Bobcat 3400, 3400XL Utility Vehicle Workshop Repair Service Manual – 6989602

(S/N: AJNT11001 & Above – S/N: AJNV11001 & Above)
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This workshop repair service manual PDF download for the 3400 & 3400XL Bobcat Utility Vehicle has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

Bobcat Utility Vehicle 3400, 3400XL
S/N: AJNT11001 & Above
S/N: AJNV11001 & Above

TABLE OF CONTENTS :

SAFETY & MAINTENANCE
DRIVE SYSTEM
MAINFRAME
ELECTRICAL SYSTEM & ANALYSIS
ENGINE SERVICE
SPECIFICATIONS
ALPHABETICAL INDEX
SERVICE MANUAL REVISION

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : 6989602 (9-10)
Total Pages : 495

This manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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MAINTENANCE SAFETY
CONTENTS
FOREWORD
FOREWORD
SAFETY INSTRUCTIONS
FIRE PREVENTION
Maintenance
Operation
Electrical
Fueling
Starting
Spark Arrestor 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
Chart
AIR CLEANER SERVICE
Pre-Filter Element
Replacing Filter Element
Engine Breather Filter
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
Oil Pump Priming Procedure
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 ARRESTOR MUFFLER
Cleaning Procedure
UTILITY VEHICLE STORAGE AND RETURN TO SERVICE
Storage
Return To Service
STOPPING THE ENGINE AND LEAVING THE UTILITY VEHICLE
Procedure

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 Installation
Caliper Removal
Caliper Parts Identification
Caliper Disassembly
Caliper Inspection
Caliper Assembly
Caliper Installation
Disc Inspection
Disc Removal And Installation
BRAKE (REAR) (S/N AJNT11001 & ABOVE)
Pad Removal
Pad Installation
Caliper Removal
Caliper Parts Identification
Caliper Disassembly
Caliper Inspection
Caliper Assembly
Caliper Installation
Disc Inspection
Disc Removal And Installation
BRAKE (REAR) (S/N AJNV11001 & ABOVE)
Pad Removal
Pad Installation
Caliper Removal
Caliper Parts Identification
Caliper Disassembly
Caliper Inspection
Caliper Assembly
Caliper Installation
Disc Inspection
Disc Removal And Installation
BRAKE (PARK)
Inspection And Maintenance
Parts Identification
Lever Removal And Installation
Cable Tension Inspection
Cable Adjustment
Caliper Removal
Caliper Parts Identification
Caliper Disassembly
Caliper Inspection
Pad Installation
Caliper Assembly
Disc Inspection
Disc Removal And Installation
Caliper Installation
GEARCASE (TRANSMISSION)
General Operation
System Troubleshooting
Shift Lever Removal And Installation
Shift Cable Inspecting
Shift Cable Adjustment
Removal And Installation
Parts Identification
Disassembly
Gear Cluster Disassembly
Snorkel Shaft Removal / Disassembly
Snorkel / Output Gear Backlash Procedure
Assembly
DRIVE BELT
Removal
Installation
Belt Inspection
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
Clutch Alignment
Clutch Offset
Clutch Center Distance
CONTINUOUS VARIABLE TRANSMISSION (CVT) (DRIVE CLUTCH)
Removal And Installation
Spring Specifications
Shift Weights
Parts Identification
Inspection
Button To Tower Clearance Inspection
Disassembly
Moveable Sheave Bushing Removal And Installation
Clutch Cover Bushing Removal And Installation
Assembly
CONTINUOUS VARIABLE TRANSMISSION (CVT) (DRIVEN CLUTCH)
Removal And Installation
Parts Identification
Disassembly
Bushing Removal
Bushing Installation
Assembly
FINAL DRIVE
Description
Front Hub Removal
Hubstrut Bearing Removal And Installation
Front Hub Installation
Front Drive Shaft Removal And Installation
Outer CV Joint And Boot (Front Drive Shaft) Removal And Installation
Propshaft Removal And Installation (S/N AJNT11001 & Above)
Propshaft Removal And Installation (S/N AJNV11001 & Above)
Support Bearing Removal And Installation (S/N AJNV11001 & Above)
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 / Inspection
Setting Ring Gear Backlash
Rear Bearing Carrier Inspection
Rear Bearing Carrier Removal
Rear Bearing Carrier Disassembly And Assembly
Rear Bearing Carrier Installation
Rear Drive Shaft Removal And Installation
Outer CV Joint And Boot (Rear Drive Shaft) Removal And Installation
Inner Plunging Joint And Boot (Rear Drive Shaft) Removal And Installation

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
Left Dash Removal And Installation
Right Dash Removal And Installation
Center Dash Removal And Installation
BUMPER COVER
Removal And Installation
STRUT
Strut Cartridge Removal And Installation
STEERING COLUMN
Removal And Installation
STEERING BOX
Removal And Installation
FUEL TANK
Removal And Installation
SHOCKS
Removal And Installation
Shock Spring Removal And Installation
CONTROL ARMS
Removal And Installation (Rear Lower Arm)
Removal And Installation (Upper Arm)
Removal And Installation (Front Arm)
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
REAR STABILIZER BAR / LINKAGE
Removal And Installation
Inspection

ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SCHEMATIC
ELECTRICAL SYSTEM INFORMATION
Glossary Of Electrical Symbols
Description
Troubleshooting
Fuse And Relay Location – Cab Panel
BATTERY
Removal And Installation
Servicing
Using A Booster Battery (Jump Starting)
CHARGING SYSTEM
Current Draw – Key OFF
Break Even Test
Stator Testing
Stator Plate Assembly Removal
Stator Plate Assembly 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
Tail Light / Brake Light Removal And Installation
Indicator Lamp Removal And Installation
Malfunction Indicator Light (MEL) Removal And Installation
ELECTRONIC CONTROL MODULE (ECU)
Description
Removal And Installation
IGNITION COIL
Description
Testing
Primary Test
Secondary Tests
Removal And Installation
ELECTRONIC FUEL INJECTION SENSORS
Crank Position Sensor (CPS) Description
Manifold Absolute Pressure Sensor (MAP)
Intake Air Temperature Sensor (IAT)
Idle Air Control (IAC)
Throttle Position Sensor (TPS)
SWITCH (HEADLIGHT)
Removal And Installation
Testing
SWITCH (BRAKE LIGHT)
Removal And Installation
Testing
SWITCH (PARKING BRAKE)
Description
Removal And Installation
Testing
SWITCH (AWD / 2WD / TURF)
Removal And Installation
Testing
SWITCH (IGNITION)
Removal And Installation
SWITCH (GEAR SELECTOR)
Removal And Installation
TEMPERATURE SENSOR
Description
Testing
Removal And Installation
DIFFERENTIAL SOLENOID
Description
Removal And Installation
DIFFERENTIAL SOLENOID (REAR RELAY)
Description
Removal And Installation
AIR SOLENOID
Description
Removal And Installation
HOURMETER
Removal And Installation
BACK-UP ALARM SYSTEM (IF EQUIPPED)
Description
Inspecting
Removal And Installation
DIAGNOSTIC TESTING
Blink Codes
Diagnostic “Blink Codes” Chart
Digital Wrench™ Diagnostic Software
Digital Wrench™ Diagnostic Connector
Digital Wrench™ SmartLink Module Kit – MEL 1721
Serial Number Location
Version And Update ID
Updates
Digital Wrench™ Feature Map
Engine Controller Reprograming (Reflash)

ENGINE SERVICE
ENGINE INFORMATION
Description
Specifications (Engine Model EH460PLE040)
Torque Values
Troubleshooting
Accessible Engine Components
Engine Removal And Installation
Engine Installation Notes
Engine Mount Replacement
Compression – Checking
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
Radiator Removal And Installation
Cooling Fan Removal And Installation
Shroud Removal And Installation
Water Pump Housing Cover Removal And Installation
Water Pump Disassembly And Assembly
Water Pump Mechanical Seal Removal (Engine Installed)
Thermostat Housing Removal And Installation
Thermostat Removal And Installation
LUBRICATION SYSTEM
Oil Tank Removal And Installation
Engine Oil Pressure – Testing
Oil Flow Diagram
Oil Flow Chart
FUEL SYSTEM (THROTTLE BODY)
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 Inspection
Fuel Injector Removal And Installation
Removal And Installation
ENGINE DISASSEMBLY AND ASSEMBLY
Cam Chain Tensioner / Rocker Arm / Camshaft Removal
Cam Chain Tensioner Inspection
Rocker Shaft / Rocker Arm Assembly Removal
Rocker Arm / Shaft Inspection
Rocker Shaft / Rocker Arm Assembly Installation
Valve Clearance Adjustment (Intake And Exhaust)
Camshaft Removal
Automatic Compression Release Removal / Inspection
Automatic Compression Release Installation
Camshaft Inspection
Cam Chain / Camshaft Installation
Camshaft Timing
Engine Parts Illustration
Cylinder Head Removal
Cylinder Head Warpage
Cylinder Head Disassembly
Valve Inspection
Combustion Chamber
Valve Seat Reconditioning
Cylinder Head Assembly
Valve Sealing Test
Cylinder Head Installation
Cylinder Removal
Cylinder Inspection
Cylinder Hone Selection / Honing Procedure
Cleaning The Cylinder After Honing
Cylinder Installation
Piston Removal
Piston – To – Cylinder Clearance
Piston / Rod Inspection
Piston Ring Installed Gap
Piston Ring Installation
Piston Installation
Crankcase Disassembly
Starter Drive Removal And Installation
Flywheel Removal And Installation
Stator Removal / Inspection
Stator Installation
Cam Chain / Tensioner Blade
Cam Chain Drive Sprocket Removal And Installation
One Way Valve Removal And Installation
Crankcase Separation
Crankcase Inspection
Crankcase Assembly
Oil Pump Removal / Inspection
Oil Pump Assembly
Counter Balancer Shaft Removal / Inspection
Crankshaft Removal / Inspection
Crankshaft Straightening
Crankcase Bearing Inspection
Oil Seal / Mechanical Seal Removal (Engine Disassembled)
Pump Shaft Oil Seal Installation
Water Pump Mechanical Seal Installation
Bearing Installation
End Play Inspection / Adjustment
Crankshaft End Play Adjustment
Counter Balancer Shaft End Play Adjustment
Oil Pump Shaft End Play Adjustment
Crankshaft / Counter Balance / Oil Pump Installation
Oil Pump Priming Procedure

SPECIFICATIONS
(3400, 3400XL) UTILITY VEHICLE SPECIFICATIONS
(3400) Utility Vehicle Dimensions
(3400 XL) Utility Vehicle Dimensions
Performance
Controls
Engine
Electrical
Drive System
Fluid And Capacities
Tires
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

ALPHABETICAL INDEX

SERVICE MANUAL REVISION
Revision No: 3400 – 1

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