Bobcat 3400, 3400XL Utility Vehicle Workshop Repair Service Manual - 6989606

(S/N: AJNU11001 & Above - S/N: AJNW11001 & 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: AJNU11001 & Above
S/N: AJNW11001 & 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
P/N : 6989606 (4-11)
Total Pages : 469


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 !!!! 

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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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 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
        
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 AJNW11001 & 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)
        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 (S/N AJNU11001 & Above)
        Propshaft Removal And Installation (S/N AJNW11001 & Above)
        Support Bearing Removal And Installation (S/N AJNW11001 & 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
        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
        
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
        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
    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
    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
        
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
        Removal
        Installation
        Oil Pump Disassembly And Assembly
        Oil Pump Inspection
        Engine Oil Pressure - Testing
    FUEL SYSTEM
        Stop Solenoid
        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
        
SPECIFICATIONS
    (3400, 3400XL) UTILITY VEHICLE SPECIFICATIONS
        (3400) Machine Dimensions
        (3400XL) Machine 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
    Revision No: 3400 - 2
    Revision No: 3400 - 3
    
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