving On Slippery Surfaces..................................................................................................................................................................................................................................... 55
		Driving Uphill................................................................................................................................................................................................................................................... 56
		Driving On A Sidehill (Sidehilling).............................................................................................................................................................................................................................. 56
		Driving Downhill................................................................................................................................................................................................................................................. 56
		Driving Through Water............................................................................................................................................................................................................................................ 57
		Driving Over Obstacles........................................................................................................................................................................................................................................... 57
		Driving In Reverse............................................................................................................................................................................................................................................... 58
		Parking On An Incline............................................................................................................................................................................................................................................ 58
		Hauling Cargo.................................................................................................................................................................................................................................................... 59
		Belt Life........................................................................................................................................................................................................................................................ 59
		Opening And Closing The Tailgate................................................................................................................................................................................................................................. 59
		Raising And Lowering The Cargo Box (With Lift Assist)............................................................................................................................................................................................................ 60
		Raising And Lowering The Cargo Box (With Power Lift Assist)...................................................................................................................................................................................................... 60
		Towing Equipment With The Utility Vehicle........................................................................................................................................................................................................................ 61
		Drive Mode Switch................................................................................................................................................................................................................................................ 62
	TOWING THE UTILITY VEHICLE........................................................................................................................................................................................................................................... 64
		Procedure........................................................................................................................................................................................................................................................ 64
	TRANSPORTING THE UTILITY VEHICLE ON A TRAILER........................................................................................................................................................................................................................ 65
		Loading And Unloading............................................................................................................................................................................................................................................ 65
		Fastening........................................................................................................................................................................................................................................................ 65
PREVENTIVE MAINTENANCE................................................................................................................................................................................................................................................... 67
	MAINTENANCE SAFETY................................................................................................................................................................................................................................................... 71
	PERIODIC MAINTENANCE AND SEVERE USE DEFINITION....................................................................................................................................................................................................................... 73
		Severe Use Definition............................................................................................................................................................................................................................................ 73
	SERVICE SCHEDULE..................................................................................................................................................................................................................................................... 74
		Chart............................................................................................................................................................................................................................................................ 74
	SEAT BELT............................................................................................................................................................................................................................................................ 75
		Inspection And Maintenance....................................................................................................................................................................................................................................... 75
	BACK-UP ALARM SYSTEM................................................................................................................................................................................................................................................. 76
		Description...................................................................................................................................................................................................................................................... 76
		Inspection....................................................................................................................................................................................................................................................... 76
	START INTERLOCK SYSTEM............................................................................................................................................................................................................................................... 77
		Inspecting....................................................................................................................................................................................................................................................... 77
	BRAKE SYSTEM......................................................................................................................................................................................................................................................... 78
		Description...................................................................................................................................................................................................................................................... 78
		Inspection And Maintenance....................................................................................................................................................................................................................................... 78
		Brake Inspection................................................................................................................................................................................................................................................. 79
	SHIFT CABLE ADJUSTMENT............................................................................................................................................................................................................................................... 80
		Inspecting....................................................................................................................................................................................................................................................... 80
		Adjustment....................................................................................................................................................................................................................................................... 80
	FRONT AND REAR SUSPENSION ADJUSTMENTS................................................................................................................................................................................................................................ 81
		Description...................................................................................................................................................................................................................................................... 81
		Shock Absorber Spring Adjustment................................................................................................................................................................................................................................. 81
	STEERING AND SUSPENSION SYSTEM....................................................................................................................................................................................................................................... 82
		Description...................................................................................................................................................................................................................................................... 82
		Inspection And Maintenance....................................................................................................................................................................................................................................... 82
	ROLL-OVER PROTECTIVE STRUCTURE (ROPS) / OCCUPANT PROTECTIVE STRUCTURE (OPS).......................................................................................................................................................................................... 84
		Description...................................................................................................................................................................................................................................................... 84
	AIR CLEANER SERVICE.................................................................................................................................................................................................................................................. 85
		Pre-Filter Element............................................................................................................................................................................................................................................... 85
		Replacing Filter Element......................................................................................................................................................................................................................................... 86
	SEAT................................................................................................................................................................................................................................................................. 87
		Removal And Installation......................................................................................................................................................................................................................................... 87
	FUEL SYSTEM.......................................................................................................................................................................................................................................................... 88
		Fuel Specifications.............................................................................................................................................................................................................................................. 88
		THIS VEHICLE IS CERTIFIED TO OPERATE ON UNLEADED REGULAR GRADE GASOLINE ONLY. A minimum of 87 octane (R+M)/2 method) of the anti-knock index is recommended. The antiknock index is posted on service station pumps in the U.S.A. Fuel containing ethanol ....... 88
		Filling The Fuel Tank............................................................................................................................................................................................................................................ 89
		Filling A Portable Fuel Container................................................................................................................................................................................................................................ 89
	ENGINE LUBRICATION SYSTEM............................................................................................................................................................................................................................................ 90
		Checking And Adding Engine Oil................................................................................................................................................................................................................................... 90
		Engine Oil....................................................................................................................................................................................................................................................... 90
		Removing And Replacing Oil And Filter............................................................................................................................................................................................................................ 91
	ENGINE COOLING SYSTEM................................................................................................................................................................................................................................................ 93
		Checking Level................................................................................................................................................................................................................................................... 93
		Cleaning......................................................................................................................................................................................................................................................... 94
		Removing And Replacing Coolant................................................................................................................................................................................................................................... 95
	ELECTRICAL SYSTEM.................................................................................................................................................................................................................................................... 96
		Description...................................................................................................................................................................................................................................................... 96
		Fuse And Relay Location.......................................................................................................................................................................................................................................... 96
		Battery Maintenance.............................................................................................................................................................................................................................................. 97
		Battery Storage.................................................................................................................................................................................................................................................. 97
		Battery Charging................................................................................................................................................................................................................................................. 97
		Using A Booster Battery (Jump Starting).......................................................................................................................................................................................................................... 98
		Removing And Installing Battery..................................................................................................................................................................................................................................100
		Headlight Replacement............................................................................................................................................................................................................................................101
		Brake Light / Tail Light Replacement.............................................................................................................................................................................................................................101
		Headlight Beam Adjustment........................................................................................................................................................................................................................................102
	CONTINUOUSLY VARIABLE TRANSMISSION (CVT).............................................................................................................................................................................................................................103
		CVT Drying.......................................................................................................................................................................................................................................................103
		CVT Filter.......................................................................................................................................................................................................................................................104
		Inspection Of The CVT............................................................................................................................................................................................................................................105
	DRIVE BELT...........................................................................................................................................................................................................................................................106
		Removal..........................................................................................................................................................................................................................................................106
		Installation.....................................................................................................................................................................................................................................................108
		Belt Inspection..................................................................................................................................................................................................................................................108
		Belt Damage......................................................................................................................................................................................................................................................109
	GEARCASE.............................................................................................................................................................................................................................................................111
		Checking Transmission Fluid......................................................................................................................................................................................................................................111
		Transmission Fluid...............................................................................................................................................................................................................................................111
		Adding Transmission Fluid........................................................................................................................................................................................................................................111
		Removing And Replacing Transmission Fluid........................................................................................................................................................................................................................111
		Checking Front Gearcase Fluid....................................................................................................................................................................................................................................112
		Front Gearcase Fluid.............................................................................................................................................................................................................................................112
		Adding Front Gearcase Fluid......................................................................................................................................................................................................................................112
		Removing And Replacing Front Gearcase Fluid......................................................................................................................................................................................................................112
	VEHICLE IMMERSION....................................................................................................................................................................................................................................................113
		Description......................................................................................................................................................................................................................................................113
	SPARK ARRESTER MUFFLER...............................................................................................................................................................................................................................................114
		Cleaning Procedure...............................................................................................................................................................................................................................................114
	SUPPORTING THE UTILITY VEHICLE ON JACKSTANDS.........................................................................................................................................................................................................................115
		Procedure........................................................................................................................................................................................................................................................115
	TIRE MAINTENANCE.....................................................................................................................................................................................................................................................116
		Tires............................................................................................................................................................................................................................................................116
		Tire Tread Depth.................................................................................................................................................................................................................................................116
		Axle And Wheel Nut Torque........................................................................................................................................................................................................................................116
		Wheel Removal And Installation...................................................................................................................................................................................................................................116
		Mounting.........................................................................................................................................................................................................................................................117
		Tire Pressure....................................................................................................................................................................................................................................................117
	FRONT COVER..........................................................................................................................................................................................................................................................117
		Removal And Installation.........................................................................................................................................................................................................................................117
	WHEEL TOE ALIGNMENT..................................................................................................................................................................................................................................................118
		Toe Adjustment...................................................................................................................................................................................................................................................118
	LUBRICATING THE UTILITY VEHICLE......................................................................................................................................................................................................................................119
		Lubrication Locations............................................................................................................................................................................................................................................119
	UTILITY VEHICLE CLEANING.............................................................................................................................................................................................................................................121
		Washing The Utility Vehicle......................................................................................................................................................................................................................................121
		Polishing The Vehicle............................................................................................................................................................................................................................................121
	UTILITY VEHICLE STORAGE AND RETURN TO SERVICE........................................................................................................................................................................................................................122
		Storage..........................................................................................................................................................................................................................................................122
		Return To Service................................................................................................................................................................................................................................................122
SYSTEM SETUP AND ANALYSIS................................................................................................................................................................................................................................................123
	DIAGNOSTIC SERVICE CODES.............................................................................................................................................................................................................................................125
		Check Engine Light...............................................................................................................................................................................................................................................125
UTILITY VEHICLE SIGN TRANSLATIONS........................................................................................................................................................................................................................................129
	UTILITY VEHICLE SIGN TRANSLATIONS....................................................................................................................................................................................................................................131
		Operation Instruction (7259757)..................................................................................................................................................................................................................................131
		Warning (7259759)................................................................................................................................................................................................................................................131
		Warning (7259755)................................................................................................................................................................................................................................................132
		Warning (7259756)................................................................................................................................................................................................................................................133
		Warning (7016342)................................................................................................................................................................................................................................................134
		Maximum Trailer Weight (7025473).................................................................................................................................................................................................................................134
		Operation Instruction (7018029)..................................................................................................................................................................................................................................134
		Operation Instruction (7259758)..................................................................................................................................................................................................................................135
		Warning (If Equipped With Back-up Alarm) (6737189)...............................................................................................................................................................................................................135
SPECIFICATIONS...........................................................................................................................................................................................................................................................137
	(3400) UTILITY VEHICLE SPECIFICATIONS................................................................................................................................................................................................................................139
		Dimensions.......................................................................................................................................................................................................................................................139
		(3400XL) Dimensions..............................................................................................................................................................................................................................................140
		Performance......................................................................................................................................................................................................................................................141
		Controls.........................................................................................................................................................................................................................................................141
		Engine...........................................................................................................................................................................................................................................................142
		Electrical.......................................................................................................................................................................................................................................................142
		Drive System.....................................................................................................................................................................................................................................................143
		Fluid And Capacities.............................................................................................................................................................................................................................................143
		Tires............................................................................................................................................................................................................................................................143
WARRANTY.................................................................................................................................................................................................................................................................145
	WARRANTY.............................................................................................................................................................................................................................................................147
ALPHABETICAL INDEX.......................................................................................................................................................................................................................................................149

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