Bobcat UV34 UV34XL Utility Vehicle Service Manual 7361390 (10-20) – PDF DOWNLOAD

Description

Bobcat UV34 UV34XL Utility Vehicle Service Manual 7361390 (10-20) – PDF DOWNLOAD

FILE DETAILS:

Bobcat UV34 UV34XL Utility Vehicle Service Manual 7361390 (10-20) – PDF DOWNLOAD

Language : English
Pages : 523
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat UV34 UV34XL Utility Vehicle Service Manual 7361390 (10-20) – PDF DOWNLOAD

(UV34) S/N B4LV11001 & Above
(UV34XL) S/N B4LY11001 & Above

FOREWORD

This manual is for the Toolcat Utility Work Machine mechanic. It provides necessary servicing and adjustment procedures for the Toolcat Utility Work Machine 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 UV34 UV34XL Utility Vehicle Service Manual 7361390 (10-20) – PDF DOWNLOAD

MAINTENANCE SAFETY 3
CONTENTS 5
FOREWORD 7
FOREWORD 9
SAFETY INSTRUCTIONS 11
FIRE PREVENTION 13
Maintenance 13
Operation 13
Electrical 13
Fueling 13
Starting 13
Spark Arrester Exhaust System 13
Welding And Grinding 13
Fire Extinguishers 14
SERIAL NUMBER LOCATIONS 15
Utility Vehicle Serial Number 15
Engine Serial Number 15
DELIVERY REPORT 16
(UV34) UTILITY VEHICLE IDENTIFICATION 17
(UV34XL) UTILITY VEHICLE IDENTIFICATION 18
SAFETY & MAINTENANCE 19
LIFTING AND BLOCKING THE UTILITY VEHICLE 21
Procedure 21
ROLL-OVER PROTECTIVE STRUCTURE (ROPS) / OCCUPANT PROTECTIVE STRUCTURE (OPS) 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
Replacing Filter Element 33
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 42
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
Inspection Of The CVT 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 54
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
Emergency Exit (When Equipped With Cab) 62
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 81
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 110
Parts Identification 112
Transmission Disassembly 115
Gear Cluster Disassembly 118
Snorkel Shaft Removal / Disassembly 119
Bevel Differential Disassembly 121
Bevel Differential Assembly 122
Snorkel Gear Backlash 125
Transmission Assembly 127
DRIVE BELT 133
Removal 133
Installation 134
Belt Inspection 135
Belt Damage 136
CONTINUOUS VARIABLE TRANSMISSION (CVT) 139
CVT System Overview 139
Drive Clutch Operation 139
Driven Clutch Operation 139
CVT Break-In (Drive Belt / Clutches) 139
Maintenance And Inspection 140
Overheating Troubleshooting 141
System Troubleshooting 142
CVT Sealing, Guard And Ducting Components Parts Identification 144
CVT (Outer) Cover Removal And Installation 145
CVT (Inner) Cover Removal And Installation 146
CONTINUOUS VARIABLE TRANSMISSION (CVT) (DRIVE CLUTCH) 147
Removal And Installation 147
Spring Specifications 148
Parts Identification 149
Disassembly 150
Assembly 160
CONTINUOUS VARIABLE TRANSMISSION (CVT) (DRIVEN CLUTCH) 163
Removal And Installation 163
Parts Identification 164
Disassembly 165
Assembly 169
FINAL DRIVE 171
Description 171
Front Bearing Carrier Removal 171
Bearing Removal And Installation 173
Front Bearing Carrier Installation 174
Front Drive Shaft Removal And Installation 176
Rear Carrier Bearing Removal 178
Bearing Removal And Installation 179
Rear Bearing Carrier Installation 181
Rear Drive Shaft Removal And Installation 183
Drive Shaft / CV Joint Handling 183
Outer CV Joint And Boot Removal And Installation 184
Inner Plunging Joint And Boot Removal And Installation 187
Propshaft Removal And Installation 190
Front Gearcase Operation 194
Front Gearcase Removal And Installation 197
Front Gearcase Parts Identification 199
Front Gearcase Disassembly / Inspection 200
Front Gearcase Assembly 204
MAINFRAME 207
ROLL OVER PROTECTIVE STRUCTURE (ROPS) 211
Removal And Installation 211
SEAT 223
Seat Back Removal And Installation 223
Seat Plate Removal And Installation 224
Operator Seat Base Removal And Installation 225
Passenger 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
Control Panel Removal And Installation 232
Storage Panel Removal And Installation 233
Lower Dash Panel Removal And Installation 234
Instrument Cluster Cover Removal And Installation 236
Upper Center Storage Cover Removal And Installation 236
BUMPER COVER 237
Removal And Installation 237
STABILIZER BAT 239
Stabilizer Bar Removal And Installation 239
STEERING COLUMN 241
Description 241
Tilt Steering Shock Removal And Installation 241
Parts Identification 242
Steering Wheel Removal And Installation 243
Steering Wheel / Upper Steering Shaft Removal And Installation 244
Steering Shaft Bearing Replacement 245
Power Steering Unit Removal 246
Power Steering Unit Installation 247
STEERING BOX 249
Removal And Installation 249
FUEL TANK 251
Removal And Installation 251
SHOCKS 255
Rear Shock Removal And Installation 255
Front Shock Removal And Installation 256
Shock Spring Removal And Installation 257
A-ARMS 259
Front Lower A-Arm Removal And Installation 259
Front Upper A-Arm Removal 260
Front Upper A-Arm Installation 262
Rear Lower A-Arm Removal 264
Lower Rear A-Arm Installation 265
Rear Upper A-Arm Removal 266
Rear Upper A-Arm Installation 267
Inspection 269
Ball Joint Removal And Installation 269
TIE ROD 271
Description 271
Removal And Installation 271
Toe Adjustment Procedure 272
TAILGATE 273
Removal And Installation 273
Latch Removal And Installation 274
CARGO BOX 277
Removal And Installation 277
FENDER 279
Upper Fender Removal And Installation 279
Lower Fender Removal And Installation 280
Fender Flare Removal And Installation 281
ROCKER PANEL 283
Removal And Installation 283
FRONT WINDOW 287
Removal And Installation 287
DOOR 289
Removal And Installation 289
DOOR LATCH 291
Removal And Installation 291
Adjustment 291
REAR PANEL 293
Removal And Installation 293
SKID PLATE 295
Removal And Installation 295
FLOORPLATE 299
UV34 299
UV34XL 302
AIR DUCTING 309
UV34 And UV34XL Rear Removal And Installation 309
UV34XL Front Duct Removal And Installation 312
ELECTRICAL SYSTEM & ANALYSIS 315
ELECTRICAL SCHEMATIC 319
ELECTRICAL SYSTEM INFORMATION 320
Glossary Of Electrical Symbols 320
Troubleshooting 323
Description 324
Fuse And Relay Location 324
BATTERY 326
Removal And Installation 326
Servicing 327
Using A Booster Battery (Jump Starting) 328
CHARGING SYSTEM 330
Current Draw – Key OFF 330
Break Even Test 331
Alternator Removal And Installation 332
Belt Adjustment 333
Belt Replacement 333
STARTER SYSTEM 334
Operation 334
Testing 334
Removal And Installation 335
LIGHTS 336
Headlight Removal And Installation 336
Headlight Adjustment 337
Taillight / Brake Light Removal And Installation 338
ELECTRONIC CONTROL MODULE (ECU) 340
Description 340
Removal And Installation 340
VEHICLE SPEED SENSOR 342
Location 342
Testing 342
SWITCH (HEADLIGHT) 344
Location 344
Removal And Installation 344
Testing 345
SWITCH (BRAKE LIGHT) 346
Description 346
Location 346
Removal And Installation 347
Testing 347
SWITCH (AWD / 2WD / TURF) 348
Location 348
Removal And Installation 348
Testing 349
SWITCH (KEY) 350
Location 350
Removal And Installation 350
Ignition Key Switch Testing 351
SWITCH (GEAR SELECTOR) 352
Location 352
Removal And Installation 352
Testing 352
GLOW PLUGS 354
Location 354
Removal And Installation 354
Testing 354
DIFFERENTIAL SOLENOID 356
Description 356
Removal And Installation 356
DIFFERENTIAL SOLENOID (REAR RELAY) 358
Description 358
Removal And Installation 358
BACK-UP ALARM SYSTEM (IF EQUIPPED) 360
Description 360
Inspecting 360
Removal And Installation 361
TEMPERATURE SENSOR 362
Description 362
Testing 362
Removal And Installation 363
Fan Control Circuit Operation / Testing 363
Fan Control Circuit Bypass Test 363
INSTRUMENT CLUSTER 364
Indicator Lamps 364
Information Display 365
Display Area 1 366
Display Area 2 367
Check Engine Light 370
Diagnostic Trouble Codes 371
Pinouts 373
Removal And Installation 374
FUEL SENDER 376
Testing 376
DIAGNOSTIC TESTING 378
Digital Wrench™ Diagnostic Software 378
Digital Wrench™ Diagnostic Connector 379
Digital Wrench™ SmartLink Module Kit – MEL1721 379
Serial Number Location 380
Version And Update ID 380
Updates 381
Digital Wrench™ Feature Map 383
Engine Controller Reprograming (Reflash) 384
ELECTRONIC POWER STEERING (EPS) 388
EPS Operation 388
Power Steering 30A Fuse 388
System Diagnosing 388
EPS Troubleshooting (Power Steering Non-Functional With MIL ON) 389
EPS Troubleshooting (Power Steering Non-Functional With MIL OFF) 390
EPS Troubleshooting (Using Digital Wrench™) 391
ENGINE SERVICE 392
ENGINE INFORMATION 394
Description 394
Specifications 395
Torque Values 399
Troubleshooting 400
Accessible Engine Components 402
Engine Removal And Installation 403
Engine Mount Replacement 409
Compression And Leakage Test 410
THROTTLE SYSTEM 412
Throttle Pedal Removal And Installation 412
Throttle Cable Removal And Installation 413
Throttle Cable Adjustment 415
Throttle Pedal Adjustment 415
MUFFLER 416
Removal And Installation 416
AIR CLEANER 418
Housing Removal And Installation 418
ENGINE COOLING SYSTEM 420
Cooling System Pressure Test 420
Radiator Cap Pressure Test 420
System Bleeding 421
Radiator Cleaning 422
Radiator Removal And Installation 423
Cooling Fan Removal And Installation 425
Thermostat Removal And Installation 426
Water Pump Removal And Installation 427
LUBRICATION SYSTEM 428
Oil Pan Removal And Installation 428
Oil Pump Removal And Installation 429
Oil Pump Inspection 429
Engine Oil Pressure – Testing 430
FUEL SYSTEM 432
Fuel Camshaft Removal And Installation 432
Fuel Camshaft Governor Disassembly And Assembly 432
Fuel Shutoff Solenoid – Checking 433
Fuel Shutoff Solenoid Removal And Installation 433
Fuel Injection Pump Removal And Installation 435
Fuel Injection Pump – Timing 437
Fuel Injector Removal And Installation 439
Fuel Injector Nozzle Pressure – Checking 440
Nozzle Spray Condition 441
Valve Seat Tightness 441
Service Notes 442
Fuel Pump Removal And Installation 442
CYLINDER HEAD 444
Glow Plugs – Testing 444
Glow Plugs Removal And Installation 444
Valve Clearance Adjustment 445
Valve Timing – Checking 446
Cylinder Head Removal And Installation 447
Cylinder Head Disassembly And Assembly 449
Cylinder Head – Servicing 449
Cylinder Head Top Clearance 450
Valve Guide – Checking 450
Reconditioning The Valve And Valve Seat 452
Valve Spring 453
Valve Tappets 454
Rocker Arm And Shaft – Checking 454
CRANKSHAFT AND PISTONS 456
Piston And Connecting Rod Removal And Installation 456
Piston And Connecting Rod – Servicing 459
Cylinder Bore – Checking 461
Connecting Rod Alignment 462
Crankshaft Gear Removal And Installation 462
Crankshaft And Bearings Removal And Installation 463
Crankshaft And Bearings – Servicing 466
CAMSHAFT AND TIMING GEARS 468
Timing Gearcase Cover Removal And Installation 468
Timing Gears Backlash – Checking 470
Idler Gear And Shaft Removal And Installation 470
Camshaft – Servicing 471
Idler Gear And Shaft Servicing 473
FLYWHEEL 474
Flywheel Removal And Installation 474
Ring Gear Removal And Installation 476
HEATING, VENTILATION AND AIR CONDITIONING (HVAC) 478
HEATER SYSTEM 480
Description 480
Components 481
HEATER UNIT 484
Removal And Installation 484
HEATER COIL 486
Removal And Installation 486
BLOWER MOTOR 488
Removal And Installation 488
THERMOSTAT 490
Removal And Installation 490
TROUBLESHOOTING 492
Blower Motor Does Not Operate 492
Blower Motor Operates Normally, But Air Flow Is Insufficient 493
Blower Motor Does Not Operate In All Settings 493
Fan Switch Testing 494
Temperature Potentiometer Testing 494
Heater System Fuse Center 495
SPECIFICATIONS 496
UTILITY VEHICLE SPECIFICATIONS 498
Dimensions 498
Dimensions 499
Performance 500
Controls 500
Engine 501
Electrical 501
Drive System 502
Fluid And Capacities 502
Tires 502
TECHNICAL SERVICE GUIDE SPECIFICATIONS 504
Engine 504
Engine Torques 504
Cooling System 504
TORQUE SPECIFICATIONS FOR BOLTS 506
Torque For General SAE Bolts 506
Torque For General Metric Bolts 507
CONVERSIONS 508
Decimal And Millimeter Equivalent Chart 508
U S To Metric Conversion Chart 509
SERVICE TOOLS REQUIRED 510
Hydraulic Tools 510
Transmission / Clutch / Drive Tools 511
Engine Tools 515
HVAC Tools 519
ALPHABETICAL INDEX 520

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