Bobcat UV34, UV34XL Utility Vehicle 7393733 (Preview)
MAINTENANCE SAFETY
CONTENTS
FOREWORD
FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
Maintenance
Operation
Electrical
Fueling
Starting
Spark Arrester Exhaust System
Welding And Grinding
Fire Extinguishers
SERIAL NUMBER LOCATIONS
Utility Vehicle Serial Number
Engine Serial Number
DELIVERY REPORT
(UV34) UTILITY VEHICLE IDENTIFICATION
(UV34XL) UTILITY VEHICLE IDENTIFICATION
SAFETY & MAINTENANCE
LIFTING AND BLOCKING THE UTILITY VEHICLE
Procedure
ROLL-OVER PROTECTIVE STRUCTURE (ROPS) / OCCUPANT PROTECTIVE STRUCTURE (OPS)
Description
TRANSPORTING THE UTILITY VEHICLE ON A TRAILER
Loading And Unloading
Fastening
TOWING THE UTILITY VEHICLE
Procedure
SERVICE SCHEDULE
Maintenance Intervals
AIR CLEANER SERVICE
Replacing Filter Element
Air Intake And Air Breather Inspection
ENGINE COOLING SYSTEM
Checking Level
Cleaning
Removing And Replacing Coolant
FUEL SYSTEM
Fuel Specifications
Filling The Fuel Tank
Removing Air From The Fuel System
Fuel Filter
Filling A Portable Fuel Container
Fuel Leak Inspection
ENGINE LUBRICATION SYSTEM
Checking And Adding Engine Oil
Engine Oil
Removing And Replacing Oil And Filter
CONTINUOUS VARIABLE TRANSMISSION (CVT)
CVT Drying
Inspection Of The CVT
GEARCASE
Checking Transmission Fluid
Transmission Fluid
Adding Transmission Fluid
Removing And Replacing Transmission Fluid
Checking Front Gearcase Fluid
Front Gearcase Fluid
Adding Front Gearcase Fluid
Removing And Replacing Front Gearcase Fluid
TIRE MAINTENANCE
Tires
Tire Tread Depth
Axle And Wheel Nut Torque
Wheel Removal And Installation
Mounting
Tire Pressure
SPARK ARRESTER MUFFLER
Cleaning Procedure
UTILITY VEHICLE STORAGE AND RETURN TO SERVICE
Storage
Return To Service
STOPPING THE ENGINE AND LEAVING THE UTILITY VEHICLE
Procedure
Emergency Exit (When Equipped With Cab)
SEAT BELT
Inspection And Maintenance
LUBRICATING THE UTILITY VEHICLE
Lubrication Locations
DRIVE SYSTEM
BRAKE
General Specifications
Torque Specifications
System Service Notes
Noise Troubleshooting
System Troubleshooting
Hydraulic Brake System Operation
System Parts Identification
Master Cylinder Removal And Installation
Foot Brake Pedal Removal And Installation
Bleeding / Fluid Removal And Installation
Brake Inspection
Brake Pad Inspection
Burnishing
BRAKE (FRONT)
Pad Removal
Pad Inspection
Pad Assembly / Installation
Caliper Removal
Caliper Parts Identification
Caliper Disassembly
Caliper Inspection
Caliper Assembly
Caliper Installation
Disc Runout
Disc Inspection
Disc Removal And Installation
BRAKE (REAR)
Caliper Removal
Pad Removal
Pad Inspection
Pad Installation
Caliper Parts Identification
Caliper Disassembly
Caliper Inspection
Caliper Assembly
Caliper Installation
Disc Runout
Disc Inspection
Disc Removal And Installation
TRANSMISSION
General Operation
System Troubleshooting
Shift Lever Removal And Installation
Shift Cable Inspecting
Shift Cable Adjustment
Shift Cable Removal And Installation
Removal
Installation
Parts Identification
Transmission Disassembly
Gear Cluster Disassembly
Snorkel Shaft Removal / Disassembly
Bevel Differential Disassembly
Bevel Differential Assembly
Snorkel Gear Backlash
Transmission Assembly
DRIVE BELT
Removal
Installation
Belt Inspection
Belt Damage
CONTINUOUS VARIABLE TRANSMISSION (CVT)
CVT System Overview
Drive Clutch Operation
Driven Clutch Operation
CVT Break-In (Drive Belt / Clutches)
Maintenance And Inspection
Overheating Troubleshooting
System Troubleshooting
CVT Sealing, Guard And Ducting Components Parts Identification
CVT (Outer) Cover Removal And Installation
CVT (Inner) Cover Removal And Installation
CONTINUOUS VARIABLE TRANSMISSION (CVT) (DRIVE CLUTCH)
Removal And Installation
Spring Specifications
Parts Identification
Disassembly
Assembly
CONTINUOUS VARIABLE TRANSMISSION (CVT) (DRIVEN CLUTCH)
Removal And Installation
Parts Identification
Disassembly
Assembly
FINAL DRIVE
Description
Front Bearing Carrier Removal
Front Bearing Removal And Installation
Front Bearing Carrier Installation
Front Drive Shaft Removal And Installation
Rear Carrier Bearing Removal
Bearing Removal And Installation
Rear Bearing Carrier Installation
Rear Drive Shaft Removal And Installation
Drive Shaft / CV Joint Handling
Outer CV Joint And Boot Removal And Installation
Inner Plunging Joint And Boot Removal And Installation
Propshaft Removal And Installation
Front Gearcase Operation
Front Gearcase Removal And Installation
Front Gearcase Parts Identification
Front Gearcase Disassembly / Inspection
Front Gearcase Assembly
MAINFRAME
ROLL-OVER PROTECTIVE STRUCTURE (ROPS)
Removal And Installation
SEAT
Seat Back Removal And Installation
Seat Plate Removal And Installation
Operator Seat Base Removal And Installation
Passenger Seat Base Removal And Installation
Seat Belt Removal And Installation
DASH
Front Access Cover Removal And Installation
Upper Dash Panel Removal And Installation
Control Panel Removal And Installation
Storage Panel Removal And Installation
Lower Dash Panel Removal And Installation
Instrument Cluster Cover Removal And Installation
Upper Center Storage Cover Removal And Installation
BUMPER COVER
Removal And Installation
STABILIZER BAR
Removal And Installation
STEERING COLUMN
Description
Tilt Steering Shock Removal And Installation
Parts Identification
Steering Wheel Removal And Installation
Steering Wheel / Upper Steering Shaft Removal And Installation
Steering Shaft Bearing Replacement
Power Steering Unit Removal
Power Steering Unit Installation
STEERING BOX
Removal And Installation
FUEL TANK
Removal And Installation
SHOCKS
Rear Shock Removal And Installation
Front Shock Removal And Installation
Shock Spring Removal And Installation
A-ARMS
Front Lower A-Arm Removal And Installation
Front Upper A-Arm Removal
Front Upper A-Arm Installation
Rear Lower A-Arm Removal
Lower Rear A-Arm Installation
Rear Upper A-Arm Removal
Rear Upper A-Arm Installation
Inspection
Ball Joint Removal And Installation
TIE ROD
Description
Removal And Installation
Toe Adjustment Procedure
TAILGATE
Removal And Installation
Latch Removal And Installation
CARGO BOX
Removal And Installation
FENDER
Upper Fender Removal And Installation
Lower Fender Removal And Installation
Fender Flare Removal And Installation
ROCKER PANEL
Removal And Installation
FRONT WINDOW
Removal And Installation
DOOR
Removal And Installation
DOOR LATCH
Removal And Installation
Adjustment
REAR PANEL
Removal And Installation
SKID PLATE
Removal And Installation
FLOORPLATE
UV34
UV34XL
AIR DUCTING
UV34 And UV34XL Rear Removal And Installation
UV34XL Front Duct Removal And Installation
ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SCHEMATIC
3400
S/N B53611001 & Above
S/N B4LW11001 & Above
3400XL
S/N B53711001 & Above
S/N B4LZ11001 & Above
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols
Troubleshooting
Description
Fuse And Relay Location
BATTERY
Removal And Installation
Servicing
Using A Booster Battery (Jump Starting)
CHARGING SYSTEM
Current Draw – Key OFF
Break Even Test
Testing Flow Chart
STARTER SYSTEM
Solenoid Testing
Starter Removal And Installation
Starting Testing Flow Chart
REGULATOR / RECTIFIER
Location
Removal And Installation
LIGHTS
Headlight Removal And Installation
Headlight Adjustment
Taillight / Brake Light Removal And Installation
ELECTRONIC CONTROL MODULE (ECU)
Description
Removal And Installation
IGNITION COIL
Description
Testing
Ignition Coil Test
Removal And Installation
ELECTRONIC FUEL INJECTION SENSORS
Crank Position Sensor (CPS)
Temp / Manifold Absolute Pressure Sensor (T-MAP)
Temp / Manifold Absolute Pressure Sensor (T-MAP)
Engine Coolant Temperature Sensor (ECT)
Accelerator Position Sensor (APS)
Oxygen Sensor
SWITCH (HEADLIGHT)
Location
Removal And Installation
Testing
SWITCH (BRAKE LIGHT)
Description
Location
Removal And Installation
Testing
SWITCH (AWD / 2WD / TURF)
Location
Removal And Installation
Testing
SWITCH (KEY)
Location
Removal And Installation
Ignition Key Switch Testing
SWITCH (GEAR SELECTOR)
Location
Removal And Installation
Testing
SWITCH (SEAT BELT)
Description
Testing
Removal And Installation
VEHICLE SPEED SENSOR
Location
Testing
Removal And Installation
DIFFERENTIAL SOLENOID
Description
Removal And Installation
BACK-UP ALARM SYSTEM (IF EQUIPPED)
Description
Inspecting
Removal And Installation
ELECTRONIC THROTTLE CONTROL (ETC)
Description
Testing
Removal And Installation
ETC Learn Procedure
INSTRUMENT CLUSTER
Indicator Lamps
Information Display
Display Area 1
Display Area 2
Check Engine Light
Diagnostic Trouble Codes
Pinouts
Removal And Installation
FUEL SENDER
Testing
DIAGNOSTIC TESTING
Digital Wrench™ Diagnostic Software
Digital Wrench™ Diagnostic Connector
Digital Wrench™ SmartLink Module Kit – MEL1722
Serial Number Location
Version And Update ID
Updates
Digital Wrench™ Feature Map
Engine Controller Reprograming (Reflash)
ELECTRONIC POWER STEERING (EPS)
EPS Operation
Power Steering 30A Fuse
System Diagnosing
EPS Troubleshooting (Power Steering Non-Functional with MIL ON)
EPS Troubleshooting (Power Steering Non-Functional with MIL OFF)
EPS Troubleshooting (Using Digital Wrench™)
ENGINE SERVICE
ENGINE INFORMATION
Description
Specifications
Torque Values
Troubleshooting
Accessible Engine Components
Engine Removal
Engine Installation
Engine Installation Notes
Engine Harness Routing
Injector Harness Routing
Ignition Harness Routing
Left Rear Engine Bay Harness Routing
Transmission Harness Routing
Front Engine Mount Removal And Installation
Cylinder Leakage Testing
THROTTLE SYSTEM
Description
Testing
Removal And Installation
EXHAUST SYSTEM
Exhaust System Components
Muffler Removal And Installation
Exhaust Manifold Removal And Installation
INTAKE SYSTEM
Intake System Components
Air Box Removal And Installation
Throttle Body Removal And Installation
Intake Manifold Removal And Installation
Intake Manifold Adapter Removal And Installation
ENGINE COOLING SYSTEM
Cooling System Components
Cooling System Pressure Test
Radiator Cap Pressure Test
System Bleeding
Radiator Cleaning
Radiator Removal And Installation
Cooling Fan Removal And Installation
Thermostat Removal And Installation
Water Pump Removal
Water Pump Parts Identification
Water Pump Disassembly
Water Pump Assembly
Water Pump Installation
Oil Cooler Removal And Installation
LUBRICATION SYSTEM
Engine Oil Pressure – Testing
FUEL SYSTEM
Fuel System Operation
System Trouble Shooting
Relieving Fuel Pressure
Initial Priming / Starting Procedure
Fuel Line (Quick Connect) Removal And Installation
Fuel Pump Test
Fuel Pump Removal
Fuel Pump Installation
Fuel Injector Description
Fuel Injector Troubleshooting
Fuel Injector Test
Fuel Injector Removal
Fuel Injector Installation
EVAPORATOR SYSTEM
Fuel Vent Line Routing (EVAP Models)
Carbon Canister Removal
Carbon Canister Installation
Purge Valve Removal And Installation
Slide the valve off the bracket.
ENGINE DISASSEMBLY / INSPECTION
Checking Engine Timing
Engine Timing Adjustment
Valve Cover Removal
Camshaft Removal
Camshaft Inspection
Cylinder Head Removal
Valve Removal
Valve Inspection
Valve Seat Reconditioning
Valve Seat Inspection
Renewing Valve Seats
Cylinder Head Inspection
Combustion Chamber Cleaning
Oil Filter Adapter Removal
Oil Pan Removal
Oil Pump Removal
Upper Crankcase Removal
Balance Shaft Removal
Crankshaft Removal
Crankshaft Inspection
Connecting Rod Bearing Selection
Crankshaft Main Bearing Selection
Cylinder / Piston Removal
Cylinder Inspection
Crankcase Inspection
Piston Disassembly
Piston Ring Removal
Piston Ring to Groove Clearance Inspection
Piston Ring Installed Gap
Piston to Cylinder Clearance
Connecting Rod Inspection
Stator Cover Removal
Flywheel Removal
Starter One-Way Clutch Removal
Starter One-Way Clutch Inspection
ENGINE ASSEMBLY
Starter One-Way Clutch Installation
Flywheel Installation
Stator Cover Installation
Piston Assembly
Cylinder / Piston Installation
Crankshaft Installation
Upper Crankcase Installation
Oil Pump Installation
Oil Pan Installation
Oil Filter Adapter Installation
Valve Installation
Cylinder Head Installation
Valve Clearance Check / Inspection
Valve Clearance Adjustment
Tappet Selection
Intake Valve Lash – Tappet Selection Matrix
Exhaust Valve Lash – Tappet Selection Matrix
Camshaft Installation
Camshaft Chain Tensioner Installation
Valve Cover Installation
CRANKSHAFT PTO SEAL
Removal
Installation
SPECIFICATIONS
UTILITY VEHICLE SPECIFICATIONS
Machine Dimensions
Machine Dimensions
Performance
Controls
Engine
Electrical
Drive System
Fluid And Capacities
Tires
TECHNICAL SERVICE GUIDE SPECIFICATIONS
Engine
Engine Torques
Cooling System
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
Torque For General Metric Bolts
CONVERSIONS
Decimal And Millimeter Equivalent Chart
U.S. To Metric Conversion Chart
SERVICE TOOLS REQUIRED
Hydraulic Tools
Transmission / Clutch / Drive Tools
Engine Tools
HVAC Tools
ALPHABETICAL INDEX
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