Bobcat UV34, UV34XL B4LV11001, B4LY11001 & Up 7361390 (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
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
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
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 BAT
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
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
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
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 – 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 Mount Replacement
Compression And Leakage Test
THROTTLE SYSTEM
Throttle Pedal Removal And Installation
Throttle Cable Removal And Installation
Throttle Cable Adjustment
Throttle Pedal 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 And Installation
Oil Pump Inspection
Engine Oil Pressure – Testing
FUEL SYSTEM
Fuel Camshaft Removal And Installation
Fuel Camshaft Governor Disassembly And Assembly
Fuel Shutoff Solenoid – Checking
Fuel Shutoff Solenoid Removal And Installation
Fuel Injection Pump Removal And Installation
Fuel Injection Pump – Timing
Fuel Injector Removal And Installation
Fuel Injector Nozzle Pressure – Checking
Nozzle Spray Condition
Valve Seat Tightness
Service Notes
Fuel Pump Removal And Installation
CYLINDER HEAD
Glow Plugs – Testing
Glow Plugs Removal And Installation
Valve Clearance Adjustment
Valve Timing – Checking
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
Cylinder Head – Servicing
Cylinder Head Top Clearance
Valve Guide – Checking
Reconditioning The Valve And Valve Seat
Valve Spring
Valve Tappets
Rocker Arm And Shaft – Checking
CRANKSHAFT AND PISTONS
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod – Servicing
Cylinder Bore – Checking
Connecting Rod Alignment
Crankshaft Gear Removal And Installation
Crankshaft And Bearings Removal And Installation
Crankshaft And Bearings – Servicing
CAMSHAFT AND TIMING GEARS
Timing Gearcase Cover Removal And Installation
Timing Gears Backlash – Checking
Idler Gear And Shaft Removal And Installation
Camshaft – Servicing
Idler Gear And Shaft Servicing
FLYWHEEL
Flywheel Removal And Installation
Ring Gear Removal And Installation
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
HEATER SYSTEM
Description
Components
HEATER UNIT
Removal And Installation
HEATER COIL
Removal And Installation
BLOWER MOTOR
Removal And Installation
THERMOSTAT
Removal And Installation
TROUBLESHOOTING
Blower Motor Does Not Operate
Blower Motor Operates Normally, But Air Flow Is Insufficient
Blower Motor Does Not Operate In All Settings
Fan Switch Testing
Temperature Potentiometer Testing
Heater System Fuse Center
SPECIFICATIONS
UTILITY VEHICLE SPECIFICATIONS
Dimensions
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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