PDF Service Manual Bobcat 3450 Utility Vehicle - 3 MB
This service manual provides complete maintenance and repair information for the Bobcat 3450 Utility Vehicle with serial numbers AJNY11001 and above.
It includes detailed instructions for all service procedures, from routine fluid changes to major component overhauls.
With this guide, technicians can accurately diagnose problems and perform repairs to factory standards.
Keep your UTV running reliably with this essential manual.
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Service Manual
3450 Utility Vehicle
S/N AJNY11001 & Above
6989610 (8-11) Printed in U.S.A. © Bobcat Company 2011
--- Page 3 ---
SAFETY INSTRUCTIONS The following publications provide information on the safe
use and maintenance of the Bobcat utility vehicle and
Safety Alert Symbol attachments:
• The Delivery Report is used to assure that complete
This symbol with a warning statement means: instructions have been given to the new owner and
“Warning, be alert! Your safety is involved!” that the vehicle is in safe operating condition.
Carefully read the message that follows.
• The Operation & Maintenance Manual delivered with
the vehicle or attachment contains operating
information as well as routine maintenance and
WARNING service procedures. It is a part of the vehicle and can
be stored in a container provided on the vehicle.
Replacement Operation & Maintenance Manuals can
Operator must have instructions before operating the be ordered from your Bobcat dealer.
utility vehicle. Untrained operators can cause injury
or death. • Safety signs (decals) instruct on the safe operation
W-2855-0510 and care of your Bobcat utility vehicle or attachment.
The signs and their locations are shown in the
Operation & Maintenance Manual. Replacement
signs are available from your Bobcat dealer.
IMPORTANT • An Operator’s Handbook fastened to the operator
cab. It’s brief instructions are convenient to the
This notice identifies procedures which must be operator. The handbook is available from your dealer
followed to avoid damage to the utility vehicle. in an English edition or one of many other languages.
I-2317-0510 See your Bobcat dealer for more information on
translated versions.
• The Service Manual and Parts Manual are available
from your dealer for use by mechanics to do shop-
type service and repair work.
DANGER
• The Utility Vehicle Operator Training Course is
The signal word DANGER on the utility vehicle and in available through your local dealer or at
the manuals indicates a hazardous situation which, if www.training.bobcat.com or www.bobcat.com.
not avoided, will result in death or serious injury. This course is intended to provide rules and practices
D-1022-0510 of correct operation of the utility vehicle. The course is
available in English and Spanish versions.
• The Utility Vehicle Safety Video is available from your
Bobcat dealer or at www.training.bobcat.com or
WARNING www.bobcat.com.
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
SI UV-0511 SM
1-9 3400, 3400XL Service Manual
--- Page 4 ---
LIFTING AND BLOCKING THE UTILITY VEHICLE Figure 10-10-2
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 SPEC-10-2.)
Always park the utility vehicle on a flat level surface.
Engage the park brake. Stop the engine and put the gear 1 1
selector in gear.
P-97357
If removing wheel(s), loosen the wheel nuts slightly
before lifting the vehicle.
Place the jackstands (Item 1) [Figure 10-10-2] under the
rear frame of the utility vehicle.
WARNING NOTE: When lifting the utility vehicle, place the jack
under the rear frame [Figure 10-10-2].
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.
W-2003-0807
Figure 10-10-1
1
P-97448
Place the jackstands (Item 1) [Figure 10-10-1] under the
frame at the front of the utility vehicle (both sides).
NOTE: When lifting the utility vehicle, place the jack
under front frame [Figure 10-10-1].
10-10-1 3450 Service Manual
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AIR CLEANER SERVICE Figure 10-60-3
Pre-Filter Element
For the correct service interval of the pre-filter element
(See SERVICE SCHEDULE on Page 10-50-1.)
The intake air pre-filter is located under the front cover.
The pre-filter traps larger particles before the air reaches 1
the main engine air filter.
Removal
Figure 10-60-1
P-97468
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 pre-filter box and squeeze the pre-filter
element (Item 1) [Figure 10-60-3] to collapse it to aid in
removal.
P-97466 DO NOT used compressed air to clean the pre-filter box.
Use a clean damp cloth and wipe out the inside of the
Remove the front cover. box.
The pre-filter box (Item 1) [Figure 10-60-1] is connected Cleaning Element
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
Figure 10-60-2 filter element thoroughly. Inspect element for tears or
damage. Replace if necessary.
Installation
1
Squeeze the pre-filter element (Item 1) [Figure 10-60-3]
2 and insert into the box. Make sure the element is properly
installed so that it fits snugly back into the box.
Reposition the pre-filter box (Item 1) [Figure 10-60-1]
back to its original location.
Reinstall the front cover.
P-97467
Rotate the pre-filter box (Item 1) back to access the pre-
filter element (Item 2) [Figure 10-60-2] for removal.
10-60-1 3450 Service Manual
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ENGINE LUBRICATION SYSTEM Engine Oil Chart
Checking And Adding Engine Oil Figure 10-90-2
Figure 10-90-1
ENGINE OIL
RECOMMENDED SAE VISCOSITY NUMBER
(LUBRICATION OILS FOR DIESEL ENGINE
CRANKCASE)
1
P-97414
Check the engine oil level every day.
Park the utility vehicle on a flat and level surface and stop
the engine.
TEMPERATURE RANGE ANTICIPATED BEFORE
NEXT OIL CHANGE (DIESEL ENGINES MUST USE API
The engine oil dipstick is located under the seat on the
CLASSIFICATION CI-4 OR BETTER)
left front corner of the engine. Remove the seat. (See
Seat Base Removal And Installation on Page 30-20-1.)
Use good quality engine oil that meets API Service
Classification of CI-4 or better [Figure 10-90-2].
Remove the dipstick (Item 1) [Figure 10-90-1] and wipe
dry with a clean cloth. Reinstall the dipstick. Remove the
dipstick and check the oil level. Keep the oil level between
the marks on the dipstick.
NOTE: Rising oil levels between checks in cool
WARNING
weather driving can indicate moisture
collecting in the oil pan. If the oil level is over AVOID INJURY OR DEATH
the full mark, change the oil. 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
10-90-1 3450 Service Manual
--- Page 7 ---
TIRE MAINTENANCE Wheel Removal And Installation
Check the tires regularly for wear, damage and pressure.
Tires
WARNING
WARNING
AVOID INJURY OR DEATH
AVOID INJURY OR DEATH Improperly installed wheels can adversely affect tire
Operating this vehicle with worn tires, improperly wear and vehicle handling, which can result in
inflated tires, non-standard tires or improperly serious injury or death. Always ensure all nuts are
installed tires will affect vehicle handling and could torqued to specification. Do not service axle nuts
cause an accident resulting in serious injury or that have a cotter pin installed. See your Bobcat
death. Always follow all tire maintenance procedures dealer.
W-2830-0510
outlined in this manual and on the safety signs
(decals). Always use the original equipment size and
type when replacing tires. Removal
W-2829-0510
1. Apply the brakes and engage the parking brake.
Tire Tread Depth 2. Stop the engine and place the gear selector in gear.
Figure 10-120-1 3. Loosen the wheel nuts slightly.
4. Raise the utility vehicle and install jackstands or
blocks. (See LIFTING AND BLOCKING THE UTILITY
VEHICLE on Page 10-10-1.)
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.
3,0 mm NOTE: Install the wheel with the valve stem facing to
(0.125 in) the outside and the rotation arrow on the tire
pointing to the front of the vehicle.
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 10-120-1] or less. 3. Place the wheel in the correct position on the wheel
hub. Be sure the valve stem is towards the outside
Axle And Wheel Nut Torque and the rotation arrows on the tire point towards the
forward rotation.
NOTE: The wheel nuts must be checked and torqued
4. Install the wheel nuts and tighten slightly.
after the first eight hours of operation of a new
machine and after the first eight hours of 5. Lower the utility vehicle to the ground. (See LIFTING
operation when wheel(s) have been removed AND BLOCKING THE UTILITY VEHICLE on Page
for service. 10-10-1.)
6. Tighten the wheel nuts to the correct torque.
Check the wheel nut torque at the correct service interval
(See SERVICE SCHEDULE on Page 10-50-1.)
Do not lubricate the studs or lug nuts. IMPORTANT
Tighten the wheel nuts to the correct torque. (See Tires Do not mix tire sizes. The front and rear tires used on
on Page SPEC-10-5.) this model are different sizes. Do not intermix front
and rear tires.
I-2332-0510
10-120-1 3450 Service Manual
--- Page 8 ---
HYDRAULIC SYSTEM Hydraulic Fluid
Description Figure 10-170-2
HYDRAULIC FLUID
The 3450 utility vehicle has a hydraulic system that is RECOMMENDED ISO VISCOSITY GRADE (VG)
powered by a 12 volt motor. The hydraulic system is AND VISCOSITY INDEX (VI)
powered as soon as the key switch is in the ON position.
The hydraulic system is located below the cargo box.
Battery drain is increased when using the hydraulic
system. Always allow the utility vehicle additional run
time (with hydraulic system turned OFF) to charge the
battery when the hydraulic system has been used for
extended periods of time.
Checking Fluid
TEMPERATURE RANGE ANTICIPATED
Use only recommended fluid in the hydraulic system.
DURING MACHINE USE
(See chart on this page.)
[1] VG 100; Minimum VI 130
[2] VG 46; Minimum VI 150
Remove the attachment.
[3] BOBCAT All-Season Fluid
Park the utility vehicle on a flat level surface, fully raise [4] BOBCAT Synthetic Fluid
the attachment arm (with attachment removed) and tilt [5] BOBCAT Biodegradable Hydraulic / Hydrostatic
the attachment interface fully back. (Cylinders must be Fluid (Unlike biodegradable fluids that are vegetable
fully retracted for proper checking and filling of the based, Bobcat biodegradable fluid is formulated to
hydraulic fluid.) prevent oxidation and thermal breakdown at operating
temperatures.)
Figure 10-170-1
Use only recommended fluid in the hydraulic system
[Figure 10-170-2].
1
P-97442
The hydraulic tank (Item 1) [Figure 10-170-1] can be
viewed from the rear of the utility vehicle to check the
fluid level.
The MAXIMUM level needs to be at the beveled surface
on the hydraulic tank (with the lift and tilt cylinders fully
retracted).
10-170-1 3450 Service Manual
--- Page 9 ---
BRAKE (CONT’D)
Hydraulic Brake System Operation
WARNING
The brake system consists of the following components
or assemblies: brake pedal, master cylinder, hydraulic
AVOID INJURY OR DEATH
brake lines, brake calipers, brake pads, and brake discs,
After opening a bottle of brake fluid, always discard
which are secured to the drive line.
any unused portion. Never store or use a partial
bottle. Brake fluid is hygroscopic, meaning it rapidly
When the foot activated brake lever is applied it applies
absorbs moisture from the air. The moisture causes
pressure on the piston within the master cylinder. As the
the boiling temperature of the brake fluid to drop,
master cylinder piston moves inward it closes a small
which can lead to early brake fade and the possibility
opening (compensating port) within the cylinder and
of accident or severe injury.
starts to build pressure within the brake system. As the W-2872-0510
pressure within the system is increased, the pistons
located in the brake calipers move outward and apply
pressure to the moveable brake pads. These pads
contact the brake discs and move the calipers in their
floating bracket, pulling the stationary side pads into the
brake discs. The resulting friction reduces brake disc and
vehicle speed.
The friction applied to the brake pads will cause the pads
to wear. As these pads wear, the piston within the caliper
moves further outward and becomes self adjusting. Fluid
from the reservoir fills the additional area created when
the caliper piston moves outward.
Brake fluid level is critical to proper system operation. Too
little fluid will allow air to enter the system and cause the
brakes to feel spongy. Too much fluid could cause brakes
to drag due to fluid expansion.
Located within the master cylinder is the compensating
port which is opened and closed by the master cylinder
piston assembly. As the temperature within the hydraulic
system changes, this port compensates for fluid
expansion or contraction. Due to the high temperatures
created within the system during heavy braking, it is very
important that the master cylinder reservoir have
adequate space to allow for fluid expansion. Never
overfill the reservoir! Do not fill the reservoir beyond
the MAX LEVEL line!
When servicing the brake system use only Bobcat DOT
4 Brake Fluid.
20-10-5 3450 Service Manual
--- Page 10 ---
BRAKE (FRONT) (CONT’D) Figure 20-11-8
Caliper Removal
Lift and block the machine. (See Procedure on Page 10-
10-1.)
2
WARNING 1
Use care when supporting vehicle so that it does not
tip or fall. Severe injury may occur if machine tips or
falls.
W-2848-0510 P-99536
Remove the tire assembly. (See TIRE MAINTENANCE Remove the two caliper mounting bolts, lock washers and
on Page 10-120-1.) washers (Item 1) and remove the caliper assembly (Item
2) [Figure 20-11-8] from the front strut.
Figure 20-11-7
2
1
P-99536
Clean caliper area before removal.
Place a container below the caliper to catch brake fluid
when removing the line. Remove brake line from caliper
(Item 1) [Figure 20-11-7].
Loosen the pad adjuster screw (Item 2) [Figure 20-11-7]
2 - 3 turns to allow brake pad removal after the caliper is
removed.
20-11-3 3450 Service Manual
--- Page 11 ---
BRAKE (REAR) (CONT’D) Figure 20-12-7
Caliper Removal
1
Lift and block the machine. (See Procedure on Page 10-
10-1.)
WARNING
1
Use care when supporting vehicle so that it does not
tip or fall. Severe injury may occur if machine tips or
falls.
W-2848-0510 P-99259
Remove the tire assembly. (See TIRE MAINTENANCE After the fluid has drained into the container, remove the
on Page 10-120-1.) two caliper mounting bolts (Item 1) [Figure 20-12-7] and
remove caliper.
Figure 20-12-6
Clean the disc, caliper body and pistons with brake
cleaner or alcohol.
1
P-99259
Clean caliper area before removal.
Place a container below the caliper to catch brake fluid
when removing the line. Remove brake line from caliper
(Item 1) [Figure 20-12-6].
20-12-3 3450 Service Manual
--- Page 12 ---
BRAKE (PARK) (CONT’D) Figure 20-20-4
Lever Removal And Installation
Figure 20-20-2 1
1
2
1
P-99499
Remove the two bolts (Item 1) [Figure 20-20-4] and
P-99502 lower the lever assembly into the wheel well.
Figure 20-20-5
Make sure the parking brake lever (Item 1) [Figure 20-
20-2] is not engaged.
Remove the cup holder (Item 2) [Figure 20-20-2] from 1 3
the vehicle.
Figure 20-20-3
2
P-99501
1
Disconnect the micro switch connector (Item 1) [Figure
20-20-5] from the harness.
Remove the clip and clevis pin (Item 2) [Figure 20-20-5]
P-99500 which secure the cable to the lever assembly.
Loosen the jam nut (Item 3) [Figure 20-20-5] and remove
Remove the nuts (Item 1) [Figure 20-20-3] from the the lever assembly from the vehicle.
parking brake lever assembly.
Installation: Tighten the jam nut to 19 N•m (14 ft-lb)
Installation: Tighten the nuts to 18 N•m (13 ft-lb) torque. torque.
20-20-3 3450 Service Manual
--- Page 13 ---
GEARCASE (TRANSMISSION)
System Troubleshooting
Check the following items when shifting difficulty is
encountered.
• Shift cable adjustment / condition
• Idle speed (throttle cable routing)
• CVT clutch alignment
• Transmission Lubricant type / quality
• Drive belt deflection (where applicable)
• Loose fasteners on sector gear cover
• Worn rod ends, clevis pins or pivot arm bushings
• Shift selector rail travel
• Worn, broken or damaged internal transmission
components
NOTE: To determine if shifting difficulty or problem
is caused by an internal transmission
problem, isolate the transmission by
disconnecting the shift cable end from the
transmission bellcrank. Manually select each
gear range at the transmission bellcrank, and
test ride vehicle. If it functions properly, the
problem is outside the transmission.
If transmission problem remains,
disassemble transmission and inspect all
gear dogs for wear (rounding) or damage.
Inspect all bearings, circlips, thrust washers
and shafts for wear.
20-30-1 3450 Service Manual
--- Page 14 ---
GEARCASE (TRANSMISSION) (CONT’D) Figure 20-30-34
Removal And Installation (Cont’d)
Figure 20-30-33
2
1
P-99763
1
Installation: Align the splines of the coupler (Item 1)
P-99764 [Figure 20-30-34] with the slots in the rubber coupler
(Item 1) [Figure 20-30-33].
Inspect the rubber coupler (Item 1) [Figure 20-30-33] for NOTE: The drive clutch may need to be moved
damage and replace as needed. slightly while joining the transmission and
engine together. Rotating the drive clutch will
Install a new gasket (Item 2) [Figure 20-30-33] on the move the coupler to aid in aligning the splines
engine mounting surface. with the rubber coupler.
Installation: If transmission lubricant was drained, fill the
transmission with the specified amount of Bobcat Utility
Vehicle synthetic gearcase lubricant prior to installation.
(See Fluid And Capacities on Page SPEC-10-4.)
20-30-11 3450 Service Manual
--- Page 15 ---
GEARCASE (TRANSMISSION) (CONT’D) Figure 20-30-63
Assembly (Cont’d)
2
Figure 20-30-61
1
P100471
Install the washer over the bellcrank shift shaft and install
P100469 the bellcrank (Item 1) by aligning the skip-tooth splines
(Item 2) [Figure 20-30-63].
Align the timing marks on the cam shift shaft and Install the retaining nut and torque to specification.
bellcrank shift shaft [Figure 20-30-61].
Bellcrank Retaining Nut: 20 N•m (15 ft-lb)
Figure 20-30-62
Figure 20-30-64
1 2
3
P100470
P100472
Place the two shafts into the transmission as an
assembly [Figure 20-30-62]. Install the washer and a new retaining ring onto the cam
shift shaft. The retaining ring should be tight on the shaft.
NOTE: Gently rock or twist the shift shafts upon