DOWNLOAD PDF Bobcat 3400 3400XL Utility Vehicle Operation & Maintenance Manual

Operation & Maintenance Manual 3400, 3400XL Utility Vehicle S/N AJNT11001 & Above S/N AJNV11001 & Above

6989601 (11-10) Revised (2-11) (4)

Printed in U.S.A.

© Bobcat Company 2011

OPERATOR SAFETY WARNINGS WARNING

Operator must have instructions before operating the utility vehicle.

Untrained operators can cause injury or death.

CORRECT

W-2855-0510

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!” Carefully read the message that follows.

P-90216

Never use the utility vehicle without instructions. See safety signs (decals) and Operation & Maintenance Manual.

CORRECT

CORRECT

CORRECT

NA5178

NA5192

P-97282

Wear eye protection and keep hands and feet inside vehicle at all times.

Always fasten your seat belt snugly.

Do not operate the vehicle with the ROPS removed.

WRONG

WRONG

NA5191

NA5180

Do not use utility vehicle in atmosphere with explosive dust, explosive gas, or where exhaust can contact flammable material.

Carry passenger(s) only in the passenger seat(s).

Keep bystanders away from work area.

No riders in Cargo Box.

WRONG

WRONG

NA5188

NA5182

Never exceed vehicle load capacities.

Check for proper tire pressure.

Never leave vehicle with engine running or with cargo box up.

To park, engage the Park Brake and stop the engine.

Never operate this vehicle if you are under age 16 and without a valid driver’s license.

WRONG

NA5206

Slow down when turning.

Secure loads.

WRONG

NA5201

Never modify equipment.

Use only accessories and attachments approved by Bobcat Company for this vehicle.

SAFETY EQUIPMENT The utility vehicle must be equipped with safety items necessary for each job. Ask your dealer for information on the safe use of attachments and accessories.

1.

2.

3.

4.

5.

SEAT BELTS: Check fasteners, check for damaged webbing or buckle.

ROLLOVER PROTECTIVE STRUCTURE (ROPS): It must be maintained in good condition.

SAFETY SIGNS (DECALS): Replace if damaged.

GRAB HANDLE(S): Replace if damaged.

START INTERLOCK SYSTEM: Check function.

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OSW70-0510

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CONTENTS FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 SAFETY & TRAINING RESOURCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 SYSTEM SETUP & ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 UTILITY VEHICLE SIGN TRANSLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 REFERENCE INFORMATION Write the correct information for YOUR Bobcat utility vehicle in the spaces below. Always use these numbers when referring to your Bobcat utility vehicle.

Utility Vehicle Serial Number Engine Serial Number

NOTES:

YOUR BOBCAT DEALER: ADDRESS: PHONE:

Doosan Benelux SA Drève Richelle 167 B-1410 Waterloo BELGIUM

Bobcat Company P.O. Box 128 Gwinner, ND 58040-0128 UNITED STATES OF AMERICA

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FOREWORD This Operation & Maintenance Manual was written to give the owner / operator instructions on the safe operation and maintenance of the Bobcat utility vehicle. READ AND UNDERSTAND THIS OPERATION & MAINTENANCE MANUAL BEFORE OPERATING YOUR BOBCAT UTILITY VEHICLE. If you have any questions, see your Bobcat dealer. This manual may illustrate options and accessories not installed on your Bobcat utility vehicle.

BOBCAT COMPANY IS IS0 9001 CERTIFIED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 REGULAR MAINTENANCE ITEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SERIAL NUMBER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Utility Vehicle Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Engine Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Noise Emission Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Operating On Public Lands In The U.S.A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Crankcase Emission Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Exhaust Emission Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Electromagnetic Interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 UTILITY VEHICLE IDENTIFICATION (3400) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 UTILITY VEHICLE IDENTIFICATION (3400XL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 FEATURES, ACCESSORIES AND ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Standard Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Options And Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

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BOBCAT COMPANY IS IS0 9001 CERTIFIED

ISO 9001 is an international standard that specifies requirements for a quality management system that controls the processes and procedures which we use to design, develop, manufacture and distribute Bobcat products.

British Standards Institute (BSI) is the Certified Registrar Bobcat Company chose to assess the Company’s compliance with the ISO 9001 at Bobcat's manufacturing facilities in Gwinner and Bismarck, North Dakota (U.S.A.), Pontchateau (France), Dobris (Czech Republic) and the Bobcat corporate offices (Gwinner, Bismarck & West Fargo) in North Dakota.

Only certified assessors, like BSI, can grant registrations.

ISO 9001 means that as a company we say what we do and do what we say. In other words, we have established procedures and policies, and we provide evidence that the procedures and policies are followed.

CALIFORNIA PROPOSITION 65 WARNING Engine Exhaust And Some Of Its Constituents Are Known To The State Of California To Cause Cancer, Birth Defects And Other Reproductive Harm.

REGULAR MAINTENANCE ITEMS ENGINE OIL FILTER 7018608

BATTERY 7017791

ENGINE BREATHER FILTER 7016378

SPARK PLUG 7018492 - (NGK BKR5E)

AIR FILTER 7016038

FRONT DIFFERENTIAL FLUID 2878408 - (1 qt)

AIR PRE-FILTER 7016382

ETHYLENE GLYCOL ANTI-FREEZE (1 U.S. gal) 6988096 - Premixed [-34°F (-37°C)] 6988097 - Concentrate BRAKE FLUID 6988958 - DOT 4 Brake Fluid - (12 oz)

CVT FILTER 7016384 DRIVE BELT 3400 = 7018600 3400XL = 7018601 ENGINE OIL 2878410

SYNTHETIC ENGINE OIL 2W-50 (12 qts)

SYNTHETIC GEARCASE FLUID 2878409 - (1 qt) GREASE 6903122

Multi Purpose #2 (14 oz Tube)

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3400, 3400XL Operation & Maintenance Manual

SERIAL NUMBER LOCATIONS

Engine Serial Number

Always use the serial number of the utility vehicle when requesting service information or when ordering parts.

Early or later models (identification made by serial number) may use different parts, or it may be necessary to use a different procedure in doing a specific service operation.

Figure 3

Utility Vehicle Serial Number Figure 1

1 P-97259

The engine serial number is located on the side of the engine block (Item 1) [Figure 3].

DELIVERY REPORT Figure 4

P-97257

The utility vehicle serial number plate is located on the seat frame just behind the passenger(s) seat [Figure 1].

B-16315

Figure 2

The delivery report [Figure 4] must be completed by the dealer and signed by the owner or operator when the Bobcat utility vehicle is delivered. An explanation of the form must be given to the owner.

Module 2 - Production Sequence (Series) Module 1 - Model / Engine Combination P-90175 Explanation of utility vehicle serial number [Figure 2]: 1. The four digit Model / Engine Combination Module number identifies the model number and engine combination.

2. The five digit Production Sequence Number identifies the order which the utility vehicle is produced.

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3400, 3400XL Operation & Maintenance Manual

EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with the U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements.

Operating On Public Lands In The U.S.A. Bobcat warrants that the spark arrester in this vehicle will meet the efficiency requirements of the USFS standard 5100-1c for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with Bobcat recommendations.

Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR 42. Violations are subject to monetary penalties. Federal regulations can be viewed on line at www.gpoaccess.gov/ecfr/.

Crankcase Emission Control System This engine is equipped with a closed crankcase system.

Blow-by gases are forced back to the combustion chamber by the intake system. All exhaust gases exit through the exhaust system.

Exhaust Emission Control System Exhaust emissions are controlled by the engine design.

An electronic fuel injection system (EFI) system controls fuel delivery. The engine and the EFI components are set at the factory for optimal performance and are not adjustable.

The emissions label is located on the frame under the seat.

Electromagnetic Interference The spark ignition system complies with Canadian ICES002.

This vehicle complies with the EMC requirements European directives 97/24/EC and 2004/108/EC.

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3400, 3400XL Operation & Maintenance Manual

UTILITY VEHICLE IDENTIFICATION (3400)

HEAD RESTS

GRAB HANDLE

FRONT LIGHTS

HIP RESTRAINT

TIRES OPERATOR & PASSENGER SEATS WITH SEAT BELTS

[1] ROPS STRUCTURE

CARGO BOX OPERATION & MAINTENANCE MANUAL

STORAGE COMPARTMENT

TAILGATE

RECEIVER HITCH

TAIL LIGHTS / BRAKE LIGHTS (2)

NA5167 NA5164

[1] ROPS - Rollover Protective Structure, per OSHA 1928.53: 2006, ISO 5700: 2006 and SAE J2194: 2009.

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3400, 3400XL Operation & Maintenance Manual

UTILITY VEHICLE IDENTIFICATION (3400XL) STORAGE BIN (LOCATED UNDER SEAT)

HEAD RESTS

GRAB HANDLE

HIP RESTRAINT

FRONT LIGHTS

TIRES

OPERATOR & PASSENGER SEATS WITH SEAT BELTS

[1] ROPS STRUCTURE

OPERATION & MAINTENANCE MANUAL

CARGO BOX

STORAGE COMPARTMENT

TAILGATE GRAB HANDLE

TAIL LIGHTS / BRAKE LIGHTS (2)

RECEIVER HITCH

NA5166 NA5165

[1] ROPS - Rollover Protective Structure, per OSHA 1928.53: 2006.

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3400, 3400XL Operation & Maintenance Manual

FEATURES, ACCESSORIES AND ATTACHMENTS

Options And Accessories

Standard Items

The utility vehicle can be equipped with the following options and field installed accessories.

The 3400 utility vehicle is equipped with the following standard items: • • • • • • •

• • • • • • • • • • • •

• • • • • • • • • • • • • • • • •

Beverage Holder (2) Cargo Box With Lift Assist Four-Wheel Drive With Locking Rear Differential Front & Rear Independent Suspension Front Headlights Rear Tail / Brake Lights Instrumentation: Park Brake and Engine Temperature Warning Lights, Hourmeter, and Gear Selector Icons (R-N-L-H) Parking Brake Power Port (12 Volt) Quick Latch Tailgate Rear Receiver Hitch Seat Belts With 3-Point Restraint Skid Plates Spark Arrester Exhaust System Tires - Standard - Front 25 x 10 - 12 Tires - Standard - Rear 25 x 11 - 12 High - Low Range Forward Travel Continuously Variable Transmission (CVT) Under Seat Storage Bin (3400XL Only)

• • • • • • • • • • • • • • • • •

Speedometer Bench Seat Kit Powered Cargo Box Lift Kit Back-up Alarm Front Brush Guard Auxiliary Battery Kit Strobe Light Kit Horn Kit Turn Signal Kit Mirror - External Mirror - Universal Rear View Front / Rear Worklight Kit Cargo Box Divider Radio Kit (with Speakers) Heavy Duty Front Spring Kit Step / Nerf Bars Cab (Hard) - (3400 Only): Windshield - Premium Glass - fixed Windshield - Premium Glass - tip out Wiper - Premium Windshield - fixed Wiper - Premium Windshield - tip out Heater Kit Cab (Soft): Windshield - Economy Poly Dash Defrost Kit Roof Canopy Gun Scabbard Mount Gun Boot, Black or Camo Gas Can Mount Chainsaw Mount Line Trimmer Rack Cooler Mount Vertical Tool Holder Cargo Box Wall Extensions Cargo Box Rail Black Rally Light (Brush Guard Mounted) Winch - With Remote Control Snow Plow Kit Speed Limit (25 mph) Kit

Attachments These and other attachments are approved for use on this model Bobcat utility vehicle. Do not use unapproved attachments. Attachments not manufactured by Bobcat may not be approved.

See your Bobcat dealer for information about approved attachments and attachment Operation & Maintenance Manuals.

•

Sprayer

Specifications subject to change without notice.

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3400, 3400XL Operation & Maintenance Manual

SAFETY & TRAINING RESOURCES SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Before Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Safe Operation Is The Operator’s Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Safe Operation Needs A Qualified Operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Equipment Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Avoid Silica Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 FIRE PREVENTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Spark Arrester Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Welding And Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Fire Extinguishers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 UTILITY VEHICLE SIGNS (DECALS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 PUBLICATIONS AND TRAINING RESOURCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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The dealer explains the capabilities and restrictions of the Bobcat utility vehicle, attachment and accessories for each application. The dealer demonstrates the safe operation according to Bobcat instructional materials, which are also available to operators. The dealer can also identify unsafe modifications or use of unapproved attachments and accessories.

SAFETY INSTRUCTIONS Before Operation Carefully follow the operating instructions in this manual.

and

maintenance

The Bobcat utility vehicle is highly maneuverable and compact. It is rugged and useful under a wide variety of conditions. This presents an operator with hazards associated with off road, rough terrain applications, common with Bobcat utility vehicle usage.

The following publications and training materials provide information on the safe use and maintenance of the Bobcat utility vehicle and attachments and accessories:

This vehicle handles differently than other vehicles, such as motorcycles, golf cars or cars. If you fail to take proper precautions, a collision or rollover can occur quickly, even during routine maneuvers like turning, braking, driving over rough terrain and up and down hills or over obstacles. This can result in severe injury or death.

•

The Delivery Report is used to assure that complete instructions have been given to the new owner and that the utility vehicle, attachments and accessories are in safe operating condition.

•

The Operation & Maintenance Manual delivered with the vehicle or attachment gives operating information as well as routine maintenance and service procedures. It is a part of the utility vehicle and can be stored in the storage compartment. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.

•

Utility vehicle signs (decals) instruct on the safe operation and care of your Bobcat vehicle, attachments and accessories. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.

•

See the PUBLICATIONS AND TRAINING RESOURCES Page in this manual or your Bobcat dealer for Service and Parts Manuals, printed materials, videos, or training courses available. Also check the Bobcat web sites www.training.bobcat.com or www.bobcat.com

This vehicle is intended for off road use only and should not be operated on public roads.

Driving this vehicle in an aggressive manner can increase the risk of head injury and requires head protection. For these aggressive driving conditions, Bobcat Company recommends that all occupants wear a properly fitting Department of Transportation (D.O.T.) approved helmet.

Always follow these instructions: •

Fasten seat belts for occupant restraint before operating.

•

Keep hands and feet inside the vehicle at all times.

•

Travel at appropriate vehicle speeds depending on the type of terrain, visibility conditions, operating conditions and your operating experience.

•

Wear eye protection.

•

Wear other personal protective equipment such as a helmet or hard hat, face protection, hearing protection, safety boots or shoes, chemical suit, respirators and gloves as needed by work location and vehicle operation.

•

NEVER attempt jumps or other stunts with the vehicle.

The dealer and owner / operator review the recommended uses of the product when delivered. If the owner / operator will be using the utility vehicle for a different application(s) he or she must ask the dealer for recommendations on the new use.

This vehicle is an ADULT VEHICLE ONLY. NEVER operate this vehicle if you are under age 16 and NEVER operate without a valid drivers license.

No person under the age of 12 may ride as a passenger in this vehicle. Any passenger must be able to comfortably reach the floor and hand holds.

Call Before You Dig

Never permit a guest to operate this vehicle unless the guest has read this manual and all safety signs (decals).

Always inspect the vehicle before each use to make sure it is in safe operating condition. Always follow the inspection procedures described in this manual.

Dial 811 (USA Only) 1-888-258-0808 (USA & Canada)

The Bobcat utility vehicle has an internal combustion engine with resultant heat and exhaust. All exhaust gases can kill or cause illness so use the utility vehicle with adequate ventilation.

When you call, you will be directed to a location in your state / province, or city for information about buried lines (telephone, cable TV, water, sewer, gas, etc.).

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3400, 3400XL Operation & Maintenance Manual

SAFETY INSTRUCTIONS (CONT’D)

Safe Operation Needs A Qualified Operator For an operator to be qualified, he or she must not use drugs or alcoholic drinks which impair alertness or coordination while working. An operator who is taking prescription drugs must get medical advice to determine if he or she can safely operate the utility vehicle, attachments and accessories.

Safe Operation Is The Operator’s Responsibility

Safety Alert Symbol This symbol with a warning statement means: “Warning, be alert! Your safety is involved!”

Carefully read the message that follows.

A Qualified Operator Must Do The Following: Understand Regulations

Written

Instructions,

Rules

and

•

The written instructions from Bobcat Company include the Delivery Report, Operation & Maintenance Manual, and utility vehicle signs (decals).

•

Check the rules and regulations at your location. The rules may include an employer’s work safety requirements. Regulations may apply to local driving requirements.

WARNING Operator must have instructions before operating the utility vehicle. Untrained operators can cause injury or death.

the

W-2855-0510

Have Training with Actual Operation

IMPORTANT

•

Operator training must consist of a demonstration and verbal instruction. This training is given by your Bobcat dealer before the product is delivered.

•

The new operator must start in an area without bystanders and use all the controls until he or she can operate the vehicle, attachments and accessories safely under all conditions of the work area. Always fasten seat belt before operating.

•

The utility vehicle Safety Video is available from your Bobcat dealer in english and spanish. It provides information for safe vehicle operation.

This notice identifies procedures which must be followed to avoid damage to the utility vehicle.

I-2317-0510

DANGER

Know the Work Conditions •

Know the weight of the materials being handled.

Never exceed the vehicle Load Capacities. Material which is very dense will be heavier than the same volume of less dense material. Reduce the size of the load if handling dense material.

•

The operator must know any prohibited uses or work areas, for example, he or she needs to know about excessive slopes.

•

Know the location of any underground lines. Call local utilities or the TOLL FREE phone number found in the Before Operation Section of this manual.

•

Wear tight fitting clothing. Always wear safety glasses when doing maintenance or service. Safety glasses, respiratory equipment and hearing protection are required for some work.

The signal word DANGER on the utility vehicle and in the manuals indicates a hazardous situation which, if not avoided, will result in death or serious injury.

D-1022-0510

WARNING The signal word WARNING on the utility vehicle and in the manuals indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

W-2856-0510

The Bobcat utility vehicle, attachments and accessories must be in good operating condition before use.

Check all of the items on the Daily Inspection as shown in the Operation & Maintenance Manual.

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FIRE PREVENTION

SAFETY INSTRUCTIONS (CONT’D) Equipment Modifications Bobcat strongly recommends that operator’s do not install on the Bobcat Utility Vehicle, any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.

Any modifications to the original equipment of the utility vehicle create a substantial safety hazard and increase the risk of bodily injuries.

Maintenance The utility vehicle and some attachments and accessories have components that are at high temperatures under normal operating conditions. The primary source of high temperatures is the engine and exhaust system. The electrical system, if damaged or incorrectly maintained, can be a source of arcs or sparks.

The warranty on your Bobcat Utility Vehicle is terminated if any equipment has been added to the vehicle, or if any modifications have been made to the vehicle, that increases speed or power.

Flammable debris (leaves, straw, etc.) must be removed regularly. If flammable debris is allowed to accumulate, it can cause a fire hazard. Clean often to avoid this accumulation. Flammable debris in the engine compartment is a potential fire hazard.

Avoid Silica Dust

The operator’s area, engine compartment and engine cooling system must be inspected every day and cleaned if necessary to prevent fire hazards and overheating.

All fuels, most lubricants and some coolants mixtures are flammable. Flammable fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a fire.

Cutting or drilling concrete containing sand or rock containing quartz may result in exposure to silica dust.

Do not exceed Permissible Exposure Limits (PEL) to silica dust as determined by OSHA or other job site Rules and Regulations. Use a respirator, water spray or other means to control dust. Silica dust can cause lung disease and is known to the state of California to cause cancer.

Operation Do not use the utility vehicle where exhaust, arcs, sparks or hot components can contact flammable material, explosive dust or gases. Do not park this vehicle near open flames or pilot lights.

Electrical

Check all electrical wiring and connections for damage.

Keep the battery terminals clean and tight. Repair or replace any damaged part or wires that are loose or frayed.

Battery gas can explode and cause serious injury. Use the procedure in the Operation & Maintenance Manual for connecting the battery and for jump starting. Do not jump start or charge a frozen or damaged battery. Keep any open flames or sparks away from batteries. Do not smoke in battery charging area.

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FIRE PREVENTION (CONT’D)

Welding And Grinding

Fueling

Always clean the utility vehicle attachments and accessories, disconnect the battery, and disconnect the wiring from the Bobcat controllers before welding. Cover fuel tank, rubber hoses, battery and all other flammable parts. Keep a fire extinguisher near the utility vehicle when welding.

Have good ventilation when grinding or welding painted parts. Wear dust mask when grinding painted parts.

Toxic dust or gas can be produced.

Stop the engine and let it cool before adding fuel. No smoking! Do not refuel a utility vehicle near open flames or sparks. Fill the fuel tank outdoors.

Dust generated from repairing nonmetallic parts such as hoods, fenders or covers can be flammable or explosive.

Repair such components in a well ventilated area away from open flames or sparks.

Starting Use the procedure in the Operation & Maintenance Manual for connecting the battery and for jump starting.

Fire Extinguishers Spark Arrestor Exhaust System The spark arrestor exhaust system is designed to control the emission of hot particles from the engine and exhaust system, but the muffler and the exhaust gases are still hot.

Check the spark arrestor exhaust system regularly to make sure it is maintained and working properly. Use the procedure in the Operation & Maintenance Manual for cleaning the spark arrestor muffler

Know where fire extinguishers and first aid kits are located and how to use them. Inspect the fire extinguisher and service the fire extinguisher regularly.

Obey the recommendations on the instructions plate.

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3400, 3400XL Operation & Maintenance Manual

UTILITY VEHICLE SIGNS (DECALS) Follow the instructions on all the safety signs (decals) that are on the utility vehicle. Replace any damaged safety signs and be sure they are in the correct locations. Safety signs are available from your Bobcat dealer.

FRONT CONSOLE

7018022

7016357

7016342

7016347

7016337

UNDER FRONT COVER

UNDER CARGO BOX ON CVT COVER

7018029

7016362

IF EQUIPPED WITH BACK-UP ALARM

6737189

7018021

UNDER SEAT

7018023

7018610

NA5167 NA5164

19

3400, 3400XL Operation & Maintenance Manual

UTILITY VEHICLE SIGNS (DECALS) (CONT’D) Follow the instructions on all the safety signs (decals) that are on the utility vehicle. Replace any damaged safety signs and be sure they are in the correct locations. Safety signs are available from your Bobcat dealer.

FRONT CONSOLE

7018025

7016357

7016347

7016342

7016337

UNDER FRONT COVER UNDER CARGO BOX ON CVT COVER

7018029

7016362

IF EQUIPPED WITH BACK-UP ALARM

6737189 7018026

UNDER SEAT

7018024

NA5165 NA5166

7018610

20

3400, 3400XL Operation & Maintenance Manual

PUBLICATIONS AND TRAINING RESOURCES OPERATOR SAFETY DVD

The following publications are also available for your Utility Vehicle. You can order them from your Bobcat dealer.

6904762

For the latest information on Bobcat products and the Bobcat Company, visit our web site at www.bobcat.com; see also www.bobcatstore.com - Provides basic safety instructions contained in all Bobcat Safety Videos in both English and Spanish.

OPERATION & MAINTENANCE MANUAL 6989601

- Complete instructions on the correct operation and the routine maintenance of the Utility Vehicle.

SERVICE MANUAL 6989602

- Complete maintenance instructions for your Utility Vehicle.

21

3400, 3400XL Operation & Maintenance Manual

22

3400, 3400XL Operation & Maintenance Manual

OPERATING INSTRUCTIONS OPERATOR CONTROLS AND INSTRUMENT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Indicator Light Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Gear Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Raising And Lowering The Cargo Box - With Power Lift Assist Switch (Optional) . . . . . . . 28 Key - Start / Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Storage Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Storage Bin - Under Seat (3400XL Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Winch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Radio (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 THROTTLE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 BACK-UP ALARM SYSTEM (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 ROLLOVER PROTECTIVE STRUCTURE (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 STOPPING THE UTILITY VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 NEW VEHICLE BREAK-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Break-In Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36 Engine And Drivetrain Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Clutches / Belt Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Daily Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 PRE-STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Entering The Utility Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Seat Belt Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Warming The Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

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3400, 3400XL Operation & Maintenance Manual

SPEEDOMETER (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 STOPPING THE ENGINE AND LEAVING THE UTILITY VEHICLE . . . . . . . . . . . . . . . . . . . .42 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 OPERATING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Driving Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43 Operating On Public Roads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Turning Improperly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Jumps And Stunts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Operating In Unfamiliar Terrain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Improper Tire Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Operating On Frozen Bodies Of Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Unauthorized Use Of The Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Driving On Slippery Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44 Driving Uphill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Driving On A Sidehill (Sidehilling) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Driving Downhill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45 Driving Through Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Driving Over Obstacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46 Driving In Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Parking On An Incline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Hauling Cargo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48 Vehicle Load Capacities (Model 3400) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 Vehicle Load Capacities (Model 3400XL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 Belt Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 Opening And Closing The Tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 Raising And Lowering The Cargo Box (With Lift Assist) . . . . . . . . . . . . . . . . . . . . . . . . . . .52 Raising And Lowering The Cargo Box (With Power Lift Assist) . . . . . . . . . . . . . . . . . . . . .52 Towing Equipment With The Utility Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53 Drive Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 TOWING THE UTILITY VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55 TRANSPORTING THE UTILITY VEHICLE ON A TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . .56 Loading And Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

24

3400, 3400XL Operation & Maintenance Manual

OPERATOR CONTROLS AND INSTRUMENT PANELS

Hourmeter

Overview

Figure 6

Figure 5 1 A

B

C

D

E

F

K

L

P-97262

J

G

H

The hourmeter (Item 1) [Figure 6] records vehicle operation time. Use the hourmeter to schedule vehicle service.

P-97260

NOTE: Hourmeter will operate only when the engine is running.

View from operator’s seat [Figure 5].

REF

DESCRIPTION

A

Park Brake Lever (See PARK BRAKE on Page 33.)

Hourmeter (See Hourmeter on Page 25.)

Indicator Light Panel (See Indicator Light Panel on Page 26.)

Key - Start / Stop (See Key - Start / Stop on Page 28.)

Gear Selector (See Gear Selector on Page 27.)

Control Panel (See Control Panel on Page 28.)

Brake Pedal (See BRAKE PEDAL on Page 33.)

Throttle Pedal (See THROTTLE PEDAL on Page 33.)

Steering Wheel Storage Compartment (Operation & Maintenance Manual and tool kit are stored in the compartment.) (See Storage Compartment on Page 29.)

Cup holder - located on both sides of the dash.

B C D E F G H J K

L

25

3400, 3400XL Operation & Maintenance Manual

OPERATOR CONTROLS AND INSTRUMENT PANELS (CONT’D) Indicator Light Panel Figure 7

1

2 3

P-97263

The indicator light panel [Figure 7] is located in front of the steering wheel. The indicator lights alert the operator to various vehicle conditions.

REF

DESCRIPTION

1

Park Brake Indicator - (Red Light) - ON when park brake is engaged.

Coolant Temperature Indicator - (Red Light) - ON when the coolant temperature exceeds the allowable range.

Gear Indicator: R (Orange Light) - ON when gear selector is in Reverse.

N (Green Light) - ON when gear selector is in Neutral.

L (White Light) - ON when gear selector is in Low. H (White Light) - ON when gear selector is in High.

2

3

26

3400, 3400XL Operation & Maintenance Manual

When To Use Low Gear And High Gear

OPERATOR CONTROLS AND INSTRUMENT PANELS (CONT’D)

Belt slippage is responsible for creating excessive heat that destroys belts, wears clutch components and causes the outer clutch cover to fail. Switch to low gear while operating at slower speeds to extend the life of the CVT components (belt, clutch, cover, etc.)

Gear Selector

IMPORTANT Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage. Always shift when the vehicle is stationary and the engine is at idle.

I-2290-0510

Figure 8

CONDITION

GEAR TO USE

Operating at speeds less than 11 km/ h (7 mph) Towing heavy loads Operating in rough terrain (swamps, mountains, etc.)

Operating at speeds greater than 11 km/h (7 mph)

Low Low Low High

1 H L N R

P-97264

The gear selector (Item 1) [Figure 8] is located to the right of the steering wheel. (The corresponding indicator light (Item 3) [Figure 7] will be illuminated based on the gear selected.)

Have the vehicle stopped and the engine at idle before moving the gear selector.

H: High gear L: Low gear N: Neutral R: Reverse Low gear is the primary driving gear for the vehicle. High gear is intended for use on hard packed surfaces with light loads.

NOTE: Maintaining the shift linkage is important to assure proper transmission function. See your Bobcat dealer if you are experiencing any shifting problems.

27

3400, 3400XL Operation & Maintenance Manual

OPERATOR CONTROLS AND INSTRUMENT PANELS (CONT’D)

REF DESCRIPTION 5

FUNCTION / OPERATION

Raising And Press the top of the switch to raise the Lowering The cargo box.

Cargo Box - With Power Lift Assist Press the bottom of the switch to Switch (Optional) lower the cargo box.

Control Panel Figure 9 1 12

2

3

4

5

6

7

8

6 7 8 9 10

9

11

10

11 12 P-97265A

NOTE: Switch locations may vary from what is shown depending on options and accessories installed on your vehicle.

REF DESCRIPTION 1

2

Check Engine Light

Light Switch

(See Raising And Lowering The Cargo Box (With Power Lift Assist) on Page 52.)

Available for accessories.

Available for accessories.

Available for accessories.

Available for accessories.

Power Port Provides a 12 volt receptacle for accessories. (The power port has spade connectors on the back of the receptacle that may be used for powering optional accessories.)

Radio (Optional) (See Radio (Optional) on Page 31.)

Speedometer (See SPEEDOMETER (OPTIONAL) (Optional) on Page 41.)

Key - Start / Stop Figure 10

FUNCTION / OPERATION

OFF

Light ON when a service diagnostic code is activated. See your Bobcat dealer for repairs. (See Check Engine Light on Page 113.)

Bottom Position - Headlights and tail lights are OFF.

ON START

Center Position - Low beam lights and tail lights ON - amber low beam light in the switch will illuminate.

1

Top Position - High beam lights and tail lights ON - amber high beam light in the switch will illuminate.

3

Drive Mode Switch

P-97285

Key (Item 1) [Figure 10]. (See STARTING THE ENGINE on Page 40.)

(Key switch must be in the ON position for the lights operate.)

Bottom position - Turf Mode (with unlocked rear differential) Center position - Two Wheel Drive (2WD - With locked rear differential)

-

The engine is OFF. Electrical circuits are off except for the power plug.

ON

Electrical circuits are on. Electrical accessories can be used.

START

Top position - Four Wheel Drive (4x4.)

4

OFF

(See Drive Mode Switch on Page 54.)

Available for accessories.

28

Turn the key to the start position to engage the starter. Key returns to the ON position when released.

3400, 3400XL Operation & Maintenance Manual

OPERATOR CONTROLS AND INSTRUMENT PANELS (CONT’D)

Storage Bin - Under Seat (3400XL Only)

Storage Compartment

Figure 13

Figure 11 1 1

P-97284 P-97267

For model 3400XL vehicles only, there is a storage bin (Item 1) [Figure 13] located under the front seat.

Remove the front seat to access the storage bin. (See SEAT(S) on Page 78.)

The storage compartment (Item 1) [Figure 11] is used for storing the Operation & Maintenance Manual and the tool kit.

Figure 12

The maximum load weight for the storage bin is 113 kg (250 lb).

1 NOTE: Always reinstall the storage bin if it has been removed for vehicle service.

8

2

3

6 5

4

7

P-97268

The tool kit (Item 1) [Figure 12] consists of the following: 1. Storage pouch 2. Socket (for spark plug) 3. Socket wrench 4. Torx™ wrench - T20 5. Torx™ wrench - T27 6. Plier (with flat and Phillips screw drivers on handles) 7. Tire air pressure tester 8. Shock absorber spring spanner wrench

29

3400, 3400XL Operation & Maintenance Manual

Figure 15

OPERATOR CONTROLS AND INSTRUMENT PANELS (CONT’D) Winch (Optional)

DANGER Stand clear of wire rope and load during winching.

Keep helpers and spectators at a safe distance. If a wire rope pulls loose or breaks under the load, it can lash back with dangerous force.

1

D-1031-1210

2 P103423

DANGER

Located on the end of the winch motor is a clutch actuator knob (Item 1) [Figure 15] that is used for controlling cable free spool or motor engaged feature.

Wear heavy leather gloves when handling wire rope.

Do not let the wire rope slip through your hands, even with gloves on. When handling the hook, always use handsaver. Never put your fingers into the hook. Placing your finger(s) in hook could result in injury.

Rotate the knob (Item 1) [Figure 15] up for free spool, this will allow the cable to be pulled from the winch.

NOTE: Always disconnect the remote switch harness from the connector before free spooling the cable. This will prevent accidental pressing of the IN / OUT switch during free spooling.

D-1033-1210

Figure 14

NOTE: Always wear heavy leather gloves when handling the winch cable and use the supplied hand saver (Item 2) [Figure 15] when spooling cable in or out.

Rotate the knob (Item 1) [Figure 15] down to engage the motor. The switch (Item 1) [Figure 14] will now control cable in or cable out function.

1

NOTE: For more information on winch operation, see the Winch User Guide supplied with the winch.

P103426

If equipped with the optional front winch, a remote switch (Item 1) [Figure 14] will be used to control cable out and cable in.

The switch is marked “IN” and “OUT”, press the “OUT” side of the switch (Item 1) to feed the cable out, press the “IN” side of the switch (Item 1) [Figure 14] to reel cable in.

30

3400, 3400XL Operation & Maintenance Manual

OPERATOR CONTROLS AND INSTRUMENT PANELS (CONT’D) Radio (Optional) This vehicle may be equipped with a Radio.

Figure 16

1

2

3

4

5

6

9

7

10

12

11 8 13 14

15

17

16 P-85255

The table on the next page shows the DESCRIPTION and FUNCTION / OPERATION for each of the controls of the radio [Figure 16].

NOTE: See DISPLAY in the table for clock setting instructions.

31

3400, 3400XL Operation & Maintenance Manual

OPERATOR CONTROLS AND INSTRUMENT PANELS (CONT’D) Radio (Optional) (Cont’d) REF. NO.

DESCRIPTION

FUNCTION / OPERATION

1

POWER

Press to turn ON; press again to turn OFF.

2

MUTE

Press to mute audio output; MUTE will appear in display screen; press again to turn OFF.

3

DISPLAY

Press to toggle between function mode (showing tuner frequency, auxiliary input, weather band information or timer) and clock mode.

Press and hold to enter clock setting mode; use FREQUENCY DOWN button to adjust hours and FREQUENCY UP button to adjust minutes; normal operation will resume automatically.

4

BAND

Press to select tuner mode. Press to cycle through 2 AM (MW) bands and 3 FM bands.

5

AUXILIARY

Press to select Auxiliary Input mode. Portable audio device (MP3 player, etc.) must be attached to auxiliary input jack.

6

WEATHER BAND

Press to select weather band; use FREQUENCY UP and FREQUENCY DOWN buttons to adjust to the clearest station.

The weather alert feature, if activated, will automatically switch from the current function to the weather band if a weather warning is received. See AUDIO / MENU ADJUSTMENT in this table.

7

TIMER

Press to access timer mode. Press to start the timer function; press again to stop timer; press again to resume timer or press and hold to reset timer and exit from timer mode.

8

DISPLAY SCREEN

Displays the time, frequency and activated functions.

9

VOLUME UP

Adjusts volume up; current volume (0 - 40) will appear briefly in display screen.

10 AUDIO / MENU ADJUSTMENT

AUDIO ADJUSTMENT: Press to cycle through bass, treble and balance settings; use VOLUME UP and VOLUME DOWN to adjust when desired option is displayed; normal operation will resume automatically.

MENU ADJUSTMENT: Press and hold for three seconds to enter menu adjustment settings; press to cycle through the following settings; use VOLUME UP and VOLUME DOWN to adjust when desired option is displayed; normal operation will resume automatically.

• Beep Confirm (On or Off) - Determines if beep will sound with each button press.

• Operation Region (USA or Europe) - Selects the appropriate region.

• Clock Display (12 or 24) - Selects a 12-hour or 24-hour clock display.

• Display Brightness (Low, Medium or High) - Determines brightness level of display screen.

• Backlight Color (Amber or Green) - Determines backlight color of display screen.

• Power On Volume (0 - 40) - Selects default volume setting when radio is turned on.

• WB Alert (On or Off) - Determines if weather band alert feature is activated.

11 FREQUENCY DOWN Press to manually tune the radio frequency down.

12 FREQUENCY UP

Press to manually tune the radio frequency up.

13 VOLUME DOWN

Adjusts volume down; current volume (0 - 40) will appear briefly in display screen.

14 SEEK FREQUENCY DOWN

Press to automatically tune frequency down to next strong station.

15 SEEK FREQUENCY UP

Press to automatically tune frequency up to next strong station.

16 PRESET STATIONS

Used to store and recall stations for each AM and FM band. Press and hold to store current station; press button to recall station.

17 AUXILIARY INPUT JACK

Connect line output of portable audio device (MP3 player, etc.) to 3,5 mm (1/8 in) jack and press AUXILIARY button.

32

3400, 3400XL Operation & Maintenance Manual

PARK BRAKE

THROTTLE PEDAL

Operation

Operation

To help prevent the vehicle from rolling, engage the park brake when parking the vehicle. When the parking brake is fully engaged and the brake indicator is illuminated, the engine speed is limited to 1300 RPM in all gears, except neutral. If throttle is applied, this limiting feature prevents operation above 1300 RPM, which protects the park brake pads from excessive wear.

Figure 18

Figure 17

1

1

P-97266

Slowly press the throttle pedal (Item 1) [Figure 18] down to increase engine speed. Spring pressure returns the pedal to the rest position when released.

P-97261

Always check that the throttle pedal returns normally before starting the engine. Make sure there is adequate throttle pedal free play. See Throttle Pedal Inspection And Maintenance. (See THROTTLE SYSTEM on Page 71.)

Always press the brake pedal before engaging or releasing the park brake.

NOTE: Inspect and adjust the park brake cable tension after the first 25 hours of operation and every 100 hours thereafter to ensure proper cable tension. (See PARKING BRAKE SYSTEM on Page 68.)

BRAKE PEDAL

To apply the park brake:

Operation

1. Apply the brake pedal (Item 1) [Figure 19].

Figure 19

2. Pull the lever (Item 1) [Figure 17] back and fully engage the park brake.

To release the park brake: 1. Apply the brake pedal (Item 1) [Figure 19].

2. Press the button (Item 1) [Figure 17] and push the lever fully forward to disengage the park brake 1

WARNING

P-97266

AVOID SERIOUS INJURY OR DEATH Operating the vehicle while the park brake is engaged could cause loss of control and result in serious injury or death. Always disengage the park brake before operating the vehicle.

Press the brake pedal (Item 1) [Figure 19] to slow or stop the utility vehicle.

Press the brake pedal while starting the vehicle.

W-2818-0510

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3400, 3400XL Operation & Maintenance Manual

Operation

BACK-UP ALARM SYSTEM (IF EQUIPPED) Description

WARNING

Figure 20

• • •

1

AVOID INJURY OR DEATH Always keep bystanders away from the work area and travel path.

The operator must always look in the direction of travel.

The back-up alarm must sound when operating the machine in the reverse direction.

W-2783-0409

The back-up alarm will sound when the operator moves the gear selector into the reverse position (with the key in the ON position).

P-97368

If alarm does not sound, see the inspection and maintenance instructions for the back-up alarm system in the preventive maintenance section of this manual. (See BACK-UP ALARM SYSTEM (IF EQUIPPED) on Page 66.)

The back-up alarm (Item 1) [Figure 20] is located near the left rear wheel.

A back-up alarm is not a substitute for looking to the rear when operating the utility vehicle in reverse, or for keeping bystanders away from the work area.

Operators must always look in the direction of travel, including reverse, and must also keep bystanders away from the work area, even though the utility vehicle is equipped with a back-up alarm.

Operators must be trained to always look in the direction of travel, including when operating the utility vehicle in reverse and to keep bystanders away from the work area. Bystanders should be trained to always keep away from the operator’s work area and travel path.

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3400, 3400XL Operation & Maintenance Manual

ROLLOVER PROTECTIVE STRUCTURE (ROPS)

STOPPING THE UTILITY VEHICLE

Description

Procedure

The Bobcat 3400 and 3400XL has a Rollover Protective Structure (ROPS) to provide protection from rollover. The seat belts must be worn for ROPS protection.

Figure 21

Check the ROPS, mounting and hardware for damage.

Never modify the ROPS. Replace the ROPS and hardware if damaged. See your Bobcat dealer for parts.

ROPS - Rollover Protective Structure per ISO 5700: 2006, SAE J2194: 2009, and OSHA 1928.53: 2006.

WARNING

2

AVOID INJURY OR DEATH Never modify ROPS by welding, grinding, drilling holes or adding attachments unless instructed to do so by Bobcat Company. Changes to the ROPS can cause loss of operator protection from rollover and result in injury or death.

1 P-97260

Gradually release pressure on the throttle pedal (Item 1) [Figure 21].

Apply the brake pedal (Item 2) [Figure 21] until the utility vehicle comes to a complete stop.

W-2596-0510

Figure 22

1

P-97261

Pull the park brake lever (Item 1) [Figure 22] back until the park brake is fully engaged.

Turn the key to the OFF position and remove the key to prevent unauthorized use of the utility vehicle.

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3400, 3400XL Operation & Maintenance Manual

Engine And Drivetrain Break-In

NEW VEHICLE BREAK-IN Break-In Period

WARNING WARNING

AVOID SERIOUS INJURY OR DEATH Failure to handle gasoline properly can result in a fire which may result in serious injury or death.

• Always exercise extreme caution whenever handling gasoline.

• Always stop the engine when refueling.

• Always refuel outdoors or in a well ventilated area.

• Remove flammable material containers from the box before filling them with fuel.

• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

• Do not overfill the tank. Do not fill the tank neck.

• If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing.

• Store gasoline in an approved gasoline container only. Store in a well-ventilated area away from sparks, open flames, heaters, or heat sources • Keep gasoline out of the reach of children.

• To avoid the possibility of fire, clean up any spilled gasoline before operating the vehicle.

AVOID SERIOUS INJURY OR DEATH Failure to operate this vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Read and understand all safety information outlined in the safety instructions of this manual.

W-2820-0510

The break-in period for your new Bobcat utility vehicle is the first 25 hours of operation, or the time it takes to use the first two full tanks of fuel.

No single action on your part is as important as a proper break-in period. Careful treatment of a new engine will result in more efficient performance and longer life of the engine. Perform the following procedures carefully.

NOTE: Excessive heat build-up during the first three hours of operation will damage close-fitting engine parts. Do not operate at full throttle or high speed for extended periods of time during the first three hours of use.

W-2857-0510

1. Fill the fuel tank with gasoline.

2. Check the oil level. Add the recommended oil as needed to maintain the oil level in the normal (safe) operating range.

3. Drive slowly at first. Select an area that allows room to familiarize yourself with vehicle operation and handling.

4. Vary the throttle positions. Do not operate at sustained idle.

Perform regular checks on fluid levels, controls and areas outlined on the daily inspection checklist. (See DAILY INSPECTION on Page 37.)

5. Pull only light loads.

6. During the break-in period, change both the oil and filter at 25 hours.

Inspect and adjust the park brake cable tension after the first 25 hours of operation and every 100 thereafter to ensure proper cable tension. (See PARKING BRAKE SYSTEM on Page 68.)

Clutches / Belt Break-In A proper break-in of the clutches and belt will ensure a longer life and better performance. Break in the clutches and belt by operating at slower speeds during the breakin period as recommended. Pull only light loads. Avoid aggressive acceleration and high speed operation during the break-in period.

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3400, 3400XL Operation & Maintenance Manual

DAILY INSPECTION

WARNING

Daily Inspection And Maintenance Inspection and maintenance work must be done at regular intervals to be sure that the utility vehicle is in good operating condition. Failure to do so will result in excessive wear and early failures. The Service Checklist is a guide for correct inspection and maintenance of the utility vehicle.

AVOID INJURY OR DEATH Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service.

Untrained operators and failure to follow instructions can cause injury or death.

NOTE: Operating a damaged vehicle can result in an accident. After any overturn or accident, have a qualified Bobcat dealer inspect the entire utility vehicle for damage, including (but not limited to) brakes, throttle and steering systems.

• •

• • • •

•

•

• • • • • •

• • •

• •

W-2003-0807

Brake System / Pedal Travel - Check for proper operation. (See BRAKE PEDAL on Page 33.)

Rollover Protective Structure (ROPS) - Check ROPS and mounting hardware. (See ROLLOVER PROTECTIVE STRUCTURE (ROPS) on Page 75.)

Seat Belt - Check entire belt for damage, latches for proper operation.

Safety Signs (Decals) - Replace if damaged or missing.

Brake Fluid - Check for proper level. (See BRAKE SYSTEM on Page 69.)

Front Suspension - Check for wear or damage. (See STEERING AND SUSPENSION SYSTEM on Page 73.)

Rear Suspension - Check for wear or damage. (See REAR SUSPENSION ADJUSTMENTS on Page 100.)

Steering - Check for free operation, check components for wear or damage. (See STEERING AND SUSPENSION SYSTEM on Page 73.)

Tires - Check for Wear, Damage, and Correct Air Pressure. (See TIRE MAINTENANCE on Page 102.)

Wheel Fasteners - Check for proper torque. (See TIRE MAINTENANCE on Page 102.)

Loose or Broken Parts - Repair or Replace as Necessary.

Engine Oil Level. (See ENGINE LUBRICATION SYSTEM on Page 81.)

Fuel Level. (See FUEL SYSTEM on Page 79.)

Engine Cooling System - Check System for Damage or Leaks, Check Coolant Level, Clean Radiator and Grille. (See ENGINE COOLING SYSTEM on Page 84.)

Throttle - Check for proper operation. (See THROTTLE SYSTEM on Page 71.)

Indicator Lights / Switches - Check for proper operation. (See Indicator Light Panel on Page 26.)

Engine Air Filter / Pre-Filter - Check System for damage or leaks. (See AIR CLEANER SERVICE on Page 76.)

Head Lights - Check for proper operation.

Brake / Tail Lights - Check for proper operation.

IMPORTANT •

•

PRESSURE WASHING DECALS Never direct the stream at a low angle toward the decal that could damage the decal causing it to peel from the surface.

Direct the stream at a 90 degree angle and at least 300 mm (12 in) from the decal. Wash from the center of the decal toward the edges.

I-2226-0910

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3400, 3400XL Operation & Maintenance Manual

No person under age 12 may ride as a passenger in this vehicle. Any passenger must be able to comfortably reach the floor and hand holds.

PRE-STARTING PROCEDURE Entering The Utility Vehicle NOTE: Always inspect your Bobcat Utility Vehicle before each use for safe operating conditions.

(See Daily Inspection And Maintenance on Page 37.)

Figure 24

WARNING AVOID INJURY OR DEATH The Bobcat Utility Vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles or cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

• Read this Operation and Maintenance Manual.

Understand all safety signs (decals), precautions and operating procedures before operating this vehicle. Keep the Operation and Maintenance Manual with the vehicle.

• This vehicle is an ADULT VEHICLE ONLY. NEVER operate this vehicle if you are under 16 and NEVER operate without a valid drivers license.

• No person under the age of 12 may ride as a passenger in this vehicle. Any passenger must be able to comfortably reach the floor and hand holds.

• Never permit a guest to operate this vehicle unless the guest has read this manual and all safety signs (decals).

P-97366

Enter the vehicle [Figure 24].

W-2817-0510

Read the Operation & Maintenance Manual (located in the storage compartment) before operating the utility vehicle.

Figure 23

WARNING Operator must have instructions before operating the machine. Untrained operators can cause injury or death.

W-2001-0502 P-97282

This vehicle is an ADULT VEHICLE ONLY. NEVER operate this vehicle if you are under age 16 and NEVER operate without a valid drivers license [Figure 23].

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3400, 3400XL Operation & Maintenance Manual

PRE-STARTING PROCEDURE (CONT’D)

Bench Seat Option

Seat Belt Adjustment

Figure 26

WARNING AVOID SERIOUS INJURY OR DEATH Falling from a moving vehicle could result in serious injury or death. Always fasten your seat belt securely before operating or riding in the Bobcat Utility Vehicle.

W-2819-0510

1

Figure 25 P-97402

If equipped with the optional bench seat, the center occupant will have a lap belt.

Fasten the seat belt (Item 1) [Figure 26].

Pull the end of the belt through the belt adjuster so that the seat belt is snug.

P-97270

Fasten the seat belt snugly [Figure 25]. The belt must be positioned over your shoulder and over your lower hips.

Make sure the belt is not twisted.

NOTE: Make sure all passenger seat belts are properly fastened before operating this utility vehicle.

IMPORTANT Check the seat belt and shoulder belt retractors for correct operation.

Keep retractors clean and replace as necessary.

I-2199-0200

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3400, 3400XL Operation & Maintenance Manual

NOTE: If the engine does not start within five seconds, release the key and wait five seconds before attempting to start engine.

STARTING THE ENGINE

WARNING

After the engine is started, vary the engine RPM slightly with the throttle to aid in warm up and ensure proper oil circulation until the engine idles smoothly.

AVOID INJURY OR DEATH When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust outside. Exhaust fumes contain odorless, invisible gases which can kill without warning.

IMPORTANT Operating the vehicle immediately after starting could cause engine damage. Allow engine to warm up for several minutes before operating the vehicle.

W-2050-0807

Always start the engine outdoors or in a well ventilated area.

I-2292-0510

Keep hands and feet inside the vehicle.

STOP THE ENGINE IF WARNING LIGHTS DO NOT GO OFF.

Press the brake pedal. Make sure the park brake is engaged.

Warming The Engine NOTE: Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle.

Place the gear selector in the neutral position.

Do not press the throttle pedal while starting the engine.

WARNING AVOID INJURY OR DEATH When operating the utility vehicle: • Keep the seat belts fastened snugly.

• Keep your hands and feet inside the vehicle.

W-2858-0510

Figure 27 OFF ON START

P-97271A

Turn the key to the START position [Figure 27]. (Engage the starter for a maximum of five seconds.) Release the key when the engine starts.

40

3400, 3400XL Operation & Maintenance Manual

SPEEDOMETER (OPTIONAL) Description An optional speedometer / odometer is available. See your Bobcat dealer.

Figure 28

1

P-97476A

If equipped with the optional speedometer (Item 1) [Figure 28], the following functions are available: •

Speedometer

•

Odometer

41

3400, 3400XL Operation & Maintenance Manual

STOPPING THE ENGINE AND LEAVING THE UTILITY VEHICLE

WARNING

Procedure

AVOID SERIOUS INJURY OR DEATH A rolling vehicle can cause serious injury or death.

Always engage the park brake after stopping the engine.

WARNING Always park machine on flat, level ground.

W-2821-0510 W-2441-1102

Figure 31

Figure 29

1

P-97270

Press the red release button (Item 1) [Figure 31] to disconnect the seat belt.

P-97272A

Release the throttle pedal completely, apply the brake pedal and come to a complete stop.

Figure 32

Park the utility vehicle on a flat and level surface [Figure 29].

NOTE: When parking inside an enclosed area, be sure that the structure is well ventilated and the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights.

Figure 30

1

P-97261

Press the brake pedal and pull the park brake lever (Item 1) [Figure 30] back and fully engage the park brake.

P-97366

Turn the engine OFF and remove the key to prevent unauthorized use.

Exit the utility vehicle [Figure 32].

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3400, 3400XL Operation & Maintenance Manual

Figure 34

OPERATING PROCEDURE Driving Procedure

WARNING IMPROPER VEHICLE USE CAN CAUSE INJURY OR DEATH NEVER Operate: • At speeds too fast for your skill level.

• After or while using alcohol or drugs.

• On hills steeper than 15 degrees.

• On public roads. A collision can occur with another vehicle.

• Never operate with passenger(s) under age 12 or who cannot comfortably reach the floor or hand holds.

• With unapproved Bobcat accessories, they may seriously affect stability.

ALWAYS: • Wear your seat belt. Vehicle rollover could cause serious injury or death.

• Wear eye protection and keep hands and feet in vehicle at all times.

• Reduce speed and use extra caution when carrying passengers.

• Avoid sharp turns or turns while applying heavy throttle.

• Operate slowly in reverse - avoid sharp turns or sudden braking.

• Make sure passenger(s) reads and understands all safety signs (decals).

• Watch for branches or other hazards that could enter the vehicle.

P-97272A

1. Perform the pre-ride inspection. (See Daily Inspection And Maintenance on Page 37.)

2. Always wear eye protection when operating the utility vehicle.

3. Enter the utility vehicle and fasten the seat belt. (See PRE-STARTING PROCEDURE on Page 38.)

4. Start the engine. (See STARTING THE ENGINE on Page 40.)

5. Press the brake pedal and move the gear selector into gear. (See Gear Selector on Page 27.)

6. Check your surroundings and determine your path of travel.

7. Release the park brake. (See PARK BRAKE on Page 33.)

8. Keep both hands on the steering wheel, slowly release the brake pedal and depress the throttle pedal with your right foot to begin driving.

W-2814-0410

9. Drive slowly. Practice maneuvering and using the throttle and brake on a level surface.

Figure 33

10. Do not carry passengers until you have at least two hours of driving experience with this vehicle.

IMPORTANT Machines warmed up with moderate engine speed and light load have longer life.

I-2015-0284

Always check ground conditions before starting your utility vehicle: P-97282

43

•

Look for signs of instability.

•

Be aware of weather conditions that can affect ground stability.

•

Check for adequate traction when riding on a slope.

3400, 3400XL Operation & Maintenance Manual

OPERATING PROCEDURE (CONT’D)

Unauthorized Use Of The Vehicle

Operating On Public Roads

Leaving the key in the vehicle can lead to unauthorized use of the utility vehicle, which could result in an accident or overturn. Always remove the key when the vehicle is not in use.

Operating this vehicle on public streets, roads or highways could result in a collision with another vehicle.

Never operate this vehicle on any public street, road or highway, including dirt and gravel roads. In some areas it is unlawful to operate this vehicle on public streets, roads and highways.

Driving On Slippery Surfaces

WARNING

Turning Improperly

AVOID SERIOUS INJURY OR DEATH Skidding or sliding can cause loss of control or overturn (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra care to reduce the chance of skidding or sliding out of control. Do not operate on excessively slippery surfaces.

Turning improperly could cause loss of traction, loss of control, accident or overturn. Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before attempting a turn at faster speeds.

Jumps And Stunts

W-2822-0510

Attempting wheelies, jumps and other stunts increases the risk of an accident or overturn. Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving.

Whenever riding on slippery surfaces such as wet trails or loose gravel, during freezing weather, follow these precautions:

Operating In Unfamiliar Terrain

1. Do not operate on excessively rough, slippery area.

Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn. Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn.

2. Slow down before entering slippery areas.

3. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids.

Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions.

4. Engage Four Wheel Drive (4x4) before wheels begin to loose traction.

Improper Tire Maintenance

IMPORTANT

Operating this vehicle with improper tires or with improper or unenven tire pressure could cause loss of control or accident.

Severe damage to the drive train may occur if the Four Wheel Drive (4x4) is engaged while the wheels are spinning. Always allow the wheels to stop spinning before engaging Four Wheel Drive (4x4).

Always use the size and type of tires specified for your vehicle.

I-2293-0510

Always maintain proper tire pressure as described in this manual and on the safety signs (decals).

Figure 35 Sideways Skid

Operating On Frozen Bodies Of Water Severe injury or death can result if the vehicle and / or the operator fall through the ice. Never operate on a frozen body of water.

Turn in the direction of skid

P-97274

5. Correct a skid by turning the steering wheel in the direction of the skid. Never apply the brakes during a skid.

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3400, 3400XL Operation & Maintenance Manual

OPERATING PROCEDURE (CONT’D)

Driving On A Sidehill (Sidehilling)

Driving Uphill

Figure 37

Climbing hills improperly can cause loss of control or vehicle overturn. Always follow the proper procedures for climbing hills as described below.

Figure 36

15° maximum NA5199

15° maximum NA5173

Driving on a sidehill is not recommended [Figure 37].

Improper procedures could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary.

Whenever traveling uphill, follow these precautions [Figure 36]:

If crossing a side hill is unavoidable, follow these precautions:

1. Avoid steep hills (15° maximum).

2. Keep the heavy end of the vehicle uphill. Always travel straight uphill.

1. Slow down.

3. Keep both feet on the floor.

2. Exercise extreme caution.

4. Always check the terrain carefully before ascending any hill.

3. Avoid crossing the side of a steep hill (15° maximum).

Driving Downhill

5. Never climb hills with excessively slippery or loose surfaces.

Figure 38

6. Proceed at a steady rate of speed and throttle opening. Never open the throttle suddenly.

7. Never go over the crest of a hill at high speeds. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.

Stalling While Climbing A Hill Stalling or rolling backwards while climbing a hill could cause overturn. Always maintain a steady speed when climbing hills.

15° maximum NA5172

If All Forward Speed Is Lost: 1. Apply the brakes.

Whenever traveling downhill, follow these precautions [Figure 38]:

2. Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed.

1. Avoid steep hills (15° maximum).

2. Keep the heavy end of the vehicle uphill. Drive straight downhill. Avoid descending a hill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight downhill when possible.

If You Begin Rolling Downhill: 1. Never apply engine power.

2. Apply the brakes gradually until the vehicle is fully stopped.

3. Keep both feet on the floor.

4. Slow down.

3. Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed

5. Apply brakes slightly to aid in slowing.

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3400, 3400XL Operation & Maintenance Manual

OPERATING PROCEDURE (CONT’D) Driving Through Water

IMPORTANT

Figure 39

After running your vehicle in water, it is critical to perform the service procedure outlined in the Preventative Maintenance Section in this manual.

Give special attention to engine oil, transmission oil, all gearcase fluid, and all grease fittings.

I-2295-0510

Driving Over Obstacles

NA5203

Figure 40

Your utility vehicle can operate through water up to a maximum recommended depth equal to the floorboards [Figure 39].

IMPORTANT Immersion can result in major damage if the vehicle is not serviced correctly and promptly. After immersion, always take the vehicle to your Bobcat dealer for service. Do not start the engine! If it is impossible to bring the vehicle to your Bobcat dealer before starting the engine, perform the Vehicle Immersion service procedure outlined in this manual and take the vehicle to your dealer at the first opportunity.

NS5190

I-2294-0510

Follow these procedures when operating over obstacles [Figure 40]:

Follow these procedures when operating through water: 1. Determine the water depths and current before entering the water.

1. Always check for obstacles before operating in a new area.

2. Choose a crossing where both banks have gradual inclines.

2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches.

3. Proceed slowly, avoid rocks and obstacles.

4. Avoid operating through deep or fast flowing water.

3. Travel slowly and use extra caution when operating on unfamiliar terrain. Not all obstacles are immediately visible.

WARNING AVOID SERIOUS INJURY OR DEATH The large tires on your Bobcat Utility Vehicle may cause the vehicle to float in deep or fast-flowing water, which could result in loss of control and lead to serious injury or death. Never cross deep or fastflowing water with this vehicle.

W-2823-0510

5. After leaving water, always dry the brakes by applying light pressure to the brake pedal repeatedly until brake performance is normal.

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3400, 3400XL Operation & Maintenance Manual

Parking On An Incline

OPERATING PROCEDURE (CONT’D) Driving In Reverse

Figure 42

Figure 41

NA5202

Avoid parking on an incline if possible. If it is unavoidable, follow these precautions [Figure 42]:

NA5179

1. Apply the brakes.

Follow these precautions when operating in reverse [Figure 41]:

2. Place the transmission in gear.

1. Always check for obstacles or people behind the vehicle. Always inspect left and right fields of vision before backing. Always look in the direction of travel.

3. Engage the park brake.

2. Back up slowly.

5. Block the rear wheels on the downhill side.

4. Turn the engine off.

3. Apply the brakes lightly for stopping.

4. Avoid turning at sharp angles.

5. Never open the throttle suddenly.

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3400, 3400XL Operation & Maintenance Manual

OPERATING PROCEDURE (CONT’D) Hauling Cargo

WARNING WARNING

AVOID INJURY OR DEATH Driving with passengers in the cargo box can result in serious injury or death. Never allow passengers to ride in the cargo box. Passengers must always ride in the cab with seat belts fastened securely.

AVOID INJURY OR DEATH Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo.

• Never exceed the vehicle rated capacity or the total rated capacity.

• REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO. • Always load the cargo box with the load as far forward and as low as possible.

• When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions.

• Always operate the vehicle with extreme care when hauling or towing loads.

• Slow down and drive in the lowest gear available.

• SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create unstable operating conditions, which could result in loss of control of the vehicle.

• OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling off-centered loads that cannot be centered, securely fasten the load and operate with extra caution. Always attach the tow load to the hitch point designated for your vehicle.

• HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle.

Avoid terrain or situations that may require backing downhill.

• USE EXTREME CAUTION when operating with loads that extend over the rack sides. Stability and maneuverability may be adversely affected, causing the vehicle to over turn.

• DO NOT TRAVEL FASTER THAN RECOMMENDED SPEEDS. Vehicle should never exceed 16 km/h (10 mph) while towing a load on a level surface. Vehicle speed should never exceed 8 km/h (5 mph) when towing loads in rough terrain, while cornering, or while ascending or descending a hill.

W-2825-0510

W-2824-0910

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3400, 3400XL Operation & Maintenance Manual

Vehicle Rated Capacity

OPERATING PROCEDURE (CONT’D) Vehicle Load Capacities (Model 3400)

The maximum amount of weight the vehicle can carry (this includes: cargo box load, weight of occupant(s), and the weights of any accessories - including cab kits) is 725 kg (1600 lb).

Maximum Cargo Box Load The maximum load that can be carried in the Cargo Box of the vehicle is 500 kg (1100 lb).

Total Rated Capacity

Maximum Trailer Hitch Tongue Weight

The maximum load that can be applied to the utility vehicle including tow weight (this includes: the Vehicle Rated Capacity and tow weight) is 1406 kg (3100 lb).

The maximum vertical load that can be applied to the receiver hitch is 68 kg (150 lb).

Figure 43 B

D

C

A

Decal Inside Cargo Box

NA5175

Refer to [Figure 43] for references below.

A - Weight of Occupant(s) B - Maximum Cargo Box Load = 500 kg (1100 lb) C - Maximum Trailer Hitch Tongue Weight = 68 kg (150 lb) D - Tow Weight (Level Ground) = 680 kg (1500 lb) (Including weight of trailer) D - Tow Weight (15° Slope Maximum) = 386 kg (850 lb) (Including weight of trailer) Vehicle Rated Capacity = A plus B = 725 kg (1600 lb) Maximum Total Rated Capacity (when towing) = A plus B plus D = 1406 kg (3100 lb) Maximum

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3400, 3400XL Operation & Maintenance Manual

Vehicle Rated Capacity

OPERATING PROCEDURE (CONT’D) Vehicle Load Capacities (Model 3400XL)

The maximum amount of weight the vehicle can carry (this includes: cargo box load, weight of occupant(s), storage bin load and the weights of any accessories including cab kits) is 840 kg (1850 lb).

Maximum Cargo Box Load The maximum load that can be carried in the Cargo Box of the vehicle is 500 kg (1100 lb).

Total Rated Capacity

Maximum Trailer Hitch Tongue Weight

The maximum load that can be applied to the utility vehicle including towed weight (this includes: the Vehicle Rated Capacity, towed weight) is 1520 kg (3350 lb).

The maximum vertical load that can be applied to the receiver hitch is 68 kg (150 lb).

Figure 44

B

D

C

A

E

A Decal Inside Cargo Box

NA5176

Refer to [Figure 44] for references below.

A - Weight of Occupant(s) B - Maximum Cargo Box Load = 500 kg (1100 lb) C - Maximum Trailer Hitch Tongue Weight = 68 kg (150 lb) D - Tow Weight (Level Ground) = 680 kg (1500 lb) (Including weight of trailer) D - Tow Weight (15° Slope Maximum) = 386 kg (850 lb) (Including weight of trailer) E - Cargo Bin Load = 113 kg (250 lb) Vehicle Rated Capacity = A plus B plus E = 840 kg (1850 lb) Maximum Total Rated Capacity (when towing) = A plus B plus D plus E = 1520 kg (3350 lb) Maximum

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3400, 3400XL Operation & Maintenance Manual

OPERATING PROCEDURE (CONT’D)

Opening And Closing The Tailgate

Belt Life

Figure 45

To extend belt life, use the low gear when hauling or towing heavy cargo.

CONDITION

GEAR TO USE

Operating at speeds less than 11 km/ h (7 mph) Towing heavy loads Operating in rough terrain (swamps, mountains, etc.)

Operating at speeds greater than 11 km/h (7 mph)

Low

1

Low Low High P-97276A

Opening Release the latch (Item 1) [Figure 45] to open the tailgate.

Closing Raise the tailgate fully to the latched position.

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3400, 3400XL Operation & Maintenance Manual

OPERATING PROCEDURE (CONT’D) Raising And Lowering The Cargo Box (With Lift Assist)

WARNING

WARNING

AVOID INJURY OR DEATH Operating the vehicle while the cargo box is raised could result in serious injury. The box could close unexpectedly and cause injury to the driver or passenger. The rear tires will also catch the rear of a raised box, damaging the vehicle and creating hazardous driving conditions. Never operate the vehicle with the cargo box in the raised position.

AVOID INJURY OR DEATH If the weight distribution on the box is located toward the rear of the box when the release lever is lifted, the box may dump unexpectedly and cause serious injury to the operator or bystanders. Never operate the dump lever without ensuring that the load is positioned evenly or at the front of the box.

W-2827-0510

W-2826-0510

Raising And Lowering The Cargo Box (With Power Lift Assist)

Figure 46

Figure 47

1

1

P-97367 P-97277A

Press the top of the switch (Item 1) [Figure 47] to raise the cargo box.

The box release lever (Item 1) [Figure 46] is located under the lower front of the cargo box (both sides).

Press the bottom of the switch (Item 1) [Figure 47] to lower the cargo box.

1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline.

2. Press the brake pedal.

3. Place the transmission in gear.

4. Engage the park brake.

5. Stop the engine and exit the vehicle.

6. Ensure that the cargo is positioned evenly or towards the front of the cargo box.

7. Release the tailgate latch (Item 1) [Figure 45] and lower the tailgate.

8. Stand clear of the side of the cargo box and pull up on the cargo box release lever (Item 1) [Figure 46].

9. Lift the front of the cargo box to dump the cargo.

10. Lower the cargo box fully and push down on the front of the box until securely latched.

11. Close the tailgate.

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3400, 3400XL Operation & Maintenance Manual

OPERATING PROCEDURE (CONT’D) Towing Equipment With The Utility Vehicle Towing improperly can alter the vehicle handling and may cause loss of control or brake instability. Always follow these precautions when towing: Figure 48

1

P-97281A

•

Never exceed trailer hitch tongue weight - 68 kg (150 lb).

•

Do not operate the vehicle faster than 16 km/h (10 mph) when towing. Towing the trailer increases braking distance

•

Do not tow more than the recommended weight for the vehicle. (See Vehicle Load Capacities (Model 3400) on Page 49.) or (See Vehicle Load Capacities (Model 3400XL) on Page 50.)

•

Attach a trailer to the trailer hitch receiver (Item 1) [Figure 48] only. Do not attach to any other location or you may loose control of the vehicle.

•

Never tow a trailer on a slope steeper than 15°.

•

Avoid sudden starts, sudden stops, and tight turns when towing. Slow down when driving on wet, slippery or rough terrains.

•

Avoid stopping on a slope when towing.

•

Always park towed equipment on level ground.

•

Make sure the coupler is of adequate capacity for the load being towed.

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3400, 3400XL Operation & Maintenance Manual

OPERATING PROCEDURE (CONT’D)

Disengaging The Four Wheel Drive (4x4)

Drive Mode Switch

To disengage Four Wheel Drive (4x4); press the switch to the center position (2WD - with rear Differential Lock) or the bottom position (Turf - with Differential Unlock). If Four Wheel Drive (4x4) is turned OFF while the front hubs are driving, they will not release until the rear wheel regain traction.

Engaging The Four Wheel Drive (4x4) Figure 49

2WD (Differential Locked)

In some situations, the front gear case may remain locked after disengaging the Four Wheel Drive (4x4) switch. If this occurs, you may notice increased steering effort and some vehicle speed restriction. Perform the following procedure to unlock the front gear case:

Turf (Differential Unlocked) 2 Wheel Drive

1. Stop the vehicle.

4x4(4WD)

1

2. Operate in reverse for at least 3 m (10 ft).

3. Stop completely.

P-97264

4. Shift into low gear and drive forward.

To engage Four Wheel Drive (4x4); press the top of the switch (Item 1) [Figure 49]. The amber 4x4 light will be illuminated when engaged.

5. If the front gear case remains locked after following these instructions, see your Bobcat dealer for service.

When Four Wheel Drive (4x4) is engaged, the front wheels will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front wheels will automatically disengage and will remain disengaged until rear wheels again lose traction and the front wheels will again automatically reengage. There is no limit to the length of time the vehicle may remain in Four Wheel Drive (4x4).

NOTE: The Four Wheel Drive (4x4) switch may be turned ON or OFF while the vehicle is moving.

Engage the Four Wheel Drive (4x4) before getting into conditions where the four wheel drive may be needed. If the rear wheels are spinning, release the throttle before switching to Four Wheel Drive (4x4).

IMPORTANT Switching to Four Wheel Drive (4x4) while the rear wheels do not have traction may cause severe drive shaft and clutch damage. Always switch to Four Wheel Drive (4x4) while the rear wheels have traction or are stopped.

I-2296-0510

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3400, 3400XL Operation & Maintenance Manual

OPERATING PROCEDURE (CONT’D)

TOWING THE UTILITY VEHICLE

Drive Mode Switch (cont’d)

Procedure

2 Wheel Drive (Differential Locked)

The utility vehicle can be towed using the following procedure.

•

Connect a strap or chain to the front tow loop for towing forward. Connect the strap or the chain to the receiver hitch to tow in the reverse direction. (Only tow for a short distance in the reverse direction.)

•

Have an operator in the utility vehicle, with the seat belt fastened, for steering and applying the brakes while towing.

•

Disengage the parking brake and place the gear selector in neutral.

•

Tow vehicle at a slow speed.

IMPORTANT Damage to the differential can occur if it is engaged while the vehicle is traveling at high speeds or while the rear wheels are spinning. Slow the vehicle to nearly stopped before engaging the Two Wheel Drive (Differential Locked).

I-2297-0510

Locking the differential in slippery or low traction conditions helps improve traction. Move the switch (Item 1) [Figure 49] to the center position (2 Wheel Drive - with differential locked).

The towing strap (chain or cable) must be rated at one and one-half times the weight of the utility vehicle. (See Performance on Page 127.)

Figure 50

Four Wheel Drive (4x4)

2 Wheel Drive (with differential locked)

TURF (with differential unlocked)

P-97279

Turf (Differential Unlocked) Press the bottom of the switch to unlock the differential and allow the rear wheels to operate independently. This mode of operation is suited to turf driving or whenever aggressive traction is not required.

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3400, 3400XL Operation & Maintenance Manual

TRANSPORTING THE UTILITY VEHICLE ON A TRAILER

Fastening

Loading And Unloading

Use the following procedure to fasten the utility vehicle to the transport vehicle to prevent it from moving during turns, sudden stops or when going up and down slopes.

WARNING

Put the gear selector in gear, engage the park brake, stop the engine and remove the key.

AVOID SERIOUS INJURY OR DEATH Adequately designed ramps of sufficient strength are needed to support the weight of the machine when loading onto a transport vehicle. Wood ramps can break and cause personal injury.

Figure 53

W-2058-0807

Be sure the transport and towing vehicles are of adequate size and capacity for the weight of utility vehicle. (See Performance on Page 127.)

1

Figure 51

P-97381

Fasten the front of utility vehicle using the front tie down point (Item 1) [Figure 53].

Figure 54

SUPPORT

P-97379

The Utility Vehicle can be loaded or unloaded forward or backward [Figure 51].

The rear of the trailer must be blocked or supported [Figure 51] when loading or unloading to prevent the front end of the trailer from raising up.

1

Figure 52

P-97380

Fasten the rear of utility vehicle using the receiver hitch safety chain loops (Item 1) [Figure 54] as the tie down point.

Use chain binders to tighten the chains and then safely tie the chain binder levers to prevent loosening.

1 P-97400

It may be necessary to remove items installed in the receiver hitch (Item 1) [Figure 52] before loading or unloading to prevent them from hitting the ground.

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3400, 3400XL Operation & Maintenance Manual

PREVENTIVE MAINTENANCE MAINTENANCE SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 PERIODIC MAINTENANCE AND SEVERE USE DEFINITION . . . . . . . . . . . . . . . . . . . . . . . . 63 Severe Use Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 BACK-UP ALARM SYSTEM (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66 START INTERLOCK SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 PARKING BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Adjusting Park Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Brake Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 THROTTLE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Throttle Freeplay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Throttle Body / Idle RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 Throttle Freeplay Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 SHIFT CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Inspecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 STEERING AND SUSPENSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Inspection And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 ROLLOVER PROTECTIVE STRUCTURE (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

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3400, 3400XL Operation & Maintenance Manual

AIR CLEANER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Pre-Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76 Replacing Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 Engine Breather Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77 SEAT(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 Fuel Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 Filling The Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 Filling A Portable Fuel Container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 Checking And Adding Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 Removing And Replacing Oil And Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81 Oil Pump Priming Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83 ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85 Removing And Replacing Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87 Fuse And Relay Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88 Using A Booster Battery (Jump Starting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89 Removing And Installing Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91 Headlight Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 Brake Light / Tail Light Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92 Headlight Beam Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93 Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93 Spark Plug Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 CVT Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 CVT Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

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3400, 3400XL Operation & Maintenance Manual

GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Checking Transmission Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Transmission Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96 Adding Transmission Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Removing And Replacing Transmission Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96 Checking Front Gear Case Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Front Gear Case Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Adding Front Gear Case Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Removing And Replacing Front Gear Case Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 VEHICLE IMMERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 SPARK ARRESTER MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 REAR SUSPENSION ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Shock Absorber Position Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100 Shock Absorber Spring Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 SUPPORTING THE UTILITY VEHICLE ON JACKSTANDS . . . . . . . . . . . . . . . . . . . . . . . . . 101 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 TIRE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Tire Tread Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Axle And Wheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102 Wheel Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 FRONT COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Belt Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 WHEEL TOE ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 Toe Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106 LUBRICATING THE UTILITY VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107 Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 UTILITY VEHICLE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108 Washing The Utility Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108 Polishing The Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 59

3400, 3400XL Operation & Maintenance Manual

UTILITY VEHICLE STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . .109 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109 Return To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

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MAINTENANCE SAFETY WARNING

Instructions are necessary before operating or servicing the utility vehicle. Read and understand the Operation & Maintenance Manual and signs (decals) on utility vehicle. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death.

W-2859-0510

Safety Alert Symbol: This symbol with a warning statement, means: “Warning, be alert! Your safety is involved!”

Carefully read the message that follows.

CORRECT

P-90216

Never service the utility vehicle without instructions.

CORRECT

WRONG

WRONG

NA5187

NA5184

NA5201

Cleaning and maintenance are required daily.

Have good ventilation when welding or grinding painted parts.

Wear dust mask when grinding painted parts. Toxic dust and gas can be produced.

Avoid exhaust fume leaks which can kill without warning. Exhaust system must be tightly sealed.

Never modify equipment or add attachments and accessories not approved by Bobcat Company.

WRONG

WRONG

WRONG

NA5183

NA5186

B-6589

Stop, cool and clean engine of flammable materials before checking fluids.

Never service or adjust utility vehicle with the engine running unless instructed to do so in the manual.

Never fill fuel tank with engine running, while smoking or when near open flame.

Keep body, jewelry and clothing away from moving parts, electrical contact, hot parts and exhaust.

Wear eye protection to guard from battery acid, compressed springs, fluids under pressure and flying debris when engines are running or tools are used.

Use eye protection approved for type of welding.

Keep access doors closed except for service.

Lead-acid batteries produce flammable and explosive gases.

Keep arcs, sparks, flames and lighted tobacco away from batteries.

Batteries contain acid which burns eyes or skin on contact.

Wear protective clothing. If acid contacts body, flush well with water. For eye contact, flush well and get immediate medical attention.

Maintenance procedures which are given in the Operation & Maintenance Manual can be performed by the owner/ operator without any specific technical training. Maintenance procedures which are not in the Operation & Maintenance Manual must be performed ONLY BY QUALIFIED BOBCAT SERVICE PERSONNEL. Always use genuine Bobcat replacement parts.

MSW41-0510

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3400, 3400XL Operation & Maintenance Manual

PERIODIC MAINTENANCE AND SEVERE USE DEFINITION Careful periodic maintenance will help keep your vehicle in the safest most reliable condition. Inspection, adjustment and lubrication of important components are explained in the Preventative Maintenance section of this manual. Inspect, clean, lubricate, adjust and replace parts as indicated in the service schedule and as necessary. Use genuine Bobcat parts available from your Bobcat dealer.

Maintenance intervals in the following service schedule are based on average operating conditions and an average speed of approximately 16 km/h (10 mph).

Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition •

Frequent immersion in mud, water or sand.

•

Frequent or environments.

•

Prolonged low speed, heavy load operation.

•

Extended idle.

•

Short trip cold weather operation.

prolonged

operation

in

dusty

Pay special attention to the engine oil level. A rise in oil level during cold weather can indicate condensation collecting in the oil sump or crankcase due to the vehicle being operated for short periods and not allowing the engine to reach operating temperature. Change the engine oil immediately if the engine oil level begins to rise. Monitor the engine oil level and discontinue use if it continues to rise. See your Bobcat dealer to determine the cause.

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3400, 3400XL Operation & Maintenance Manual

SERVICE SCHEDULE Chart Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The service schedule is a guide for correct maintenance of the Bobcat product.

WARNING

Instructions are necessary before operating or servicing the utility vehicle.

Read and understand the Operation & Maintenance Manual and signs (decals) on the utility vehicle. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service. Untrained operators and failure to follow instructions can cause injury or death.

W-2859-0510

SERVICE SCHEDULE ITEM Brake Fluid, Fuel, Engine Oil and Coolant Brake System and Pedal Travel Throttle ROPS and Seat Belt

HOURS

SERVICE REQUIRED Check the levels and add as needed.

DAILY [4]

10

25

50 100 200

[4] Ensure proper operation.

Ensure proper operation.

Check the condition of the ROPS and mounting hardware. Check the condition of seat belts. Clean or replace seat belt retractors as needed.

Front and Rear Suspension and Steering Inspect for broken parts, loose hardware and free operation.

[4] Safety Signs (Decals) Check for damaged or missing signs (decals). Replace any signs that are damaged or missing.

Frame Fasteners Inspect and ensure tightness.

Head Lights, Tail Lights, Indicator Lights Check for proper operation and apply dielectric grease when a lamp is and Switches replaced.

Wheel Nuts Check for loose wheel nuts and tighten to correct torque. See TIRE MAINTENANCE in this Manual.

Engine Air Filter Inspect, clean and replace as needed.

[4] [5] [4] [5] Engine Air Pre-Filter Inspect, clean and replace as needed.

Battery Check cables, connections, clean and test.

Front Differential Lubricant Check lubricant level; add as needed.

[2] [4] [2] [4] Transmission Lubricant Check lubricant level; add as needed.

[4] [5] Engine Breather Filter Inspect. Replace if necessary or at the same time as the engine air filter.

[4] Brake Pad Wear Inspect. Replace if necessary.

Shift Linkage Inspect, lubricate and adjust.

Front Prop Shaft Yoke Locate the fitting(s) and grease (3 pumps maximum).

[4] [5] Throttle Cable Inspect for damage. Adjust or replace if necessary.

[5] Air Intake System Inspect all air intake lines and throttle body flange for leaks and repair if necessary.

Park Brake Cable Tension Check tension and adjust if necessary.

Fuel System Check for leaks at tank cap, lines and throttle body.

[6] Radiator Check for leaks and clean external surfaces.

Cooling Hoses, Engine Mounts, Exhaust Inspect for damage or leaks (if applicable) Replace components if Pipe and Muffler necessary.

Engine Oil and Filter Replace oil and filter. Clean oil tank screen. See specification section for [1] [4] proper synthetic oil requirements.

[5] Spark Plug Inspect condition and gap. Replace if necessary.

Wiring Inspect for wear and routing. Apply dielectric grease to connectors subjected to water, mud, etc.

Clutches, (Drive and Driven) and Drive Inspect for damage or wear. Clean clutches and replace worn parts.

[4] Belt [4] Front and Rear Suspension and Steering Inspect for steering freeplay and suspension wear.

Front Wheel Bearings Inspect. Replace as needed.

Toe Adjust Inspect front axle toe adjustment. Adjust if necessary and when parts are replaced.

Brake Fluid Replace the fluid.

Coolant Replace the coolant Every 2 years Spark arrester Muffler Empty Spark Chamber.

Every 300 Hours or 3 years

[1] [2] [3] [4] [5] [6]

[3]

First oil and filter change must occur at one month or 25 hours (whichever comes first); then as scheduled.

Change yearly.

Change as scheduled or every 2 years (whichever comes first).

Perform these procedure more often for vehicles subjected to severe use.

Emission Control System Service.

Replace lines every 2 years.

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3400, 3400XL Operation & Maintenance Manual

Figure 55

SEAT BELT Inspection And Maintenance

1

WARNING

3

Failure to properly inspect and maintain the seat belt can cause lack of operator restraint resulting in serious injury or death.

W-2466-0703

2

Check the seat belt daily for correct function.

4

Inspect the seat belt system thoroughly yearly or more often if the utility vehicle is exposed to severe environmental conditions or applications.

The seat belt system should be repaired or replaced if it shows cuts, fraying, extreme or unusual wear, significant discolorations due to ultraviolet (UV) rays from the sun, dusty / dirty conditions, abrasion to the seat belt webbing, or damage to the buckle, latch plate, retractor (if equipped), and hardware.

B-22283A

The items below are referenced in [Figure 55].

1. Check the webbing. If the system is equipped with a retractor, pull the webbing completely out and inspect the full length of the webbing. Look for cuts, wear, fraying, dirt and stiffness.

2. Check the buckle and latch for proper function. Make sure latch plate is not excessively worn or deformed and buckle is not damaged.

3. Check the retractor web storage device (if equipped) by extending the seat belt webbing to determine if it extends and retracts the webbing correctly.

4. Check webbing in areas exposed to ultraviolet (UV) rays from the sun or extreme dust or dirt. If the original color of the webbing in these areas is extremely faded and / or the webbing is packed with dirt, the webbing strength may have weakened.

See your Bobcat dealer for approved seat belt system replacement parts for your utility vehicle.

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3400, 3400XL Operation & Maintenance Manual

Inspect the back-up alarm electrical connections and the wire harness for tightness and damage. Repair or replace any damaged components.

BACK-UP ALARM SYSTEM (IF EQUIPPED) Description

Figure 58

This utility vehicle may be equipped with a back-up alarm system. The back-up alarm will sound when the key switch is in the ON position and the operator moves the Gear Selector Lever to the reverse travel position.

Inspecting

1 Figure 56

P-97264

1 The back-up alarm activation switch is an integral part of the Gear Selector Lever (Item 1) [Figure 58].

If the back-up alarm does not sound, [with the key switch in the ON position, engine not running and the Gear Selector Lever (Item 1) [Figure 58] is in the reverse travel position], check for 12 volt power at the electrical connector at the back-up alarm (Item 1) [Figure 57].

P-97369

Inspect for damaged or missing back-up alarm decal (Item 1) [Figure 56] located on the panel below operator’s seat. Replace if required.

If no power is detected, check harness connectors to make sure all connections are correct.

Enter the utility vehicle and perform the PRE-STARTING PROCEDURE. (See PRE-STARTING PROCEDURE on Page 38.)

Repair or replace components as needed.

Turn the key switch to the ON position but do not start the engine.

Move the Gear Selector Lever (Item 1) [Figure 58] to the reverse travel position. The back-up alarm must sound.

Figure 57

1

P-97368

The back-up alarm (Item 1) [Figure 57] is located on the frame by the left rear tire.

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3400, 3400XL Operation & Maintenance Manual

START INTERLOCK SYSTEM Inspecting The utility vehicle is equipped with a Start Interlock System. The brake pedal must be pressed for the engine to start.

Figure 59

1

P-97261

Figure 60

1

P-97266

To check the function of the Start Interlock System; pull the park brake lever (Item 1) [Figure 59] back fully, move the gear selector lever to neutral, remove foot from the brake pedal (Item 1) [Figure 60] and turn the key switch to the START position. The engine must not start.

If the engine starts when your foot is NOT on the brake pedal, see your Bobcat dealer for service.

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3400, 3400XL Operation & Maintenance Manual

PARKING BRAKE SYSTEM

Adjusting Park Brake Cable

Description

Figure 62

The park brake system requires regular inspection and maintenance. See the SERVICE SCHEDULE for intervals. (See SERVICE SCHEDULE on Page 64.)

2

1

Inspect and adjust the park brake cable to ensure proper cable tension. Loss of tension in the park brake cable may cause illumination of the park brake light (Item 2) [Figure 61] and cause activation of the engine rpm limiting feature.

Inspection And Maintenance Figure 61 P-97287

Position the utility vehicle on a flat level surface. Engage the park brake and stop the engine. Move the gear selector to neutral (N). Exit the utility vehicle. Place blocks in front of and behind the rear wheels so the utility vehicle can not roll.

2

Release the park brake.

1 Raise the cargo box.

Loosen the nut (Item 1) approximately 1.5 turns then tighten the nut (Item 2) [Figure 62] until it is tight to the cable mounting bracket.

P-97261

Repeat the inspection and maintenance procedure.

Press the brake pedal and pull the Park Brake Lever (Item 1) [Figure 61] back fully to engage the park brake.

With the key switch in the ON position, the Parking Brake light (Item 2) [Figure 61] will be illuminated.

The parking brake function check should be performed on a slope (15 degrees maximum). Conduct the check in an area free of objects and bystanders.

Back the utility vehicle up the slope. Engage the park brake lever fully, put the gear selector in the neutral position and stop the engine. Remove foot from brake pedal. The utility vehicle must not move.

If the utility vehicle moves after the inspection procedure, adjust the park brake cable and then repeat above procedure.

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3400, 3400XL Operation & Maintenance Manual

Park the utility vehicle on a flat, level surface. Engage the parking brake, stop the engine and exit the utility vehicle.

BRAKE SYSTEM Description

The brake master cylinder (Item 1) [Figure 63] can be viewed through an access hole in the left front wheel well.

The brake system requires regular inspection and maintenance. See the SERVICE SCHEDULE for intervals. (See SERVICE SCHEDULE on Page 64.)

The brake fluid level needs to be between the minimum and maximum fluid level lines [Figure 63].

The front and rear brakes are hydraulic disc type brakes activated by the brake pedal.

Figure 64

Inspection And Maintenance Brake Fluid

1

WARNING AVOID INJURY OR DEATH After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury.

P-97289

W-2872-0510

To add brake fluid, remove the front cover. (See FRONT COVER on Page 103.)

Check and change the brake fluid as scheduled. See the SERVICE SCHEDULE for intervals. (See SERVICE SCHEDULE on Page 64.) See your Bobcat dealer for changing brake fluid.

Clean the area around master cylinder cap (Item 1) [Figure 64] thoroughly to avoid any contamination from getting into the brake fluid reservoir when removing the cap.

NOTE: Change the brake fluid any time the fluid becomes contaminated, the fluid level is below the minimum, or any time the type and brand of brake fluid in the reservoir is unknown. Always use DOT 4 brake fluid in the utility vehicle.

Do Not overfill the brake fluid reservoir.

Remove the master cylinder cap (Item 1) [Figure 64] and use a clean, long neck funnel to add NEW brake fluid to the master cylinder until it is at the maximum fluid line.

Figure 63 Replace the cap as soon as the brake fluid has been added.

Apply the brakes forcefully for a few seconds and then check the brake fluid leakage around all of the brake fittings.

MAXIMUM MINIMUM

1

P-97370

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3400, 3400XL Operation & Maintenance Manual

BRAKE SYSTEM (CONT’D) Brake Inspection Figure 65

1

P-97290

Position the utility vehicle on a flat level surface. Engage the park brake and stop the engine. Exit the utility vehicle.

Check the brake pedal (Item 1) [Figure 65] for excessive travel or a spongy feel.

The correct amount of free travel on the brake pedal is 2,29 mm (0.090 in) [Figure 65].

Figure 66

1,0 mm(0.046 in) P-97291

The minimum pad thickness is 1,0 mm (0.046 in) [Figure 66].

NOTE: The tires must be removed to inspect brake pads. (See TIRE MAINTENANCE on Page 102.)

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3400, 3400XL Operation & Maintenance Manual

The correct throttle pedal freeplay is 1,6 - 3,2 mm (0.06 0.12 in).

THROTTLE SYSTEM Description

Throttle Body / Idle RPM

The throttle system requires regular inspection and maintenance. See the SERVICE SCHEDULE for intervals. (See SERVICE SCHEDULE on Page 64.)

The idle rpm is preset by the manufacturer. If the engine idle speed is not satisfactory, see your Bobcat dealer for adjustment.

Throttle Freeplay Adjustment

WARNING

Figure 68

AVOID INJURY OR DEATH Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks during operation. Always inspect the pedal for free movement and return before starting the engine and occasionally during operation. Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal. Immediately contact your Bobcat dealer for service if throttle problems arise.

1

W-2828-0510 P-97345

Throttle Freeplay

Figure 69

If the throttle pedal has excessive play due to cable stretch or mis-adjustment, it will cause a delay in the throttle response, especially at low engine speed. The throttle may also not open fully. If the throttle pedal has no freeplay, the throttle may be hard to control, and idle speed may be erratic.

2

1

Adjust freeplay as necessary.

Inspection And Maintenance Figure 67 P-97346

1

Position the utility vehicle on a flat level surface. Engage the park brake and stop the engine. Exit the utility vehicle.

1,6 - 3,4 mm (0.06 - 0.12 in)

Remove the seat. (See SEAT(S) on Page 78.)

The adjustment for the throttle cable is located under the boot (Item 1) [Figure 68]. Squeeze the end of the rubber boot and slide it far enough to expose the end of the in line cable adjuster.

Loosen the adjuster lock nut (Item 1) [Figure 69].

P-97344

Rotate the adjuster (Item 2) [Figure 69] until the correct amount of throttle pedal freeplay is achieved.

Position the utility vehicle on a flat level surface. Engage the park brake, place the gear selector lever in neutral.

Start the engine and allow to warm to operating temperature.

NOTE: While adjusting, lightly flip the throttle pedal up and down.

Tighten the lock nut (Item 1) [Figure 69] and slide the rubber boot (Item 1) [Figure 68] back to its original location.

Measure the distance the throttle pedal (Item 1) [Figure 67] moves before the engine picks up speed.

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3400, 3400XL Operation & Maintenance Manual

3. Move the gear select lever (Item 1) to the high range position. Make sure the lever (Item 1) is not contacting the top of the shift slot (Item 2) [Figure 71].

SHIFT CABLE ADJUSTMENT Inspecting Shift cable adjustment is necessary when any of the following is noticed: •

Noise on deceleration.

•

Inability to engage a gear

•

Excessive gear clash (noise).

•

Gear selector is moving out of desired range.

If there is any contact at either the bottom (Item 2) [Figure 70] or the top (Item 2) [Figure 71] of the gear selector shift slot, the shift cable will need to be adjusted.

Do the following: Adjustment Figure 72

Inspect the shift cable, clevis pins, and pivot bushings and replace if worn or damaged. Check the cable adjustment per the following procedure: Figure 70

2

1

1

P-97364

1. Loosen the jam nuts (Item 1 and 2) [Figure 72]

2

2. Rotate the two jam nuts (Item 1 and 2) [Figure 72], as needed, to move the gear selector lever up or down so the lever does not contact the slot at either the bottom or top position.

P-97418

Figure 71 3. Evenly tighten the two jam nuts (Item 1 and 2) [Figure 72] until tight to the cable mount.

2

1

4. Check operation of the gear selector. Start the engine. With the gear selector in neutral (the N light will be illuminated), slowly increase engine speed. No utility vehicle movement should occur and no gear clash noise detected. Shift into low gear (the L light will be illuminated), slowly increase the engine speed to check forward travel. Move gear selector to the reverse position (the R light will be illuminated), slowly increase engine speed to check reverse travel.

If the gear selector lever and cable can not be adjusted as indicated above, see your Bobcat dealer for service.

P-97419

1. Stop the vehicle on flat level surface, engage the park brake and stop the engine.

2. Move the gear select lever (Item 1) to the reverse position. Make sure the lever (Item 1) is not contacting the bottom of the shift slot (Item 2) [Figure 70].

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3400, 3400XL Operation & Maintenance Manual

Figure 74

STEERING AND SUSPENSION SYSTEM Description The steering system requires regular inspection and maintenance. See the SERVICE SCHEDULE for intervals. (See SERVICE SCHEDULE on Page 64.)

Inspection And Maintenance Figure 73

P-97294

Check The Front Suspension.

Rock the wheel side to side and top to bottom to check for excessive freeplay [Figure 74].

Figure 75 5 4 3 5

P-97293

3

Check the steering wheel for specified freeplay and smooth operation.

1

Position the utility vehicle on level ground.

6 Lightly turn the steering wheel while holding the front tire.

There should be 20 - 25 mm (0.8 - 1.0 in) [Figure 73] of freeplay.

2

If there is excessive freeplay or strange noises, or the steering feels rough or “catchy”, have the steering system inspected by your Bobcat dealer.

P-97299

While rocking the wheel side to side and top to bottom, also check the lower ball joints (Item 1), tie rod ends (Item 2), A-arms (Item 3) and upper strut mount (Item 4) [Figure 75] for excessive free play or damage. Make sure all hardware is tight. Repair or replace as necessary.

Check inner and outer axle shaft boots (Item 5) and the steering boots (Item 6) [Figure 75] for tears or cracking.

Repair or replace as necessary.

See your Bobcat dealer for service.

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3400, 3400XL Operation & Maintenance Manual

STEERING AND SUSPENSION SYSTEM (CONT’D) Inspection And Maintenance (Cont’d) Figure 76 2

1

3

3

1 P-97371

Check The Rear Suspension.

Rock the wheel side to side and top to bottom to check for excessive freeplay [Figure 76].

Inspect the upper and lower control arms (Item 1) [Figure 76] for damage (both sides). Repair or replace as needed.

Inspect the coil spring assembly (Item 2) [Figure 76] for damage (both sides). Repair or replace as needed.

Inspect the inner and outer axle shaft boots (Item 3) [Figure 76] for damage (both sides). Replace as needed.

Check all mounting hardware for tightness.

See your Bobcat dealer for service.

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3400, 3400XL Operation & Maintenance Manual

ROLLOVER PROTECTIVE STRUCTURE (ROPS)

Figure 78

Description 1

Figure 77

1

1 1 P-97292A

Figure 79

P-97292A

The utility vehicle has a Rollover Protective Structure (ROPS) to provide protection from rollover [Figure 77].

The seat belt must be worn for rollover protection.

1

Check the ROPS, mounting, and hardware for damage.

Never modify the ROPS. Replace the ROPS and hardware if damaged. See your Bobcat dealer for parts.

1

ROPS - Rollover Protective Structure per ISO 5700: 2006, SAE J2194: 2009, and OSHA 1928.53: 2006.

1

1

1

P-97372

WARNING

Make sure all ROPS mounting hardware [Figure 78], [Figure 79] and [Figure 80] is tight.

The correct torque for ROPS tube to ROPS tube mounting hardware (Item 1) [Figure 79] is 34 - 38 N•m (25 - 28 ft-lb).

AVOID INJURY OR DEATH Never modify ROPS by welding, grinding, drilling holes or adding attachments unless instructed to do so by Bobcat Company. Changes to the ROPS can cause loss of operator protection from rollover and result in injury or death.

Figure 80 1

W-2596-0510

1 P-97312

The correct torque for ROPS to frame mounting hardware (Item 1) [Figure 80] is 20 - 24 N•m (16 - 18 ftlb).

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3400, 3400XL Operation & Maintenance Manual

Figure 83

AIR CLEANER SERVICE Pre-Filter Element For the correct service interval of the pre-filter element (See SERVICE SCHEDULE on Page 64.)

The intake air pre-filter is located under the front cover.

The pre-filter traps larger particles before the air reaches the main engine air filter.

1

Removal Figure 81

P-97302

NOTE: The fiber pre-filter element must be gently removed from the box to avoid tearing or damaging the element. Inspect the element for damage. If any damage is found, replace the element.

1

Reach into the box and squeeze the pre-filter element (Item 1) [Figure 83] to collapse it to aid in removal.

P-97300

DO NOT used compressed air to clean the pre-filter box.

Use a clean damp cloth and wipe out the inside of the box.

Remove the front cover. (See FRONT COVER on Page 103.)

Cleaning Element

The pre-filter box (Item 1) [Figure 81] is connected to a rubber hose so the box can be relocated to access the element.

If the element is dirty, clean it with a high flash point solvent, followed by hot soapy water. Rinse and dry the filter element thoroughly. Inspect element for tears or damage. Replace if necessary.

Figure 82

Installation Squeeze the element (Item 1) [Figure 83] and insert into the box. Make sure the element is properly installed so that it fits snugly back into the box.

1 2

Reposition the box (Item 1) [Figure 81] back to its original location.

Reinstall the front cover.

P-97301

Rotate the box (Item 1) back to access the pre-filter element (Item 2) [Figure 82] for removal.

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3400, 3400XL Operation & Maintenance Manual

Figure 86

AIR CLEANER SERVICE (CON’D) Replacing Filter Element Raise the cargo box. (See Raising And Lowering The Cargo Box (With Lift Assist) on Page 52.) or (See Raising And Lowering The Cargo Box (With Power Lift Assist) on Page 52.)

For the correct service interval of the air cleaner (See SERVICE SCHEDULE on Page 64.)

1

Check the air intake hose, the filter element and the air cleaner housing for cracks, tears or damage. Check to make sure all connections are tight.

P-97308

Clean the inside of the filter housing. (Do not use compressed air.)

Figure 84 1

NOTE: There is a small notch (Item 1) [Figure 86] that locates the cover correctly on the filter housing. Make sure the notch in the cover matches the tab on the housing when reinstalling the cover.

2

Install the new filter element (Item 1) [Figure 85].

NOTE: Apply a small amount of general purpose grease to the inner sealing edges of the filter to aid in installing.

1

Locate the notch on the cover (Item 1) [Figure 86] with the tab on the housing and install the cover.

P-97306

Open the four retaining clamps (Item 1) and remove the cover (Item 2) [Figure 84].

Secure the cover (Item 2) with the four retaining clamps (Item 1) [Figure 84].

Figure 85

Engine Breather Filter For the correct service interval of the engine breather filter (See SERVICE SCHEDULE on Page 64.)

Figure 87

1 1

P-97307

Remove the filter element (Item 1) [Figure 85] (slowly twist and turn the element to remove).

P-97321

Remove and replace the engine breather filter (Item 1) [Figure 87].

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3400, 3400XL Operation & Maintenance Manual

Figure 89

SEAT(S) Removal And Installation Figure 88

1 2

P-97310

1

Installation P-97309

Position the tabs (Item 1) on the rear of the seat to the grooves (Item 2) [Figure 89] in the frame.

Removal Figure 90 Lift up on the front corners (Item 1) [Figure 88] of the seat (one corner at a time). (There is a retainer post on the front corners of the seat that fits into a grommet that secures the front seat.)

1

2

Slide the seat forward to remove.

P-97311

Position the seat posts (Item 1) into the rubber grommets (Item 2) [Figure 90] in the frame.

Press down on the front corners (Item 1) [Figure 88] until the seat is secured.

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3400, 3400XL Operation & Maintenance Manual

FUEL SYSTEM

Fuel Specifications THIS VEHICLE IS CERTIFIED TO OPERATE ON UNLEADED REGULAR GRADE GASOLINE ONLY. A minimum of 87 octane (R+M)/2 method) of the anti-knock index is recommended. The antiknock index is posted on service station pumps in the U.S.A. Fuel containing ethanol blends up to 10% by volume and meeting the minimum octane requirement are approved.

WARNING AVOID SERIOUS INJURY OR DEATH Failure to handle gasoline properly can result in a fire which may result in serious injury or death.

• Always exercise extreme caution whenever handling gasoline.

• Always stop the engine when refueling.

• Always refuel outdoors or in a well ventilated area.

• Remove flammable material containers from the box before filling them with fuel.

• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

• Do not overfill the tank. Do not fill the tank neck.

• If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing.

• Store gasoline in an approved gasoline container only. Store in a well-ventilated area away from sparks, open flames, heaters, or heat sources • Keep gasoline out of the reach of children.

• To avoid the possibility of fire, clean up any spilled gasoline before operating the vehicle.

Use only clean, fresh, unleaded regular grade gasoline.

Always stop the engine before refueling. Remove flammable material containers from the box before filling them with fuel. Make sure the refueling area is well ventilated and free of any source of flame or sparks.

Gasoline is extremely flammable. (See FUEL SYSTEM on Page 79.)

WARNING AVOID SERIOUS INJURY OR DEATH Gasoline is extremely flammable and can be explosive under certain conditions. Turn the engine switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.

Never fill the tank so the fuel level rises into the filler neck. If the tank is overfilled, heat may cause the fuel to expand and overflow through the vent in the fuel tank.

W-2857-0510

W-2871-0510

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3400, 3400XL Operation & Maintenance Manual

FUEL SYSTEM (CONT’D)

Filling A Portable Fuel Container

Filling The Fuel Tank

Static electric spark can explosively ignite gasoline vapors when filling ungrounded portable containers.

Always put the container ON THE GROUND before filling.

WARNING

Keep the nozzle in contact with container while filling.

AVOID INJURY OR DEATH Stop and cool the engine before adding fuel. NO SMOKING! Failure to obey warnings can cause an explosion or fire.

NEVER fill container in the cargo box or on the utility vehicle.

W-2063-0807

Figure 91

WARNING FIRE AND EXPLOSION CAN CAUSE SERIOUS INJURY OR DEATH Static electric spark can explosively ignite gasoline vapors when filling ungrounded portable containers.

• ALWAYS place the container ON THE GROUND before filling.

• Keep the nozzle in contact with container while filling.

• NEVER fill container in the cargo box, storage bins or on the machine.

1

W-2801-0709

P-97316

Remove the fill cap (Item 1) [Figure 91].

Use a clean, approved safety container to add fuel of the correct specification. Add fuel only in an area that has free movement of air and no open flames or sparks. NO SMOKING! Install and tighten the fuel cap (Item 1) [Figure 91].

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3400, 3400XL Operation & Maintenance Manual

ENGINE LUBRICATION SYSTEM

Removing And Replacing Oil And Filter

Checking And Adding Engine Oil

Follow the service interval for replacing the engine oil and filter (See SERVICE SCHEDULE on Page 64.)

Figure 92

Run the engine until it is at operating temperature.

Position the utility vehicle on a flat and level surface. Stop the engine and engage the park brake.

1 Remove the seat. (See SEAT(S) on Page 78.)

Clean the reservoir around the drain plug and clean the engine around the oil filter.

Figure 93

P-97318

Check the engine oil level every day.

1

Park the utility vehicle on a flat and level surface. Start the engine and let it idle for 20 - 30 seconds. Stop the engine. Remove the seat. (See SEAT(S) on Page 78.)

1

The engine oil fill cap / dipstick is located in the oil reservoir under the seat.

P-97318A

Remove the cap / dipstick (Item 1) [Figure 92] and wipe dry with a clean cloth. Reinstall the cap / dipstick and tighten completely. Remove the cap / dipstick and check the oil level. Keep the oil level between the marks on the dipstick. (Always install and tighten the cap / dipstick.)

The engine oil drain plug is located on the oil reservoir (Item 1) [Figure 93].

Remove the drain plug (Item 1) [Figure 93]. Drain the oil into a container and recycle or dispose of used oil in an environmentally safe manner.

NOTE: Rising oil levels between checks in cool weather driving can indicate moisture collecting in the oil reservoir. If the oil level is over the full mark, change the oil.

Reinstall the drain plug and tighten to 19 N•m (14 ft-lb).

Engine Oil Bobcat recommends the use of Bobcat synthetic engine oil 2W-50 or a similar oil. (See REGULAR MAINTENANCE ITEMS on Page 7.)

NOTE: Mixing brands or using a non-recommended oil may cause serious engine damage. Always use the recommended oil. Never substitute or mix oil brands.

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3400, 3400XL Operation & Maintenance Manual

Reinstall the hose (Item 2) and clamp (Item 1) [Figure 95].

ENGINE LUBRICATION SYSTEM (CONT’D) Removing And Replacing Oil And Filter (Cont’d)

NOTE: Any time the lower hose is removed, the Oil Pump Priming Procedure must be performed.

(See Oil Pump Priming Procedure on Page 83.)

Figure 94

Figure 96

1 1

P-97321

Remove the oil filter (Item 1) [Figure 94] and clean the filter housing surface.

P-97318

Use a genuine Bobcat filter only.

Remove the fill cap / dipstick (Item 1) [Figure 96].

Put clean oil on the new filter gasket, install the filter and hand tighten.

Put the correct quantity of oil in the engine (See Fluid And Capacities on Page 128.) Reinstall the fill cap.

Figure 95

Put the gear selector lever in neutral, engage the parking brake and start the engine. Let it run for several minutes.

Stop the engine and check for leaks at the filter.

Remove the cap / dipstick (Item 1) [Figure 96] and check the oil level. (See Checking And Adding Engine Oil on Page 81.)

2

Add oil as needed if it is not at the top mark on the dipstick.

1

Install the cap / dipstick.

3 P-97373

WARNING

Mark the orientation on the fitting / screen (Item 3) [Figure 95] before removing.

AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil.

Failure to use care around combustibles can cause explosion or fire.

Remove the clamp (Item 1) and the lower hose (Item 2) [Figure 95].

Remove the fitting / screen (Item 3) [Figure 95] from the oil tank. Clean the screen.

W-2103-0508

Install thread sealant to the fitting threads and reinstall the fitting. Tighten the fitting / screen until it is orientated as previously marked. (The maximum torque on the fitting is 34 N•m (25 ft-lb). Do not over tighten.)

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3400, 3400XL Operation & Maintenance Manual

Figure 98

ENGINE LUBRICATION SYSTEM (CONT’D) Oil Pump Priming Procedure NOTE: The oil pump priming procedure must be performed whenever the oil hose connection between the oil tank and oil pump inlet hose has been disconnected.

Park the vehicle on a flat and level surface.

1

Move the gear selector to the neutral position, engage the park brake and stop the engine.

Remove the seat. (See SEAT(S) on Page 78.)

P-97348

Figure 97

Clamp or pinch off the vent hose approximately two inches from the oil tank (Item 1) [Figure 98] (to avoid the end of the tank fitting), and before the vent hose pressure relief slit (Item 1) [Figure 97].

1

Start the engine and run the engine for 10 to 20 seconds.

Stop the engine.

Remove the clamp or stop pinching off the hose (Item 1) [Figure 98] and position it back to its original location.

The oil pump will now be properly primed and ready for field operation.

NOTE: If the system is primed properly you should hear some air release when the vent hose is unclamped. If not, the system has not primed properly. Repeat the process if necessary.

P-97347

NOTE: The oil reservoir vent hose has a pressure relief slit (Item 1) [Figure 97] cut into the hose from the factory. If replacing this hose, make sure that there is a slit in this hose for proper venting.

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3400, 3400XL Operation & Maintenance Manual

NOTE: The cooling system is factory filled with ethylene glycol coolant (green color). DO NOT mix ethylene glycol with propylene glycol.

ENGINE COOLING SYSTEM Checking Level Follow the service interval for checking the coolant level. (See SERVICE SCHEDULE on Page 64.)

IMPORTANT WARNING

AVOID ENGINE DAMAGE Always use the correct ratio of water to antifreeze.

AVOID INJURY Stop the engine and allow to cool before adding coolant or you can be burned.

Too much antifreeze reduces cooling system efficiency and may cause serious premature engine damage.

W-2106-0907

Too little antifreeze reduces the additives which protect the internal engine components; reduces the boiling point and freeze protection of the system.

Figure 99

Always add a premixed solution. Adding full strength concentrated coolant can cause serious premature engine damage.

1

I-2124-0497

Ethylene Glycol

WARNING P-97322A

AVOID BURNS Do not remove radiator cap when the engine is hot.

You can be seriously burned.

The coolant recovery tank is located under the front cover. The coolant level can be visually check by looking through an access hole (Item 1) [Figure 99] in the right front corner of the utility vehicle.

W-2070-1203

Add premixed coolant; 50% ethylene glycol 50% distilled water to the recovery tank if the coolant level is low.

(Mixture of up to 60% ethylene glycol 40% water is acceptable.)

Figure 100

One U.S. gal of ethylene glycol mixed with one U.S. gal of distilled water is the correct mixture of coolant to provide a -37°C (-34°F) freeze protection.

MAXIMUM MINIMUM

Use a refractometer to check the condition of ethylene glycol in your cooling system.

P-97323

The coolant level in the recovery tank must be between the marks on the tank when the engine is cool [Figure 100]. (Illuminate the back side of the recovery tank with a flash light to see the fluid level easier.)

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3400, 3400XL Operation & Maintenance Manual

ENGINE COOLING SYSTEM (CONT’D)

Figure 101

Cleaning

WARNING

1

AVOID INJURY Use safety goggles when using air or water under pressure. Do not use cold water to clean a hot engine.

W-2064-0907 P-97342

Check the cooling system every day to prevent overheating, loss of performance or engine damage.

Figure 102

Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan. Interference with the radiator air flow can lead to overheating and consequent engine damage.

IMPORTANT

1

Do not use a pressure washer to clean the radiator.

High pressure can damage the fins.

I-2318-0510

P-97326

Remove the front cover. (See FRONT COVER on Page 103.)

Use low air or water pressure to remove debris in the area of the radiator (Item 1) [Figure 101] and (Item 1) [Figure 102].

Check the cooling system for leaks.

Reinstall the front cover.

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3400, 3400XL Operation & Maintenance Manual

Figure 104

ENGINE COOLING SYSTEM (CONT’D) Removing And Replacing Coolant

2

Follow the service interval for replacing the coolant. (See SERVICE SCHEDULE on Page 64.)

Remove the front cover. (See FRONT COVER on Page 103.)

1

WARNING

1

AVOID INJURY Stop the engine and allow to cool before adding coolant or you can be burned.

P-99339

W-2106-0907

Remove the five bolts (Item 1) and remove the right front inner fender panel (Item 2) [Figure 104].

Figure 105

WARNING AVOID BURNS Do not remove radiator cap when the engine is hot.

You can be seriously burned.

1

W-2070-1203

Figure 103 3

1

P-99340

At the bottom right corner of the radiator, open the drain valve (Item 1) [Figure 105] and drain the coolant into a container.

Close the drain valve.

2

Dispose of the used coolant in an environmentally safe manner.

Add premixed coolant to the coolant radiator until it is full.

Install the cap (Item 3) [Figure 103].

Add premixed coolant to the coolant recovery tank until it is at the full mark. Install the cap (Item 1) [Figure 103].

P-97326

Remove the cap (Item 1) [Figure 103] from the coolant recovery tank.

Put the transmission in neutral, engage the parking brake and start the engine. Allow the engine to run until it is at operating temperature.

Remove the hose (Item 2) [Figure 103] from the coolant recovery tank where it attaches to the radiator. Drain the coolant into a container.

Stop the engine and check the coolant level. Add premixed coolant to the recovery tank as needed.

Reinstall the right panel and the front cover.

NOTE: Some coolant level drop is normal after the coolant system has been drained and refilled.

The system will need to purge any air that was trapped in the system. Observe the coolant levels and maintain as recommended by adding coolant to recovery tank.

Reconnect the hose (Item 2) [Figure 103].

Open the radiator cap (Item 3) [Figure 103].

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3400, 3400XL Operation & Maintenance Manual

Figure 108

ELECTRICAL SYSTEM Description The utility vehicle has a 12 volt, negative ground, stator charging system. The electrical system is protected by fuses and relays. The fuses will protect the electrical system when there is an electrical overload. The reason for the overload must be found before starting the engine again.

9

Fuse And Relay Location

1

5

7

2

6

8

3

12

11

10

4

Figure 106 7176366

There is a decal [Figure 108] on the front of the vehicle fuse and relay panel cover which shows location and size of fuses and relays. Description and amp ratings (or relays) are also shown below.

1

P-97327

The fuse and relay panel (Item 1) [Figure 106] is located under the front cover. (See FRONT COVER on Page 103.)

Figure 107

REF

DESCRIPTION

AMP REF

DESCRIPTION

AMP

1

Power Lift Assist (Optional)

20

9

Chassis (Lights, Drive line, Accessories)

R

2

ACC

20

10 ECM

R

3

SPARE

20

11 Cooling Fan

R

4

SPARE

10

12 EFI (Regulator, Fuel Pump, Hourmeter)

R

5

Unswitched Power

10

6

Drive

20

7

EFI

20

8

Lights

20

R = Relay

P-97328

Remove the cover to get access to the fuses and relays [Figure 107].

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3400, 3400XL Operation & Maintenance Manual

ELECTRICAL SYSTEM (CONT’D)

Battery Charging

Battery Maintenance

Conventional Battery 1. Remove the battery from the vehicle to prevent damage from leaking or spilling electrolyte during charging. (See Removing And Installing Battery on Page 91.)

WARNING

2. Charge the battery with a charger output no larger than 1/10 of the battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater.

AVOID INJURY OR DEATH Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.

3. Reinstall the battery.

In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes.

Sealed Battery

If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.

The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory. Never pry the sealing strip off or add other fluid to this battery.

The following battery charging instructions apply only to the installation of a sealed battery which is the factory installed battery in this model. Read all instructions before preceding with the installation of this battery.

W-2065-0807

The single most important thing about maintaining a sealed battery is to keep it fully charged. Since the battery is sealed and the sealing strip cannot be removed, you must use a voltmeter or multimeter to measure DC voltage.

Figure 109

For a refresh charge, follow all the instructions below: 1. Check battery voltage with a voltmeter or a multimeter. A fully charged battery will register 12.8 V or higher.

2. If the voltage is less than 12.8 volts, recharge the battery at 1.3 amp or less until the battery voltage is 12.8 V or higher.

P-09589

3. When using an automatic charger, refer to the charger manufacture’s instructions for recharging.

When using a constant current charger, use the following guidelines:

P-09590

Always verify the battery condition before and 1 - 2 hours after the end of charging.

Always clean the battery terminals and cable ends when installing a new or used battery [Figure 109].

CHARGE TIME

Put grease on the battery terminals and cable ends to prevent corrosion.

STATE OF VOLTAGE CHARGE

ACTION

Battery Storage Whenever the vehicle is not used for a period of 3 months or more, remove the battery from the vehicle, ensure that the battery is fully charged and stored out of the sun in a cool, dry place. Check battery voltage during storage and recharge as needed to maintain a full charge.

Bobcat recommends maintaining battery charge by using a Bobcat Battery tender charger or by charging about once a month to make up for normal self-discharge. The Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined voltage.

88

(USING CONSTANT CURRENT CHARGER @ STANDARD AMPS SPECIFIED ON TOP OF BATTERY

100%

12.8 - 13.0V

None, check at 3 months from date of manufacture

None required

75% - 100%

12,5 - 12.8V

May need slight charge, if no charge given check in 3 months

3-6 hours

50% - 75%

12.0 - 12.5V

Needs Charge

5-11 hours

25% - 50%

11.5 - 12.0V

Needs Charge

At least 13 hours, verify state of charge

05 - 25%

11.5V or less Needs charge with desulfating charger

At least 20 hours

3400, 3400XL Operation & Maintenance Manual

ELECTRICAL SYSTEM (CONT’D)

Figure 110

Using A Booster Battery (Jump Starting) 2

1

IMPORTANT Do not use a running vehicle when jump starting, high current loads may damage charging system: • Bobcat recommends using a portable charge pack or a stand alone battery when jump starting.

• If jump starting from a second vehicle is necessary, make sure the engine of the second vehicle is off before attempting to start the vehicle with the dead battery.

I-2NEW-0610

If it is necessary to use a booster battery to start the engine, BE CAREFUL! NOTE: Do not jump start using a running vehicle.

Stop the engine on the vehicle being used for the booster battery before attempting to start the utility vehicle.

P-97329

Using A Portable Power Pack

The key switch must be OFF. The booster battery must be 12 volt.

Remove the seat. (See SEAT(S) on Page 78.)

Connect the positive (+) cable (Item 1) [Figure 110] of the booster pack to the positive (+) battery terminal.

WARNING

Connect the negative (-) cable (Item 2) [Figure 110] of the booster pack to a frame ground.

Start the engine.

BATTERY GAS CAN EXPLODE AND CAUSE SERIOUS INJURY OR DEATH Keep arcs, sparks, flames and lighted tobacco away from batteries. When jumping from booster battery make final connection (negative) at machine frame.

After the engine has started, remove the ground (-) cable (Item 2) [Figure 110] first. Remove the cable from the positive terminal (Item 1) [Figure 110].

Do not jump start or charge a frozen or damaged battery. Warm battery to 16°C (60°F) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery. Never lean over battery while boosting, testing or charging.

W-2066-0910

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3400, 3400XL Operation & Maintenance Manual

ELECTRICAL SYSTEM (CONT’D) Using A Booster Battery (Jump Starting) (Cont’d)

IMPORTANT

Figure 111

Damage to the charging system can occur if: • Engine is operated with battery cables disconnected.

• Battery cables are connected when using a fast charger or when welding. (Remove both cables from the battery.)

• Extra battery cables (booster cables) are connected incorrectly.

2

4

I-2217-0610 P-97330

1

3

P-39258

Using A Second Battery Or Vehicle For Jump Starting NOTE: Do not jump start using a running vehicle.

Stop the engine on the vehicle being used for the booster battery before attempting to start the utility vehicle.

Connect the end of the first cable (Item 1) to the positive (+) terminal of the booster battery. Connect the other end of the same cable to the positive (+) battery terminal (Item 2) [Figure 111] of the utility vehicle.

Connect the end of the second cable (Item 3) to the negative terminal of the booster battery. Connect the other end of the same cable to a frame ground (Item 4) [Figure 111] on the utility vehicle.

Start the engine.

After the engine has started, remove the ground (-) cable (Item 4) [Figure 111] first. Remove the cable from the positive terminal (Item 2) [Figure 111]. Then remove the cables from the booster battery.

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3400, 3400XL Operation & Maintenance Manual

ELECTRICAL SYSTEM (CONT’D)

WARNING

Removing And Installing Battery

WARNING

BATTERY GAS CAN EXPLODE AND CAUSE SERIOUS INJURY OR DEATH Keep arcs, sparks, flames and lighted tobacco away from batteries. When jumping from booster battery make final connection (negative) at machine frame.

AVOID INJURY OR DEATH Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body.

Do not jump start or charge a frozen or damaged battery. Warm battery to 16°C (60°F) before connecting to a charger. Unplug charger before connecting or disconnecting cables to battery. Never lean over battery while boosting, testing or charging.

In case of acid contact, wash immediately with water.

In case of eye contact get prompt medical attention and wash eye with clean, cool water for at least 15 minutes.

W-2066-0910

If electrolyte is taken internally drink large quantities of water or milk! DO NOT induce vomiting. Get prompt medical attention.

W-2065-0807

Figure 112 4

3

3

1

2

P-97331

Remove the seat. (See SEAT(S) on Page 78.)

Disconnect the negative (-) cable (Item 1) [Figure 112].

Disconnect the positive (+) cable (Item 2) [Figure 112].

Remove the battery hold down bolts (Item 3) and battery hold down clamp (Item 4) [Figure 112].

Remove the battery.

NOTE: When installing the battery, do not touch any metal parts with the battery terminals.

Install the battery.

Install and tighten the battery hold down clamp and bolts.

Connect and tighten the battery cables. Connect the negative (-) cable last to prevent sparks.

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3400, 3400XL Operation & Maintenance Manual

ELECTRICAL SYSTEM (CONT’D)

Brake Light / Tail Light Replacement

Headlight Replacement

Figure 115

WARNING 1

AVOID INJURY Hot components can cause burns to skin. Allow lamps to cool before servicing.

W-2831-0510

2 Figure 113 1

2 1

P-97334

Remove the two screws (Item 1) and remove the rear lens (Item 2) [Figure 115].

Figure 116

P-97332

Open the front cover. (See FRONT COVER on Page 103.)

The high beam light bulb (Item 1) is to the inside and the low beam light bulb (Item 2) [Figure 113] is to the outside (both sides).

1

2

Figure 114 3

2

1 P-97337

Rotate the socket (Item 1 or 2) [Figure 116] approximately 1/4 turn and remove from the housing.

P-97333

The brake light is the top light and the tail light is the bottom light (both sides).

Rotate the bulb socket (Item 1) [Figure 114] approximately 1/8 turn counterclockwise to remove from the light housing.

Install the new bulb (Item 3) [Figure 116].

When installing the new bulb (Item 2) [Figure 114], Do Not touch the bulb with bare fingers. The oil on your skin will affect the performance of the light bulb. Use a clean cloth to grip the new bulb when inserting it into the connector. (See instructions included with the bulb for additional information.)

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3400, 3400XL Operation & Maintenance Manual

ELECTRICAL SYSTEM (CONT’D)

Spark Plug

Headlight Beam Adjustment

Follow the service interval for changing the spark plug. (See SERVICE SCHEDULE on Page 64.)

Figure 117 NOTE: Using a non-recommended spark plug can result in serious engine damage. Always use Bobcat recommended spark plugs.

7,6 m (25 ft)

X

254 mm (10.0 in) Low Beam

152 mm (6.0 in) High Beam

MODEL

GAP

NEW PLUG TORQUE

USED PLUG TORQUE

All

0,9 mm (0.035 in)

24 N•m (18 ft - lb)

24 N•m (18 ft - lb)

Spark Plug Inspection The spark plug condition is indicative of the engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds. Immediately check the spark plug for correct color.

X

P-97338

WARNING

When performing the headlight adjustment procedure, there should be both an operator and passenger(s) in the seat(s) for correct beam adjustment to simulate actual vehicle operation [Figure 117].

A hot exhaust system and engine can cause burns.

Wear protective gloves when removing a spark plug for inspection.

1. Place the vehicle on a flat and level surface with the headlight approximately 7,6 m (25 ft) from a wall.

W-2866-0510

2. Engage the park brake, stop the engine and exit the utility vehicle.

Figure 118

3. Measure the distance (X) from the floor to the center of the headlight. On the wall, directly in front of the vehicle, make a mark (X) on the wall at the same height.

1

4. The most intense part of the light should be aimed approximately 254 mm (10.0 in) for low beam, 152 mm (6.0 in) for high beam, below the (X) mark placed on the wall.

P-97341

5. Remove the front cover. (See FRONT COVER on Page 103.)

Remove the seat. (See SEAT(S) on Page 78.)

Remove the spark plug boot (Item 1) [Figure 118] and using the spark plug wrench supplied with the tool kit, remove the spark plug.

Installation: Tighten the spark plug to torque listed above.

Normal Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrode must not be burned or eroded. This indicated the proper type and heat range for the engine and the service.

The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect throttle body adjustments.

Wet Fouled Plug The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn.

General causes of fouling are excessive oil, use of a nonrecommended oil or incorrect throttle body adjustment.

6. Locate the headlight adjusting screws on the back of the headlight.

7. Loosen the screw, adjust the headlight and tighten the screw.

8. Repeat steps 5 - 8 until the headlights are in correct adjustment.

9. Reinstall the front cover.

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3400, 3400XL Operation & Maintenance Manual

CONTINUOUSLY VARIABLE TRANSMISSION (CVT)

CVT Drying There may be some instances when water is accidently ingested into the CVT system. Use the following instructions to remove the water before operating.

WARNING

Figure 119

AVOID SERIOUS INJURY OR DEATH Failure to comply with the instructions in this warning can result in serious injury or death.

Do not modify any component of the CVT system.

Doing so may reduce its strength so that a failure may occur at a high speed. The CVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.

1

The CVT system rotates at high speeds, creating large amounts of force on clutch components.

Extensive engineering and testing has been conducted to ensure safety of this product. However, as an owner, you have the following responsibilities to make sure this system remains safe: •

•

•

P-97356

1. Position the vehicle on a flat level surface. Stop the engine and exit the vehicle.

Always follow all recommended maintenance procedures. See your Bobcat dealer as outlined in the owners manuals.

The CVT system is intended for use on the Bobcat product only. Do not install it on any other product.

Always make sure the CVT housing is secured in place during operation.

2. Remove the drain plug (Item 1) [Figure 119] from the bottom of the clutch cover and allow the water to drain completely. Reinstall the drain plug.

3. Apply the brakes, engage the park brake, and start the engine.

W-2865-0510

4. Shift the gear selector to the neutral position.

5. Apply varying throttle for 10 - 15 seconds to expel the moisture and air-dry the belt and clutches. Do not hold the throttle wide open for more than 10 seconds.

6. Allow the engine RPM to settle to idle speed. Apply the brakes, release the park brake and shift the gear selector to low.

7. Test the belt for slippage. If the belt slips, repeat the above steps.

8. If the belt continues to slip, take the vehicle to your Bobcat dealer for service as soon as possible.

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3400, 3400XL Operation & Maintenance Manual

Installation

CONTINUOUSLY VARIABLE TRANSMISSION (CVT) (CONT’D)

Squeeze the element (Item 1) [Figure 83] and insert into the air box. Make sure the element is properly installed so that it fits snugly back into the air box.

CVT Filter The CVT system uses air flow to help cool the clutches and drive belt.

Lower the cargo box.

Follow the service interval for cleaning and changing the CVT filter. (See SERVICE SCHEDULE on Page 64.)

Figure 120

1

P-97360

Park the vehicle on a flat and level surface. Engage the park brake and stop the engine.

Raise the cargo box.

Removal The filter (Item 1) [Figure 120] is located in the air box behind the seat.

NOTE: The fiber element must be gently removed from the air box to avoid tearing or damaging the element. Inspect the element for damage.

If any damage is found, replace the element.

Reach into the air box and squeeze the element (Item 1) [Figure 120] to collapse it to aid in removal.

Use a clean damp cloth and wipe out the inside of the air baffle.

Cleaning Element If the element is dirty, clean it with a high flash point solvent, followed by hot soapy water. Rinse and dry the filter element thoroughly. Inspect element for tears or damage. Replace if necessary.

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3400, 3400XL Operation & Maintenance Manual

GEARCASE

Transmission Fluid

Checking Transmission Fluid

For the correct fluid information, (See Fluid And Capacities on Page 128.)

Follow the service interval for checking the transmission fluid level. (See SERVICE SCHEDULE on Page 64.)

Adding Transmission Fluid

Use only recommended fluid in the transmission. (See Fluid And Capacities on Page 128.)

If needed, remove the fill / check plug (Item 1) [Figure 121]. Use a long neck, flexible funnel and add fluid until it is at the bottom edge of the plug opening.

Put the utility vehicle on a flat and level surface.

Reinstall the plug and tighten to 16 N•m (12 ft-lb) torque.

Engage the park brake, stop the engine and exit the vehicle.

Removing And Replacing Transmission Fluid

Figure 121

Replace transmission fluid at the correct service interval.

(See SERVICE SCHEDULE on Page 64.)

Replace the fluid if it becomes contaminated.

Install a funnel and a container under the drain plug (Item 2) [Figure 121]. (See Fluid And Capacities on Page 128.)

1

2

Remove the drain plug (Item 2) [Figure 121]. Dispose of the used fluid in an environmentally safe manner.

Reinstall the drain plug (Item 2) [Figure 121] and tighten to 16 N•m (12 ft-lb) torque.

Remove the fill / check plug (Item 1) [Figure 121]. Use a long neck, flexible funnel and add fluid until it is at the bottom edge of the plug opening.

P-97339

The fill / check plug (Item 1) and drain plug (Item 2) [Figure 121] are located on the right side of the transmission, to the inside of the right rear tire.

Reinstall the fill / check plug (Item 1) [Figure 121] and tighten to 16 N•m (12 ft-lb) torque.

To check the fluid level, remove the plug (Item 1) [Figure 121]. The fluid level is correct when at the bottom edge of the fill plug.

WARNING AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil.

Failure to use care around combustibles can cause explosion or fire.

W-2103-0508

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3400, 3400XL Operation & Maintenance Manual

GEARCASE (CONT’D)

Front Gear Case Fluid

Checking Front Gear Case Fluid

For the correct fluid information, (See Fluid And Capacities on Page 128.)

Follow the service interval for checking the front gear case fluid level. (See SERVICE SCHEDULE on Page 64.)

Adding Front Gear Case Fluid

Use only recommended fluid in the front gear case. (See Fluid And Capacities on Page 128.)

If needed, remove the fill / check plug (Item 1) [Figure 121]. Use a long neck, flexible funnel and add fluid until it is at the bottom edge of the plug opening.

Put the utility vehicle on a flat and level surface.

Reinstall the plug and tighten to 11 -13 N•m (8 - 10 ft-lb) torque.

Engage the park brake, stop the engine and exit the vehicle.

Removing And Replacing Front Gear Case Fluid

Figure 122

Replace front gear case fluid at the correct service interval. (See SERVICE SCHEDULE on Page 64.)

Replace the fluid if it becomes contaminated.

Loosen the lug nuts on the left front wheel. Raise the front of the vehicle and install jackstands. Remove the left front wheel. Remove the left fender well panel.

Install a funnel and a container under the drain plug (Item 2) [Figure 122]. (See Fluid And Capacities on Page 128.)

1

2

Remove the drain plug (Item 2) [Figure 122]. Dispose of the used fluid in an environmentally safe manner.

P-97340

Reinstall the drain plug (Item 2) [Figure 122] and tighten to 15 N•m (11 ft-lb) torque.

The fill / check plug (Item 1) is located on the left front edge of the gear case and drain plug (Item 2) [Figure 122] is located on the bottom of the gear case.

Remove the fill / check plug (Item 1) [Figure 122]. Use a long neck, flexible funnel and add fluid until it is at the bottom edge of the plug opening.

To check the fluid level, remove the plug (Item 1) [Figure 122]. The fluid level is correct when at the bottom edge of the fill plug.

Reinstall the fill / check plug (Item 1) [Figure 122] and tighten to 11 -13 N•m (8 - 10 ft-lb) torque.

WARNING AVOID INJURY OR DEATH Always clean up spilled fuel or oil. Keep heat, flames, sparks or lighted tobacco away from fuel and oil.

Failure to use care around combustibles can cause explosion or fire.

W-2103-0508

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VEHICLE IMMERSION Description

IMPORTANT Immersion can result in major damage if the vehicle is not serviced correctly and promptly. After immersion, always take the vehicle to your Bobcat dealer for service. Do not start the engine! If it is impossible to bring the vehicle to your Bobcat dealer before starting the engine, perform the Vehicle Immersion service procedure outlined in this manual and take the vehicle to your dealer at the first opportunity.

I-2294-0510

NOTE: If your vehicle becomes immersed, major engine damage can result if the utility vehicle is not thoroughly inspected. Take the vehicle to your Bobcat dealer before starting the engine.

If it is impossible to take your utility vehicle to your dealer before starting it, follow the steps outlined below: 1. Move the vehicle to dry land or at the least, to water below the floorboards.

2. Dry any water present in the air cleaner housing. Filter replacement is required if water is present.

3. Thoroughly dry the air box filter (located under the front cover).

4. Remove the spark plug. Turn the engine over several times using the start key.

5. Dry the spark plug and reinstall or replace with a new spark plug.

6. Attempt to start the engine. If necessary, repeat the drying procedure.

7. Take the utility vehicle to your Bobcat dealer for service as soon as possible, whether you succeed in starting it or not.

8. If water has been in the CVT, follow the CVT drying procedure. (See CVT Drying on Page 94.)

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3. Purge accumulated carbon from the system by momentarily revving the engine several times.

SPARK ARRESTER MUFFLER Cleaning Procedure

4. If carbon is expelled, cover or plug the exhaust outlet (Item 2) [Figure 123] and rap on the pipe around the cleanout plug while revving the engine several times.

Clean the spark arrester muffler at the correct service interval. (See SERVICE SCHEDULE on Page 64.) Do not operate the utility vehicle with a defective exhaust system.

5. If particles are still are still suspected to be in the muffler, elevate the rear of the vehicle one foot higher than the front. Place blocks in front of and behind both front wheels.

WARNING

6. Repeat steps 3 and 4 until no more particles are expelled when the engine is revved.

Stop engine and allow the muffler to cool before cleaning the spark chamber. Wear safety goggles.

Failure to obey can cause serious injury.

7. Stop the engine and allow the spark arrester to cool.

W-2011-1285

8. Reinstall the plug(s) (Item 1) [Figure 123] and remove the outlet cover or plug.

WARNING

IMPORTANT

AVOID INJURY OR DEATH When an engine is running in an enclosed area, fresh air must be added to avoid concentration of exhaust fumes. If the engine is stationary, vent the exhaust outside. Exhaust fumes contain odorless, invisible gases which can kill without warning.

This vehicle is factory equipped with a U.S.D.A. Forestry Service approved spark arrester exhaust system.

The spark arrester muffler, if equipped, must be cleaned to keep it in working condition. The spark arrester muffler must be serviced by dumping the spark chamber every 300 hours of operation.

W-2050-0807

Engage the parking brake. Move the shift selector to the neutral position. Stop the engine and allow it to cool.

If this machine is operated on flammable forest, brush, or grass covered land, it must be equipped with a spark arrester attached to the exhaust system and maintained in working order. Failure to do so will be in violation of California State Law, Section 4442.

PRC. Refer to local laws and regulations for spark arrester requirements.

Remove any combustible materials from the area.

Figure 123

I-2331-0211

1 2 P-97359

1. Remove the plug (Item 1) [Figure 123] from the cleanout hole in the spark arrester muffler.

2. Start the engine.

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REAR SUSPENSION ADJUSTMENTS

Shock Absorber Spring Adjustment

Description

Figure 125

The rear suspension can be adjusted to provide stiffer or softer suspension.

NOTE: Model 3400XL is factory supplied with the rear suspension shock absorbers in the outer holes.

Shock Absorber Position Adjustment Figure 124 1

P-97349

2

The rear springs can be adjusted to increase or decease the ride height by rotating the adjuster (Item 1) [Figure 125]. This adjustment may be needed to level the vehicle if installing an accessory or attachment to the rear of the vehicle.

1

Figure 126 P-97358

1. Park the vehicle on a flat and level surface.

RAISE

2. Engage the parking brake, stop the engine and exit the vehicle. Place blocks in front of and behind the front tires.

1

LOWER

3. Raise the rear of the vehicle until the rear wheel are slightly off the ground and install jackstands under the rear frame. (See SUPPORTING THE UTILITY VEHICLE ON JACKSTANDS on Page 101.)

P-97350

4. Remove the top shock mounting bolt (Item 1) [Figure 124].

1. Park the vehicle on a flat and level surface.

5. Reposition the shock absorbers to the desired mounting hole (Item 1 or 2) [Figure 124] and reinstall the mounting bolts and nuts. (Tighten the bolts to 40 N•m (30 ft-lb) torque.)

2. Engage the parking brake, stop the engine and exit the vehicle.

3. Raise the rear of the vehicle until the rear wheels are just off the ground and install jackstands under the rear frame. (See SUPPORTING THE UTILITY VEHICLE ON JACKSTANDS on Page 101.)

6. Remove the jackstands.

NOTE: The inner mounting will provided a softer ride.

The outer mounting holes will provide a stiffer ride.

4. Use the spring adjusting spanner wrench (Item 1) [Figure 126] (included with the tool kit), to rotate the spring adjuster. Rotate counterclockwise (as viewed from above) to raise the ride height, clockwise to lower.

5. Remove the jackstands.

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SUPPORTING THE UTILITY VEHICLE ON JACKSTANDS

Figure 127

Procedure For service work under the utility vehicle, or to remove the wheels, always support the utility vehicle with jackstands or blocks of adequate capacity for weight of utility vehicle (See Performance on Page 127.)

1 Always park the utility vehicle on a flat level surface.

1

Engage the park brake. Stop the engine and put the gear selector in gear.

If removing wheel(s), loosen the wheel nuts slightly before lifting the vehicle.

P-97355

Place the jackstands (Item 1) [Figure 127] under the frame at the front of the utility vehicle.

WARNING

NOTE: When lifting the utility vehicle, place the jack under front frame [Figure 127].

AVOID INJURY OR DEATH Instructions are necessary before operating or servicing machine. Read and understand the Operation & Maintenance Manual, Operator’s Handbook and signs (decals) on machine. Follow warnings and instructions in the manuals when making repairs, adjustments or servicing. Check for correct function after adjustments, repairs or service.

Untrained operators and failure to follow instructions can cause injury or death.

Figure 128

W-2003-0807

1

1 P-97357

Place the jackstands (Item 1) [Figure 128] under the rear frame of the utility vehicle.

NOTE: When lifting the utility vehicle, place the jack under the rear frame [Figure 128].

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Wheel Removal And Installation

TIRE MAINTENANCE

Check the tires regularly for wear, damage and pressure.

Tires

WARNING

WARNING

AVOID INJURY OR DEATH Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Bobcat dealer.

AVOID INJURY OR DEATH Operating this vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures outlined in this manual and on the safety signs (decals). Always use the original equipment size and type when replacing tires.

W-2830-0510

Removal

W-2829-0510

1. Apply the brakes and engage the parking brake.

2. Stop the engine and place the gear selector in gear.

Tire Tread Depth

3. Loosen the wheel nuts slightly.

Figure 129

4. Raise the utility vehicle and install jackstands or blocks. (See SUPPORTING THE UTILITY VEHICLE ON JACKSTANDS on Page 101.)

5. Remove the wheel nuts. Remove the wheel.

Recommended tire pressure must be maintained to avoid excessive tire wear and loss of stability and handling capability. Check for correct pressure before operating.

NOTE: Install the wheel with the valve stem facing to the outside and the rotation arrow on the tire pointing to the front of the vehicle.

3,0 mm (0.125 in)

Installation P-97351

1. Apply the brakes and engage the parking brake.

2. Place the gear selector in gear.

Always replace tires when tread depth is worn to 3 mm (0.125 in) [Figure 129] or less.

3. Place the wheel in the correct position on the wheel hub. Be sure the valve stem is towards the outside and the rotation arrows on the tire point towards the forward rotation.

Axle And Wheel Nut Torque Check the wheel nut torque at the correct service interval (See SERVICE SCHEDULE on Page 64.)

4. Install the wheel nuts and tighten slightly.

5. Lower the utility vehicle to the ground. (See SUPPORTING THE UTILITY VEHICLE ON JACKSTANDS on Page 101.)

Do not lubricate the studs or lug nuts.

6. Tighten the wheel nuts to the correct torque.

Tighten the wheel nuts to the correct torque. For correct torque, (See Tires on Page 129.)

IMPORTANT Do not mix tire sizes. The front and rear tires used on this model are different sizes. Do not intermix front and rear tires.

I-2332-0510

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TIRE MAINTENANCE (CONT’D)

FRONT COVER

Mounting

Removal And Installation

Tires are to be repaired only by an authorized person using the proper procedures and safe equipment.

Figure 130

Tires and rims must always be checked for correct size before mounting. Check rim and tire bead for damage.

2

The rim flange must be cleaned and free of rust.

The tire bead and rim flange must be lubricated with a rubber lubricant before mounting the tire.

1

1

Avoid excessive pressure which can rupture the tire and cause serious injury or death.

P-97325

During inflation of the tire, check the tire pressure frequently to avoid over inflation.

Remove the two fasteners (Item 1) holding the front cover (Item 2) [Figure 130] and remove the cover using the wrench supplied with the tool kit.

WARNING AVOID INJURY OR DEATH Do not inflate tires above specified pressure. Failure to use correct tire mounting procedure can cause an explosion which can result in injury or death.

W-2078-1007

Tire Pressure Remove flammable material before filling. For tire pressures, (See Tires on Page 129.)

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3400, 3400XL Operation & Maintenance Manual

Figure 132

DRIVE BELT Removal Stop the machine on a flat level surface. Engage the parking brake, put the gear selector in gear (L) and stop the engine.

Allow the belt and clutches to cool.

Raise the cargo box.

1 Disconnect the negative battery cable before installing the belt.

Figure 131

P-97374

NOTE: Do not allow the belt to be twisted or turned inside out. This damages the internal belt cords and may cause the belt to flip (invert) during usage. If this happens, the belt must be replaced.

IMPORTANT 1 3

Do not use any type of tool to remove the drive belt from the clutches or drive belt and / or clutch damage may occur.

2 P-97365

I-2333-0510

NOTE: Mark the drive belt rotation. If reusing the existing belt, it must be reinstalled so that it rotates in the same direction.

Pull upward and rearward on the belt to open the driven clutch sheaves.

Pull out and down on the belt (Item 1) [Figure 132] to slip the belt over the driven clutch outer sheave.

Loosen the clamp (Item 1) [Figure 131].

Figure 133

Remove the eight bolts (Item 2) and the CVT outer cover (Item 3) [Figure 131].

1

P-97375

Remove the belt from the drive clutch (Item 1) [Figure 133].

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DRIVE BELT (CONT’D)

Belt Inspection

Installation

Inspect the belt for hourglass (extreme circular wear in at least one spot and on one side of the belt). Hour glassing occurs when the drive train does not move and the drive clutch engages on the belt.

Engage the parking brake and put the gear selector in neutral (N). Stop the engine.

Disconnect the negative battery cable before installing the belt.

Inspect belt for loose cords, missing cogs, cracks, abrasion, thin spots, pr excessive wear. Compare belt measurements with a new belt. Replace as needed.

Figure 134 Belts with thin spots, burn marks, etc. should be replaced to eliminate noise, vibration, or erratic CVT operation.

Figure 135

1

2 P-97376

NOTE: Do not allow the belt to be twisted or turned inside out. This damages the internal belt cords and may cause the belt to flip (invert) during usage. If this happens, the belt must be replaced.

P-97377

Make sure the belt can be rotated by hand and that the drive clutch is fully open and the driven clutch is in the closed position.

If installing the existing belt, make sure it is being installed in the correct rotation direction.

To check belt deflection (stretch), place a straight edge (Item 1) over the top of the belt. Press down in the center of the belt until lightly tensioned and measure (Item 2) [Figure 135] the belt deflection.

If installing a new belt, install the belt so the numbers on the belt are readable when installed.

Loop the belt over the drive clutch and over the top of the driven sheave [Figure 134].

The correct deflection is 29 - 32 mm (1.12 - 1.25 in).

While pushing down on the top of belt, turn the back or moveable driven sheave clockwise [Figure 134] until the belt is installed.

If the belt deflection is out of range, either install a new belt or the driven clutch will need to be adjusted. See your Bobcat dealer for clutch adjustment.

Reinstall the CVT cover.

Installation: Tighten the bolts to 5 - 5,6 N•m (45 - 50 in lb) torque.

Reconnect the negative battery cable.

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WHEEL TOE ALIGNMENT

Toe Adjustment

Inspection

Figure 137

The wheel toe alignment requires regular inspection and maintenance. (See SERVICE SCHEDULE on Page 64.)

Stop the machine on a flat level surface. Engage the parking brake and stop the engine.

Figure 136

1 254 mm (10.0 in) NA5216

NA5215

1. Turn the steering wheel so it is in the straight ahead position.

NOTE: Be sure the steering wheel is straight ahead before determining which tie rod needs adjustment.

2. Place a chalk mark (Item 1) [Figure 136] on the center of the front tires at approximately 254 mm (10 in) up from the floor (or as close to the centerline of the front axle as possible).

If the toe alignment is incorrect, measure the distance between the center of the vehicle and each wheel. This will determine which tie rod needs adjusting [Figure 137].

NOTE: It is important that the height of both marks be equally positioned to get an accurate measurement.

NOTE: During tie rod adjustment, make sure to use a wrench on both the tie rod end and the jam nut. Tie rod end damage could occur if the tie rod end is not held securely while loosening or tightening the tie rod jam nut.

3. Measure the distance between the marks and record this measurement. (We will call this dimension A.) 4. Disengage the parking brake and roll the vehicle ahead until the chalk marks are to the rear of the front tires (approximately at the centerline of the front axle).

Engage the barking brake.

1. Hold the tie rod end securely and loosen the jam nut.

2. Use a wrench on the flat spot on the tie rod and a wrench on the tie rod end. Rotate the tie rod to shorten or lengthen until the alignment is as required to achieve the proper toe setting.

5. Measure the distance between the chalk marks and record the dimension. (We will call this dimension B.)

3. When alignment is correct, hold the tie rod end securely and tighten the jam nut to 16 - 19 N•m (14 16 ft-lb) torque.

6. The difference between dimension A and B is the toe alignment. The recommended toe tolerance is 3,17 6,35 mm (0.125 - 0.25 in) to out. (This means the measurement “A” in front of the tire should be wider than the measurement “B” at the rear of the tire.

Toe Out

3,17 - 6,35 mm (0.125 - 0.25 in)

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3400, 3400XL Operation & Maintenance Manual

Figure 139

LUBRICATING THE UTILITY VEHICLE Lubrication Locations

1

Lubricate as specified for the best performance of the utility vehicle (See SERVICE SCHEDULE on Page 64.)

Always use a good quality lithium based multi-purpose grease.

2 2

Park the vehicle on flat level ground. Engage the park brake and stop the engine.

Model 3400 has only ONE grease fitting, Model 3400XL has two grease fittings.

P-97362A

Lubricate the following: The cover (Item 1) [Figure 139] located below the front seat needs to be removed to access the second grease fitting on model 3400XL only.

Figure 138

The cover has four tabs (Item 2) that retain the cover to the panel.) Lift up on the cover (Item 1) [Figure 139] to remove.

Figure 140

1

P-97361

2

1. Drive shaft u-joint (1) [Figure 138]. Located below the right front corner of the cargo box.

Apply 3 pumps of grease maximum.

P-97363

2. The 3400XL has a two piece drive shaft going to the front axle, lubricate the front grease fitting (1) [Figure 140] (located under the front seat).

Apply 3 pumps of grease maximum.

Reinstall the cover (Item 1) [Figure 139].

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UTILITY VEHICLE CLEANING Washing The Utility Vehicle

IMPORTANT

Keeping your Utility Vehicle clean will not only improve appearance but can also extend the life of some components.

•

IMPORTANT

•

High water pressure may damage components.

Bobcat recommends washing the vehicle by hand or with a garden hose, using mild soap.

I-2226-0910

If high pressure water systems are used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and safety signs (decals). Avoid directing the water stream at the following components:

I-2299-0510

IMPORTANT Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle. Wash vehicle promptly if contact occurs.

I-2300-0510

The best and safest way to clean your utility vehicle is with a garden hose and a pail of mild soap and water.

•

Use professional type washing cloth, cleaning the upper body first and the lower part last.

•

Rinse with clean water frequently.

•

Dry surfaces with a chamois to prevent water spots.

Do not use a power washer to clean the vehicle.

•

Do not use medium to heavy duty compounds on the finish.

•

Always use clean clothes and pads for cleaning and polishing. Old or reused cloths and pads may contain dirt particles that will scratch the finish.

Wheel bearings

•

Radiator

•

Transmission seals

•

Brakes

•

Vehicle and body panels

•

Safety Signs (decals)

•

Switches and controls

•

Electrical components and wiring

Lubricate all grease fittings immediately after washing.

Allow the engine to run for several minutes to evaporate any water that may have entered the engine or exhaust.

Avoid the use of harsh cleaners which can scratch the finish.

•

•

If a safety sign (decal) becomes damaged, illegible or comes off, replace the safety sign (decal). See your Bobcat dealer for replacements.

Washing Tips •

PRESSURE WASHING DECALS Never direct the stream at a low angle toward the decal that could damage the decal causing it to peel from the surface.

Direct the stream at a 90 degree angle and at least 300 mm (12 in) from the decal. Wash from the center of the decal toward the edges.

Polishing The Vehicle Bobcat recommends the use of common household aerosol furniture polish for polishing the finish on your utility vehicle. Follow the instruction on the container.

Polishing Tips

108

•

Avoid the use of automotive products, some of which can scratch the finish of the utility vehicle.

•

Always use clean clothes and pads for cleaning and polishing. Old or reused cloths and pads may contain dirt particles that will scratch the finish.

3400, 3400XL Operation & Maintenance Manual

UTILITY VEHICLE STORAGE AND RETURN TO SERVICE

Return To Service

Storage

After the utility vehicle has been in storage, it is necessary to follow a list of items to return the utility vehicle to service.

Sometimes it may be necessary to store your utility vehicle for an extend period of time. Below is a list of items to perform before storage.

•

Check the engine and transmission oil levels; check coolant level.

•

Install a fully charged battery.

•

Make sure the spark plug is properly torqued. (See Engine on Page 127.)

Park the utility vehicle in a dry protected shelter.

•

Fill the fuel tank and put fuel stabilizer in the fuel tank.

Run the engine 15 - 20 minutes to circulate the stabilizer through the fuel system. (Follow the instructions on the fuel stabilizer container.)

Lubricate the utility vehicle as shown in the Operation & Maintenance Manual.

•

Check tire inflation and remove blocks from under frame.

•

Remove cover from exhaust pipe opening.

•

If the fuel system was drained, add fuel.

•

Perform the items listed on daily Inspection. (See DAILY INSPECTION on Page 37.)

•

Start the engine and let run for a few minutes while observing the instrument panels and systems for correct operation.

•

Operate utility vehicle, check for correct function.

•

Stop the engine and check for leaks. Repair as needed.

•

Thoroughly clean the utility vehicle including the engine compartment.

•

Lubricate the utility vehicle as shown in the Operation & Maintenance Manual.

•

Replace worn or damaged parts.

• •

NOTE: If fuel system additive is not used to stabilize the fuel, the fuel system should be completely drained. Allow the engine to run until it stops on its own.

•

Drain and flush the cooling system. Refill with premixed coolant.

•

Replace all fluids and filters (engine, transmission, front gear case, etc.).

•

Inspect and clean or replace air filters. Clean the air baffles.

•

Put blocks under the frame to remove weight from the tires.

•

Remove the spark plug. Using a squeeze bottle and a clear plastic hose, add 2 - 3 tablespoons of engine oil through the spark plug hole. Reinstall the spark plug and torque properly.

NOTE: Do this carefully, if you miss the spark plug hole, oil will drain from the spark plug cavity into the hole at the front of the cylinder head and appear to be an oil leak.

•

With the spark plug wire removed, turn the engine over several times to force the oil around the cylinder walls and the piston rings leaving a protective film.

•

Apply dielectric grease to the inside of the spark plug cap and reinstall on the spark plug.

•

Put all controls in neutral position.

•

Remove the battery. Be sure the electrolyte level is correct (if applicable) then charge the battery. Store it in a cool, dry place above freezing temperatures and charge it periodically during storage.

•

Cover the exhaust pipe opening.

•

Tag the utility vehicle to indicate that it is in storage condition.

•

Store in a dry, well ventilated area. Do not use plastic or a coated cover over the vehicle. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

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SYSTEM SETUP & ANALYSIS DIAGNOSTIC SERVICE CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Check Engine Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Service Codes List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

111

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NOTE: Corroded or loose grounds can cause multiple service codes and/or abnormal symptoms. The same symptoms could apply if the voltage is low, such as loose or corroded battery cables. If you observe these symptoms, check grounds and positive leads first.

DIAGNOSTIC SERVICE CODES Check Engine Light NOTE: To avoid serious engine damage, service vehicle immediately if the check engine light comes ON. See your Bobcat dealer for service.

The Diagnostic Service Codes will help your dealer identify and correct problems with your utility vehicle.

Figure 141

1

P-97265

The check engine light (Item 1) [Figure 141] will illuminate if a diagnostic service code is enabled. The engine check light diagnostic mode is for informational purposes only. See your Bobcat dealer for service.

To view the diagnostic codes, do the following: 1. Stop the vehicle on a flat, level surface.

2. Engage the parking brake, place the gear selector in the neutral position and stop the engine.

3. Remove foot from the brake pedal. (The brake pedal must not be pressed while trying to activate the service codes.)

4. Turn the ignition key to the OFF position; then turn the key “ON-OFF-ON-OFF-ON” within five seconds.

(Leave the key in the ON position as the last step.)

5. The codes will be shown as a blinking code pattern with the check engine light (see codes listed below).

NOTE: If you do not get the “Check Engine Light” to flash codes, turn the key to the OFF position and wait for at least five seconds before attempting to retry step five.

If a code has been activated, the codes can only be deleted by your Bobcat dealer using a computer program that will check the diagnostic codes to determine if any corrective action needed before deletion.

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DIAGNOSTIC SERVICE CODES (CONT'D) Service Codes List BLINK CODE

CHECK ENGINE LIGHT ON?

DESCRIPTION NO.

FLASH

12

1 Blink - Pause - 2 Blinks

22

2 Blinks - Pause - 2 Blinks

31

3 Blinks - Pause - 1 Blink

41

4 Blinks - Pause - 1 Blink

42

4 Blinks - Pause - 2 Blinks

44 45 46 47

4 Blinks - Pause - 4 Blinks 4 Blinks - Pause - 5 Blinks 4 Blinks - Pause - 6 Blinks 4 Blinks - Pause - 7 Blinks

51

5 Blinks - Pause - 1 Blink

55

5 Blinks - Pause - 5 Blinks

56

5 Blinks - Pause - 6 Blinks

58

5 Blinks - Pause - 8 Blinks

61 74

6 Blinks - Pause - 1 Blink 7 Blinks - Pause - 4 Blinks

Beginning of the Blink Code Sequence (this will be present any time the Diagnostic Codes are checked) TPS Circuit: Open or Short To Ground TPS Circuit: Short To Battery Voltage System Voltage Low System Voltage High IAT Circuit: Short To Ground IAT Circuit: Open or Short To Battery Voltage ECT Circuit: Short To Ground ECT Circuit: Open or Short To Battery CPS Circuit Fault MAP Circuit: Open or Short To Ground MAP Circuit: Short To Battery Voltage IAC Circuit: Short To Ground IAC Circuit: Open or Short To Battery Voltage Injector 1: Open or Short To Ground Injector 1: Open or Short To Battery Voltage Check Engine Light: Open or Short To Ground Check Engine Light: Open or Short To Battery Voltage Fuel Pump Driver Circuit: Open or Short To Ground Fuel Pump Driver Circuit: Short To Battery Voltage Cooling Fan Driver Circuit: Open or Short To Ground Cooling Fan Driver Circuit: Short To Battery Voltage End of Blink Code Sequence Rear Differential Lock Control Circuit: Open or Short To Ground Rear Differential Lock Control Circuit: Short To Battery Voltage

Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes

TPS = Throttle Position Sensor IAC = Intake Air Temperature Sensor ECT = Engine Temperature Sensor MAP = Manifold Absolute Pressure CPS = Crankshaft Position Sensor NOTE: Any additional codes, not shown, will require the Bobcat dealer to use diagnostic software to view.

Diagnostic codes subject to change without notice.

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UTILITY VEHICLE SIGN TRANSLATIONS UTILTY VEHICLE SIGN TRANSLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Warning (7018022) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Warning (7018025) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Warning (7018021) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 Warning (7018026) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 Warning (7016342) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Caution (7016347) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121 Park Brake (7016357) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Park Brake (7016337) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Maximum Trailer Weight (7018610) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Operation Instruction (7018029) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Warning (7016362) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Warning (If Equipped With Back-up Alarm) (6737189) . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

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UTILTY VEHICLE SIGN TRANSLATIONS Warning (7018022)

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UTILTY VEHICLE SIGN TRANSLATIONS (CONT’D) Warning (7018025)

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UTILTY VEHICLE SIGN TRANSLATIONS (CONT’D) Warning (7018021)

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UTILTY VEHICLE SIGN TRANSLATIONS (CONT’D) Warning (7018026)

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UTILTY VEHICLE SIGN TRANSLATIONS (CONT’D) Warning (7016342)

Caution (7016347)

Park Brake (7016357)

Park Brake (7016337)

Maximum Trailer Weight (7018610)

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UTILTY VEHICLE SIGN TRANSLATIONS (CONT’D) Operation Instruction (7018029)

Warning (7016362)

Warning (If Equipped With Back-up Alarm) (6737189)

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SPECIFICATIONS UTILITY VEHICLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 (3400) Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125 (3400XL) Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Fluid And Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

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UTILITY VEHICLE SPECIFICATIONS (3400) Dimensions • •

Dimensions are given for utility vehicle equipped with standard tires. All dimensions are shown in millimeters.

Respective imperial dimensions are given in inches enclosed by parentheses.

Where applicable, specification conform to SAE, ANSI or ISO standards and are subject to change without notice.

1245 mm (49.0 in)

1219 mm (48.0 in)

1524 mm (60.0 in)

1905 mm (75.0 in)

1930 mm (76.0 in)

241 mm (9.5 in) TO BOTTOM OF RECEIVER HITCH

2870 mm (113.0 in)

1499 mm (59.0 in)

330 mm (13.0 in)

241 mm (9.5 in)

50° 787 mm (31.0 in)

305 mm (12.0 in) Turning Radius - Turf Mode = 2527 mm (99.5 in) Turning Radius - Two Wheel Drive Mode = 3099 mm (122 in) Turning Radius - Four Wheel Drive (4x4) = 3048 mm (120 in)

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Box Inside Dimensions: 1371 x 927 x 292 mm (54.0 x 36.5 x 11.5 in)

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UTILITY VEHICLE SPECIFICATIONS (CONT’D) (3400XL) Dimensions • •

Dimensions are given for utility vehicle equipped with standard tires. All dimensions are shown in inches. Respective metric dimensions are given in millimeters enclosed by parentheses.

Where applicable, specification conform to SAE, ANSI or ISO standards and are subject to change without notice.

1245 mm (49.0 in)

1219 mm (48.0 in)

1524 mm (60.0 in)

1905 mm (75.0 in)

241 mm (9.5 in) TO BOTTOM OF RECEIVER HITCH

1930 mm (76.0 in) 3676 mm (144.7 in)

1499 mm (59.0 in)

330 mm (13.0 in)

241 mm (9.5 in)

50°

787 mm (31.0 in)

305 mm (12.0 in) Turning Radius - Turf Mode = 3607 mm (142 in) Turning Radius - Two Wheel Drive = 4147 mm (153.25 in) Turning Radius - Four Wheel Drive (4x4) = 4140 mm (153 in)

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Box Inside Dimensions: 1371 x 927 x 292 mm (54.0 x 36.5 x 11.5 in)

3400, 3400XL Operation & Maintenance Manual

UTILITY VEHICLE SPECIFICATIONS (CONT’D) Performance Load Capacity

3400

3400XL

500 kg (1100 lb)

500 kg (1100 lb)

725 kg (1600 lb)

840 kg (1850 lb)

Total Rated Capacity (Includes: the Vehicle Rated Capacity and the tow weight)

1406 kg (3100 lb)

1520 kg (3350 lb)

Trailer Hitch Tongue Weight (Max)

68 kg (150 lb)

68 kg (150 lb)

Tow Capacity (Includes the Weight of Trailer)

680 kg (1500 lb)

680 kg (1500 lb)

Hitch Type

Standard 2 in. Receiver

Standard 2 in. Receiver

Operating Weight

653 kg (1440 lb)

759 kg (1673 lb)

Operating Slope Limit

15° Maximum

15° Maximum

0 - 39 km/h (0 - 24 mph) 0 - 48 km/h (0 - 30 mph) 0 - 39 km/h (0 - 24 mph)

0 - 42 km/h (0 - 26 mph) 0 - 48 km/h (0 - 30 mph) 0 - 42 km/h (0 - 26 mph)

Cargo Box Load (Maximum) Vehicle Rated Capacity (Includes: cargo box load, weight of occupant(s), and the weight of any accessories)

Travel Speed - Low Gear - High Gear - Reverse Controls Vehicle Steering Engine

Steering Wheel Foot pedal engine speed control; key-type starter switch.

Brake Pedal

Foot pedal activates four wheel disc brakes.

Parking Brake

Lever applied, mechanically activated disc brake.

Engine Make/Model

Fuji EH500PLE260

Fuel/Cooling

Unleaded Gasoline / Liquid

Horsepower (SAE Net)

19 kW (25.6 hp) @ 6000 rpm

Type Of Cycle

4 - Stroke

Air Induction

Naturally Aspirated

Low Idle RPM

1100 rpm

High Idle RPM

6500 rpm

Number of Cylinders

1

Displacement

0,498 L (30.4 in3)

Bore/Stroke

92,0 / 75 mm (3.62 / 2.95 in)

Lubrication

Tandem Gear Pump Pressure System with Filter - Dry Sump

Crankcase Ventilation Air Pre-Cleaner

Closed Breather Cleanable and replaceable fiber cartridge

Air Cleaner

Replaceable dry paper cartridge

Ignition

Spark

Engine Coolant

Ethylene Glycol / Water Mixture

Spark Plug

BKR5E

Spark Plug Gap

0,9 mm (0.04 in) 127

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UTILITY VEHICLE SPECIFICATIONS (CONT’D) Electrical Stator

25 Amp

Battery

12 volts, 30 A/hr

Starter

12 volts, gear reduction type, 0,7 kW (0.94 hp)

Instrumentation

Warning lights (Red): Parking Brake, Low Engine Oil Pressure.

Indicator Lights (Orange): Reverse (R).

Indicator Lights (Green): Neutral (N).

Indicator Lights (White): Low Gear (L) and High Gear (H).

Hourmeter

Head Light

Low beam 2 x 35W / High Beam 2 x 35W

Tail Light

2 x incandescent

Drive System Gearbox Ratio FWD - Low Gear

23.91:1

Gearbox Ratio FWD - High Gear

14.37:1

Gearbox Ratio Reverse

21.74:1

Final Drive ratio - Front

3.818

Final Drive ratio - Rear

3.7

Suspension - Front

Macpherson Strut 152,4 mm (6.0 in) Travel

Suspension - Rear

Dual Control Arm, IRS 152,4 mm (6.0 in) Travel

Suspension - Rear Adjustment

Spring Preload Adjust

Rear Differential Type

Lockable

Rear Differential Selection

Lock / Unlock Switch

Steering

Rack and Pinion

Brakes - Front and Rear

Hydraulic Disc

Brakes - Parking

Mechanical Disc

Fluid And Capacities

Engine Cooling System Fuel Tank

Capacity (3400)

Capacity (3400XL)

2,4 L (2.3 qt)

2,7 L (2.8 qt)

Fluid (See REGULAR MAINTENANCE ITEMS on Page 7.)

ETHYLENE GLYCOL ANTI-FREEZE

34,1 L (9 U.S. gal) 34,1 L (9 U.S. gal) UNLEADED REGULAR GRADE GASOLINE ONLY

Engine Lubrication & Filter

1,9 L (2.0 qt)

1,9 L (2.0 qt)

BOBCAT UTILITYVEHICLE SYNTHETIC 2W-50

Main Gear Case (Transmission) Lubricating Oil

2,0 L (2.1 qt)

2,0 L (2.1 qt)

GEARCASE SYNTHETIC LUBRICANT

Differential - Front

275 mL (9.3 oz)

275 mL (9.3 oz)

FRONT DIFFERENTIAL FLUID

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UTILITY VEHICLE SPECIFICATIONS (CONT’D) Tires Tire Size

Wheel Size

3400 - Tire Pressure

3400XL - Tire Pressure

Front

25 x 10 - 12

12 x 6

69 kPa (10 psi)

69 kPa (10 psi)

Rear

25 x 11 - 12

12 x 8

69 kPa (10 psi)

152 kPa (22 psi)

NUT TYPE

LOCATION

TORQUE

2-Piece Flange Nut

Front and Rear

47 N•m (35 ft-lb)

Front and Rear

40 N•m plus 90° (1/4 turn) (30 ft-lb) plus 90° (1/4 turn)

Lug Nut

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WARRANTY WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

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WARRANTY

WARRANTY Bobcat Utility Vehicle Bobcat Company warrants to its authorized dealers and authorized dealers of Bobcat Equipment Ltd., who in turn warrant to the owner, that each new Bobcat Utility Vehicle will be free from proven defects in material and workmanship with respect to all components of the product except as otherwise specified herein for twelve (12) months or 1000 hours (whichever comes first). The foregoing time periods shall all commence after delivery by the authorized Bobcat dealer to the original buyer.

During the warranty period, the authorized Bobcat dealer shall repair or replace, at Bobcat Company's option, without charge for parts and labor, any part of the Bobcat product except as otherwise specified herein which fails because of defects in material or workmanship. The owner shall provide the authorized Bobcat dealer with prompt written notice of the defect and allow reasonable time for repair or replacement.

Bobcat Company may, at its option, require failed parts to be returned to the factory. Travel time of mechanics and transportation of the Bobcat product to the authorized Bobcat dealer for warranty work are the responsibility of the owner. The remedies provided in this warranty are exclusive.

This warranty does not apply to non Bobcat branded tires. The owner shall rely solely on the manufacturer’s tire warranty, if any. This warranty does not cover replacement of scheduled service items such as oil, filters, tune-up parts, other high-wear items or any damage caused by the use of non-Bobcat fluids and filters. This warranty does not cover accidental damage, air flow obstructions, normal wear and tear, abuse, improper handling, any vehicle that has been altered structurally, modified, neglected, improperly maintained, used for racing, or used for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover damage to the following items if caused by fire, explosions or any other cause beyond Bobcat’s reasonable control: paint or finish, stress cracks, tearing or puncturing of upholstery material or corrosion.

THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES AND CONDITIONS, EXCEPT THE WARRANTY OF TITLE. BOBCAT COMPANY DISCLAIMS ALL OTHER WARRANTIES AND CONDITIONS, EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTIES OR CONDITIONS OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. IN NO EVENT SHALL BOBCAT COMPANY OR THE AUTHORIZED BOBCAT DEALER BE LIABLE FOR ANY SPECIAL, INCIDENTAL, INDIRECT OR CONSEQUENTIAL DAMAGES WHATSOEVER, INCLUDING, BUT NOT LIMITED TO, LOSS OR INTERRUPTION OF BUSINESS, LOST PROFITS, OR LOSS OF MACHINE USE, WHETHER BASED ON CONTRACT, WARRANTY, TORT, NEGLIGENCE, STRICT LIABILITY, STATUTE OR OTHERWISE, EVEN IF BOBCAT COMPANY OR THE AUTHORIZED BOBCAT DEALER HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES. THIS EXCLUSION OF SPECIAL, INCIDENTAL, INDIRECT AND CONSEQUENTIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE. THE TOTAL LIABILITY OF BOBCAT COMPANY AND THE AUTHORIZED BOBCAT DEALERS WITH RESPECT TO THE PRODUCT AND SERVICES FURNISHED HEREUNDER SHALL NOT EXCEED THE PURCHASE PRICE OF THE PRODUCT UPON WHICH SUCH LIABILITY IS BASED.

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WARRANTY (CONT’D) In this emissions limited warranty, the term “Manufacturer” means Polaris Industries Inc. (Polaris) as the holder of the U.S. Environmental Protection Agency (U.S. EPA) Certificate of Conformity for the vehicle. The Emissions Limited Warranty is in addition to the standard limited warranty for your vehicle.

Emissions Limited Warranty The Manufacturer warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped to conform with applicable U.S. Environmental Protection Agency (U.S. EPA) emission regulations for offroad recreational vehicles. The Manufacturer warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations.

The emissions warranty period for this emissions-certified vehicle starts on the date the vehicle is first purchased and continues for a period of 500 hours of engine operation, 5000 kilometers (3107 miles) of vehicle travel, or 30 calendar months from the date of purchase, whichever comes first.

This emissions limited warranty covers components whose failure increases the vehicle’s regulated emissions, and it covers components of systems whose only purpose is to control regulated emissions. Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner. This emissions limited warranty does not cover components whose failure does not increase the vehicle’s regulated emissions.

For exhaust emissions, emission-related components include any parts related to engine control in the following systems: Air-induction system, Fuel system, Aftertreatment devices, Crankcase ventilation valves, Ignition system, Exhaust gas recirculation systems, Sensors and / or Electronic control units.

The following parts are considered emission-related components for evaporative emissions: Fuel Tank, Fuel Cap, Fuel Line, Fuel Line Fittings, Clamps*, Pressure Relief Valves*, Control Valves*, Control Solenoids*, Electronic Controls*, Vacuum Control Diaphragms*, Control Cables*, Control Linkages*, Purge Valves, Vapor Hoses, Liquid / Vapor Separator, Carbon Canister, Canister Mounting Brackets and / or Carburetor Purge Port Connector. (*As related to the evaporative emission control system.)

The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of the Manufacturer, repair or replacement of any defective materials, components or products.

THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. THE MANUFACTURER SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR OTHERWISE. ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN. THE MANUFACTURER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply if it is inconsistent with the controlling state law.

This limited warranty excludes failures not caused by a defect in material or workmanship. This limited warranty does not cover damage due to accidents, abuse or improper handling, maintenance or use. This limited warranty does not cover any vehicle that has been structurally altered, or when the vehicle has been used in racing competition. This limited warranty also does not cover physical damage, corrosion or defects caused by fire, explosions or other similar causes beyond the control of the Manufacturer. Owners are responsible for performing the scheduled maintenance identified in the manual(s) and instruction(s) included with the vehicle. The Manufacturer may deny warranty claims for failures that have been caused by improper maintenance or use, by accidents for which the Manufacturer has no responsibility, or by acts of God. Any qualified repair shop or person may maintain, replace, or repair the emission control devices or systems on your vehicle. The Manufacturer recommends that you contact an authorized dealer or service center to perform any service that may be necessary for your vehicle. The Manufacturer also recommends that you use only Original Manufacturer parts. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission controls. Tampering with emission controls is prohibited by federal law.

If you have any questions regarding your rights and responsibilities under this emissions limited warranty, please contact the appropriate party in the order indicated: 1. Authorized vehicle dealer or service center 2. The Manufacturer’s Warranty Department at 1-888-704-5290

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ALPHABETICAL INDEX AIR CLEANER SERVICE . . . . . . . . . . . . . . . 76 BACK-UP ALARM SYSTEM (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 BACK-UP ALARM SYSTEM (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 BOBCAT COMPANY IS IS0 9001 CERTIFIED .. . .. .. .. . .. .. .. . .. .. .. . .. .. .. . .. .. .7 BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . 33 BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . 69 CONTINUOUSLY VARIABLE TRANSMISSION (CVT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 DAILY INSPECTION . . . . . . . . . . . . . . . . . . 37 DELIVERY REPORT . . . . . . . . . . . . . . . . . . . 8 DIAGNOSTIC SERVICE CODES . . . . . . . 113 DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . 104 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . 87 EMISSION CONTROL SYSTEMS . . . . . . . . . 9 ENGINE COOLING SYSTEM . . . . . . . . . . . 84 ENGINE LUBRICATION SYSTEM . . . . . . . . 81 FEATURES, ACCESSORIES AND ATTACHMENTS . . . . . . . . . . . . . . . . . . . . . . 12 FIRE PREVENTION . . . . . . . . . . . . . . . . . . . 17 FRONT COVER . . . . . . . . . . . . . . . . . . . . . 103 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . 79 GEARCASE . . . . . . . . . . . . . . . . . . . . . . . . . 96 LUBRICATING THE UTILITY VEHICLE . . 107 MAINTENANCE SAFETY . . . . . . . . . . . . . . 61 NEW VEHICLE BREAK-IN . . . . . . . . . . . . . . 36 OPERATING PROCEDURE . . . . . . . . . . . . 43 OPERATOR CONTROLS AND INSTRUMENT PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 OPERATOR SAFETY WARNINGS . . . . . . . . 1 PARK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . 33 PARKING BRAKE SYSTEM . . . . . . . . . . . . 68 PERIODIC MAINTENANCE AND SEVERE USE DEFINITION . . . . . . . . . . . . . . . . . . . . . 63 PRE-STARTING PROCEDURE . . . . . . . . . . 38 PUBLICATIONS AND TRAINING RESOURCES . . . . . . . . . . . . . . . . . . . . . . . . 21 REAR SUSPENSION ADJUSTMENTS . . . 100 REGULAR MAINTENANCE ITEMS . . . . . . . . 7 ROLLOVER PROTECTIVE STRUCTURE (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

ROLLOVER PROTECTIVE STRUCTURE (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 SAFETY INSTRUCTIONS . . . . . . . . . . . . . . 15 SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . 65 SEAT(S) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 SERIAL NUMBER LOCATIONS . . . . . . . . . . . 8 SERVICE SCHEDULE . . . . . . . . . . . . . . . . . 64 SHIFT CABLE ADJUSTMENT . . . . . . . . . . . 72 SPARK ARRESTER MUFFLER . . . . . . . . . . 99 SPEEDOMETER (OPTIONAL) . . . . . . . . . . . 41 START INTERLOCK SYSTEM . . . . . . . . . . . 67 STARTING THE ENGINE . . . . . . . . . . . . . . . 40 STEERING AND SUSPENSION SYSTEM . 73 STOPPING THE ENGINE AND LEAVING THE UTILITY VEHICLE . . . . . . . . . . . . . . . . . . . . 42 STOPPING THE UTILITY VEHICLE . . . . . . 35 SUPPORTING THE UTILITY VEHICLE ON JACKSTANDS . . . . . . . . . . . . . . . . . . . . . . 101 THROTTLE PEDAL . . . . . . . . . . . . . . . . . . . 33 THROTTLE SYSTEM . . . . . . . . . . . . . . . . . . 71 TIRE MAINTENANCE . . . . . . . . . . . . . . . . 102 TOWING THE UTILITY VEHICLE . . . . . . . . 55 TRANSPORTING THE UTILITY VEHICLE ON A TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . 56 UTILITY VEHICLE CLEANING . . . . . . . . . 108 UTILITY VEHICLE IDENTIFICATION (3400) 10 UTILITY VEHICLE IDENTIFICATION (3400XL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 UTILITY VEHICLE SIGNS (DECALS) . . . . . 19 UTILITY VEHICLE SPECIFICATIONS . . . . 125 UTILITY VEHICLE STORAGE AND RETURN TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . 109 UTILTY VEHICLE SIGN TRANSLATIONS . 117 VEHICLE IMMERSION . . . . . . . . . . . . . . . . 98 WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . 133 WHEEL TOE ALIGNMENT . . . . . . . . . . . . . 106

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