Bobcat 3450 Utility Vehicle Service Manual – 6989610 (4-11)

(S/N: AJNY11001 & Above)
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This workshop repair service manual PDF download for the 3450 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 3450
S/N: AJNY11001 & Above

TABLE OF CONTENTS :

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

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : 6989610 (4-11)
Total Pages : 514

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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More Info : http://www.sitelux.com

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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

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 COOLING SYSTEM
Checking Level
Cleaning
Removing And Replacing Coolant
FUEL SYSTEM
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
Checking Rear Gearcase Fluid
Rear Gearcase Fluid
Adding Rear Gearcase Fluid
Removing And Replacing Rear 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
RELIEVING HYDRAULIC PRESSURE
Procedure
HYDRAULIC SYSTEM
Description
Checking Fluid
Hydraulic Fluid
Removing And Replacing Hydraulic Fluid

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)
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)
System Troubleshooting
Shift Lever Removal And Installation
Shift Cable Inspecting
Shift Cable Adjustment
Removal And Installation
Parts Identification
Disassembly
Gear Cluster Disassembly
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 And Ducting Components Parts Identification
CVT (Outer) Cover Removal And Installation
CVT (Inner) Cover Removal And Installation
Clutch Offset
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
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
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
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
Rear Propshaft Removal And Installation
Rear Gearcase Operation
Rear Gearcase Removal And Installation
Rear Gearcase Parts Identification
Rear Gearcase Disassembly
Rear 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
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
ATTACHMENT ARM
Removal And Installation
FRONT MOUNT
Removal And Installation

ELECTRICAL SYSTEM & ANALYSIS
ELECTRICAL SCHEMATICS
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
Alternator Voltage Test
Low Voltage Test
Removal And Installation
Alternator Belt Adjustment
Belt Replacement
STARTER SYSTEM
Testing
Removal And Installation
STOP SOLENOID
Description
LIGHTS
Headlight Removal And Installation
Headlight Adjustment
Tail Light / Brake Light Removal And Installation
Indicator Lamp Removal And Installation
Glow Plug Light Removal And Installation
Oil Pressure Light Removal And Installation
VEHICLE CONTROL MODULE
Description
Removal And Installation
SPEED SENSORS
Engine Speed Sensor Removal And Installation
Vehicle Speed Sensor Removal And Installation
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 (KEY)
Removal And Installation
SWITCH (GEAR SELECTOR)
Removal And Installation
SWITCH (JOYSTICK)
Testing
Removal And Installation
SWITCH (FLOAT)
Testing
Removal And Installation
SWITCH (ATTACHMENT ARM LOCK)
Testing
Removal And Installation
TEMPERATURE SENSOR
Description
Testing
Removal And Installation
DIFFERENTIAL SOLENOID
Description
Removal And Installation
DIFFERENTIAL SOLENOID (REAR RELAY)
Description
Removal And Installation
OIL PRESSURE SENSOR
Location
Removal And Installation
HOURMETER
Removal And Installation
BACK-UP ALARM SYSTEM (IF EQUIPPED)
Description
Inspecting
Removal And Installation
JOYSTICK
Removal And Installation
SOLENOID (HYDRAULIC PUMP)
Testing
Removal And Installation

ENGINE SERVICE
ENGINE INFORMATION
Description
Specifications
Torque Values
Troubleshooting
Engine Removal And Installation
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 Disassembly And Assembly
Thermostat Housing Removal And Installation
LUBRICATION SYSTEM
Oil Pan Removal And Installation
Oil Pump Disassembly And Assembly
Oil Pump Inspection
Engine Oil Pressure – Testing
FUEL SYSTEM
Stop Solenoid
Removal And Installation
High-Pressure Fuel Injection Lines Removal And Installation
Fuel Return Line Removal And Installation
Fuel Injection Pump Removal
Fuel Injection Pump Installation
Injection Pump – Timing
Fuel Injector Removal And Installation
Fuel Injector Disassembly
Fuel Injector Assembly
Fuel Injector Nozzle Pressure – Checking
Nozzle Spraying Condition
CYLINDER HEAD
Intake And Exhaust Valves
Valve Clearance Adjustment
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
Cylinder Head – Servicing
Valve Guide – Checking
Reconditioning The Valve And Valve Seat
Valve Spring
Valve Tappets
Rocker Arm And Shaft – Checking
Push Rod Alignment – Checking
CRANKSHAFT AND PISTONS
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod – Servicing
Cylinder Bore – Checking
Crankshaft And Bearings Removal
Crankshaft And Bearings Installation
Crankshaft And Bearings – Servicing
Honing And Boring
CAMSHAFT AND TIMING GEARS
Timing Gearcase Cover Removal And Installation
Timing Gears Backlash – Checking
Timing Gears Removal
Timing Gears Installation
Idler Gear And Camshaft Removal And Installation
Camshaft – Servicing
Idler Gear And Shaft – Servicing

HYDRAULIC SYSTEM
CYLINDER (LIFT)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
CYLINDER (TILT)
Testing
Removal And Installation
Parts Identification
Disassembly
Assembly
HYDRAULIC POWER UNIT
Main Relief Valve Testing
Removal And Installation
HYDRAULIC CONTROL VALVE
Removal And Installation
Disassembly And Assembly
AUXILIARY CONTROL VALVE (IF EQUIPPED)
Removal And Installation
Disassembly And Assembly
HYDRAULIC RESERVOIR
Removal And Installation
FRONT AUXILIARY HYDRAULIC COUPLER BLOCK
Removal And Installation

SPECIFICATIONS
(3450) UTILITY VEHICLE SPECIFICATIONS
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: 3450 – 1
Revision No: 3450 – 2
Revision No: 3450 – 3

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