Bobcat 3400, 3400XL Utility Vehicle 7255694 (03-21) (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
Biodiesel Blend Fuel
Filling The Fuel Tank
Fuel Filter
Removing Air From The Fuel System
Filling A Portable Fuel Container
ENGINE LUBRICATION SYSTEM
Checking And Adding Engine Oil
Engine Oil Chart
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
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
ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SCHEMATIC
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
Alternator Removal And Installation
Belt Adjustment
Belt Replacement
STARTER SYSTEM
Operation
Testing
Removal And Installation
FUEL SOLENOID
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
VEHICLE SPEED SENSOR
Location
Testing
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
GLOW PLUGS
Location
Removal And Installation
Testing
DIFFERENTIAL SOLENOID
Description
Removal And Installation
DIFFERENTIAL SOLENOID (REAR RELAY)
Description
Removal And Installation
BACK-UP ALARM SYSTEM (IF EQUIPPED)
Description
Inspecting
Removal And Installation
TEMPERATURE SENSOR
Description
Testing
Removal And Installation
Fan Control Circuit Operation / Testing
Fan Control Circuit Bypass Test
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 And Leakage Test
Cylinder Head Diagnostics
Fuel Limiter
Idle Speed Setting
Timing Belt Inspection
THROTTLE SYSTEM
Throttle Pedal Removal And Installation
Throttle Cable Removal And Installation
Throttle Freeplay
Inspection And Maintenance
Throttle Freeplay Adjustment
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 Removal And Installation
LUBRICATION SYSTEM
Oil Pan Removal And Installation
Oil Pump Removal
Oil Pump Inspection
Oil Pump Installation
Engine Oil Pressure – Testing
FUEL SYSTEM
Service Notes
Operation
Initial Priming / Starting Procedure
Fuel Line Removal / Installation
Fuel Tank Removal
Fuel Tank Installation
Fuel Pump
Fuel Sender
Injector Timing
ENGINE DISASSEMBLY AND INSPECTION
Crankcase Vacuum Regulator Valve Removal
Intake Manifold Removal
Exhaust Manifold Removal
Drive Pulley Removal
Flywheel Removal
Timing Belt Removal
Timing Pulleys Removal
Water Pump Removal
Speed Governor Removal
Rocker Arm Cover Removal
Fuel Rail Removal
Unit Injector Removal
Rocker Arm Assembly Removal
Camshaft Removal
Camshaft Inspection
Cylinder Head Removal
Valve Removal
Valve And Spring Inspection
Pre-Combustion Chamber Removal
Piston And Connecting Rod Removal
Piston And Piston Ring Inspection
Connecting Rod Inspection
Cylinder Inspection
Crankshaft Removal
Crankshaft Inspection
ENGINE ASSEMBLY
Crankshaft Installation
Piston And Connecting Rod Installation
Oil Pan Installation
Pre-Combustion Chamber Installation
Valve Installation
Cylinder Head Installation
Camshaft Installation
Rocker Arm Assembly Installation
Valve / Rocker Arm Clearance
Speed Governor Installation
Unit Injector Installation
Fuel Rail Installation
Rocker Arm Cover Installation
Oil Pump Installation
Water Pump Installation
Timing Pulleys Installation
Timing Belt Installation
Flywheel Installation
Drive Pulley Installation
Starter Installation
Exhaust Manifold Installation
Intake Manifold Installation
Crankcase Vacuum Regulator Valve Installation
SPECIFICATIONS
3400 UTILITY VEHICLE SPECIFICATIONS
Dimensions (S/N B3FK16999 & Below)
Dimensions (S/N B3FK17001 & Above)
(3400XL) Dimensions (S/N B3FM16999 & Below)
(3400XL) Dimensions (S/N B3FM17001 & 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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