Bobcat 3400, 3400XL Utility Vehicle 7255691 (02-20) (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
UTILITY VEHICLE IDENTIFICATION (3400)
UTILITY VEHICLE IDENTIFICATION (3400XL)
SAFETY & MAINTENANCE
LIFTING AND BLOCKING THE UTILITY VEHICLE
Procedure
ROLLOVER PROTECTIVE STRUCTURE (ROPS)
Description
TRANSPORTING THE UTILITY VEHICLE ON A TRAILER
Loading And Unloading
Fastening
TOWING THE UTILITY VEHICLE
Procedure
SERVICE SCHEDULE
Maintenance Intervals
AIR CLEANER SERVICE
Pre-Filter Element
Replacing Filter Element
ENGINE COOLING SYSTEM
Checking Level
Cleaning
Removing And Replacing Coolant
FUEL SYSTEM
Fuel Specifications
Filling The Fuel Tank
Filling A Portable Fuel Container
ENGINE LUBRICATION SYSTEM
Checking And Adding Engine Oil
Engine Oil
Removing And Replacing Oil And Filter
CONTINUOUS VARIABLE TRANSMISSION (CVT)
CVT Drying
CVT Filter
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
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 And Installation
Parts Identification
Transmission Disassembly
Gear Cluster Disassembly
Snorkel Shaft Removal / Disassembly
Planetary Differential Disassembly
Planetary 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
Bearing Carrier Removal
Bearing Removal And Installation
Bearing Carrier Installation
Front Drive Shaft Removal And 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
Propshaft U-Joint Disassembly
Propshaft U-Joint Assembly
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
OPERATOR SEAT
Seat Back Removal And Installation
Seat Base Removal And Installation
Seat Belt Removal And Installation
DASH
Front Access Cover Removal And Installation
Upper Dash Panel Removal And Installation
Lower Dash Panel Removal And Installation
Storage Panel Removal And Installation
BUMPER COVER
Removal And Installation
REAR SUSPENSION LINK AND AXLE BRACE
Upper Suspension Link Removal And Installation
Lower Suspension Link Removal And Installation
Axle Brace Removal And Installation
Rear Axle Bearing Replacement
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
Lower A-Arm Removal And Installation
Upper A-Arm Removal
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
Removal And Installation (Front)
Removal And Installation (Rear)
Flare Removal And Installation
FRONT WINDOW
Removal And Installation
DOOR
Removal And Installation
DOOR LATCH
Removal And Installation
Adjustment
REAR PANEL
Removal And Installation
ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SCHEMATICS
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols
Troubleshooting
Description
Fuse And Relay Location
BATTERY
Removal And Installation
Servicing
Using A Booster Battery (Jump Starting)
Battery Terminal Blocks
CHARGING SYSTEM
Current Draw – Key OFF
Break Even Test
Stator Testing
Stator Removal
Stator Installation
Testing Flow Chart
STARTER SYSTEM
Testing
Removal And Installation
Parts Identification
Starting Testing Flow Chart
REGULATOR / RECTIFIER
Location
Removal And Installation
Testing
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)
Engine Coolant Temperature Sensor (ECT)
Pedal Position Sensor (PPS)
SWITCH (HEADLIGHT)
Location
Removal And Installation
Testing
SWITCH (BRAKE LIGHT)
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
TEMPERATURE SENSOR
Description
Testing
Removal And Installation
DIFFERENTIAL SOLENOID
Description
Removal And Installation
DIFFERENTIAL SOLENOID (REAR RELAY)
Description
Removal And Installation
BACK-UP ALARM SYSTEM
Description
Inspection
Removal And Installation
ELECTRONIC THROTTLE CONTROL (ETC)
Description
Testing
Removal And Installation
INSTRUMENT CLUSTER
Information Display
Pinouts
Information Display Area
Diagnostic Trouble Codes
Removal And Installation
FUEL SENDER
Testing
DIAGNOSTIC TESTING
Digital Wrench™ Diagnostic Software
Digital Wrench™ Diagnostic Connector
Digital Wrench™ SmartLink Module Kit – MEL1721
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 And Installation
Engine Installation Notes
Engine Mount Replacement
Compression – Checking
THROTTLE SYSTEM
Description
Testing
Removal And Installation
MUFFLER
Removal And Installation
AIR CLEANER
Housing Removal And Installation
ENGINE COOLING SYSTEM
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 Cover And Impeller Service
Water Pump Mechanical Seal / Oil Seal Removal
Water Pump Mechanical Seal / Oil Seal 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 Pressure Regulator Description
Fuel Pressure Regulator Test
Fuel Pressure Regulator Replacement
Fuel Pump Removal And Installation
Fuel Injector Description
Fuel Injector Troubleshooting
Fuel Injector Test
Fuel Injector Removal And Installation
FUEL SYSTEMS DIAGNOSTICS
Instrument Cluster Trouble Code Display
ENGINE DISASSEMBLY / INSPECTION
Setting Top-Dead-Center (TDC)
Valve Cover Removal
Camshaft / Carrier Removal
Camshaft Sprocket Inspection
Camshaft Inspection
Exhaust Camshaft Decompression Mechanism
Cam Chain And Guide Service
Cylinder Head Removal
Cylinder Head Disassembly
Cylinder Head Inspection
Cylinder Head Warp Inspection
Valve Inspection
Combustion Chamber Cleaning
Valve Seat Reconditioning
Cylinder Removal
Cylinder Inspection
Piston Removal
Piston-To-Cylinder Clearance
Piston / Rod Inspection
Piston Ring Installed Gap
Honing to Oversize
Crankcase Disassembly
Starter One-Way Clutch Removal / Inspection
Stator Removal
Oil Pump Removal
Oil Pump Assembly
Crankcase Breather Service
Crankcase Separation
Balance Shaft Removal / Inspection
Crankshaft Removal
Crankshaft Inspection
PTO Side Crankcase Bearing Service
MAG Side Crankcase Bearing Service
Oil Pickup Assembly Inspection
Oil Pressure Regulator (Bypass) Valve Inspection
Crankcase Inspection
ENGINE ASSEMBLY
Crankcase Assembly – PTO Side
Balance Shaft Installation / Timing
Final Crankcase Assembly
Piston Ring Installation
Piston / Connecting Rod Assembly
Cylinder Installation
Cylinder Head Assembly
Valve Sealing Test
Cylinder Head Installation
Valve Clearance Check / Adjustment
Intake Valve Lash – Tappet Selection Matrix
Exhaust Valve Lash – Tappet Selection Matrix
Camshaft Installation / Timing
Valve Cover Installation
Starter One-Way Clutch Installation
Flywheel Installation
Stator And Stator Cover Installation
SPECIFICATIONS
3400 UTILITY VEHICLE SPECIFICATIONS
Dimensions (B3FL16999 & Below)
Dimensions (B3FL17001 & Above)
(3400XL) Dimensions (B3FN16999 & Below)
(3400XL) Dimensions (B3FN17001 & Above)
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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