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Bobcat 3600 Utility Vehicle Service Manual SNB3C211001 & Above – PDF DOWNLOAD
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Description
Bobcat 3600 Utility Vehicle Service Manual SNB3C211001 & Above – PDF DOWNLOAD
FILE DETAILS:
Bobcat 3600 Utility Vehicle Service Manual SNB3C211001 & Above – PDF DOWNLOAD
Language : English
Pages : 688
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Bobcat 3600 Utility Vehicle Service Manual SNB3C211001 & Above – PDF DOWNLOAD
FOREWORD
This manual is for the Toolcat Utility Work Machine mechanic. It provides necessary servicing and adjustment procedures for the Toolcat Utility Work Machine and its component parts and systems. Refer to the for operating instructions, starting procedure, daily checks, etc.
SAFETY INSTRUCTIONS
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.
IMPORTANT
This notice identifies procedures which must be followed to avoid damage to the machine
The following publications provide information on the safe use and maintenance of the Bobcat machine and attachments / implements:
- The Delivery Report is used to assure that complete instructions have been given to the new owner and that the machine is in safe operating condition.
- The Operation & Maintenance Manual delivered with the machine or attachment / implement contains operating information as well as routine maintenance and service procedures. It is a part of the machine and can be stored in a container provided on the machine. Replacement Operation & Maintenance Manuals can be ordered from your Bobcat dealer.
- Machine signs (decals) instruct on the safe operation and care of your Bobcat machine or attachment / implement. The signs and their locations are shown in the Operation & Maintenance Manual. Replacement signs are available from your Bobcat dealer.
- An Operator’s Handbook fastened to the operator cab. It’s brief instructions are convenient to the operator. The handbook is available from your dealer in an English edition or one of many other languages. 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 shoptype service and repair work.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Bobcat 3600 Utility Vehicle Service Manual SNB3C211001 & Above – PDF DOWNLOAD
MAINTENANCE SAFETY.................................................................... 3 CONTENTS.............................................................................. 5 FOREWORD.............................................................................. 7 FOREWORD.......................................................................... 9 SAFETY INSTRUCTIONS............................................................... 11 FIRE PREVENTION................................................................... 13 Maintenance................................................................... 13 Operation..................................................................... 13 Electrical.................................................................... 13 Fueling....................................................................... 13 Starting...................................................................... 13 Spark Arrester Exhaust System................................................. 13 Welding And Grinding.......................................................... 13 Fire Extinguishers............................................................ 14 SERIAL NUMBER LOCATIONS........................................................... 15 Utility Vehicle Serial Number................................................. 15 Engine Serial Number.......................................................... 15 DELIVERY REPORT................................................................... 16 UTILITY VEHICLE IDENTIFICATION.................................................... 17 SAFETY AND MAINTENANCE................................................................ 19 LIFTING AND BLOCKING THE UTILITY VEHICLE.......................................... 21 Procedure..................................................................... 21 ROLL-OVER PROTECTIVE STRUCTURE (ROPS) / OCCUPANT PROTECTIVE STRUCTURE (OPS)....... 23 Description................................................................... 23 TRANSPORTING THE UTILITY VEHICLE ON A TRAILER..................................... 25 Loading And Unloading......................................................... 25 Fastening..................................................................... 25 TOWING THE UTILITY VEHICLE........................................................ 27 Procedure..................................................................... 27 SERVICE SCHEDULE.................................................................. 29 Maintenance Intervals......................................................... 29 AIR CLEANER SERVICE............................................................... 33 Pre-Filter Element............................................................ 33 Replacing Filter Element...................................................... 34 ENGINE COOLING SYSTEM............................................................. 35 Checking Level................................................................ 35 Cleaning...................................................................... 36 Removing And Replacing Coolant................................................ 37 FUEL SYSTEM....................................................................... 39 Fuel Specifications........................................................... 39 Biodiesel Blend Fuel.......................................................... 39 Filling The Fuel Tank......................................................... 40 Fuel Filter................................................................... 40 Removing Air From The Fuel System............................................. 41 Filling A Portable Fuel Container............................................. 41 ENGINE LUBRICATION SYSTEM......................................................... 43 Checking And Adding Engine Oil................................................ 43 Engine Oil Chart.............................................................. 43 Removing And Replacing Oil And Filter......................................... 44 HYDRAULIC / HYDROSTATIC SYSTEM.................................................... 47 Checking Fluid................................................................ 47 Hydraulic Fluid............................................................... 47 Adding Fluid.................................................................. 47 Removing And Replacing Hydraulic / Hydrostatic Filter......................... 48 Removing And Replacing Hydraulic / Hydrostatic Fluid.......................... 49 GEARCASE.......................................................................... 51 Checking Transmission Fluid................................................... 51 Transmission Fluid............................................................ 52 Adding Transmission Fluid..................................................... 52 Removing And Replacing Transmission Fluid..................................... 52 Checking Front Gearcase Fluid................................................. 53 Front Gearcase Fluid.......................................................... 54 Adding Front Gearcase Fluid................................................... 54 Removing And Replacing Front Gearcase Fluid................................... 54 TIRE MAINTENANCE.................................................................. 55 Tires......................................................................... 55 Tire Tread Depth.............................................................. 55 Axle And Wheel Nut Torque..................................................... 55 Wheel Removal And Installation................................................ 55 Mounting...................................................................... 56 Tire Pressure................................................................. 56 SPARK ARRESTER MUFFLER............................................................ 57 Cleaning Procedure............................................................ 57 UTILITY VEHICLE STORAGE AND RETURN TO SERVICE..................................... 59 Storage....................................................................... 59 Return To Service............................................................. 59 STOPPING THE ENGINE AND LEAVING THE UTILITY VEHICLE............................... 61 Procedure..................................................................... 61 Emergency Exit (When Equipped With Cab)....................................... 62 SEAT BELT......................................................................... 63 Inspection And Maintenance.................................................... 63 LUBRICATING THE UTILITY VEHICLE................................................... 65 Lubrication Locations......................................................... 65 DRIVE SYSTEM.......................................................................... 67 BRAKE............................................................................. 69 General Specifications........................................................ 69 Torque Specifications......................................................... 69 System Service Notes.......................................................... 70 Noise Troubleshooting......................................................... 71 System Troubleshooting........................................................ 72 Hydraulic Brake System Operation.............................................. 73 System Parts Identification................................................... 74 Master Cylinder Removal And Installation...................................... 75 Foot Brake Pedal Removal And Installation..................................... 76 Bleeding / Fluid Removal And Installation..................................... 77 Brake Inspection.............................................................. 79 Brake Pad Inspection.......................................................... 79 Burnishing.................................................................... 80 BRAKE (FRONT)..................................................................... 81 Pad Removal................................................................... 81 Pad Inspection................................................................ 82 Pad Assembly / Installation................................................... 83 Caliper Removal............................................................... 84 Caliper Parts Identification.................................................. 85 Caliper Disassembly........................................................... 86 Caliper Inspection............................................................ 87 Caliper Assembly.............................................................. 88 Caliper Installation.......................................................... 88 Disc Runout................................................................... 89 Disc Inspection............................................................... 89 Disc Removal And Installation................................................. 90 BRAKE (REAR)...................................................................... 91 Pad Removal................................................................... 91 Pad Inspection................................................................ 92 Pad Installation.............................................................. 92 Caliper Removal............................................................... 93 Caliper Parts Identification.................................................. 94 Caliper Disassembly........................................................... 95 Caliper Inspection............................................................ 96 Caliper Assembly.............................................................. 97 Caliper Installation.......................................................... 97 Disc Runout................................................................... 98 Disc Inspection............................................................... 98 Disc Removal And Installation................................................. 99 TRANSMISSION......................................................................101 Shift Lever Removal And Installation..........................................101 Shift Cable Adjustment........................................................102 Shift Cable Removal And Installation..........................................103 Removal And Installation......................................................105 Parts Identification..........................................................113 Differential Operation........................................................117 Transmission Disassembly......................................................118 Snorkel Shaft Removal / Disassembly...........................................121 Transmission Shaft Service....................................................123 Planetary Differential Disassembly............................................125 Planetary Differential Assembly...............................................128 Snorkel Gear Backlash.........................................................130 Transmission Assembly.........................................................133 FINAL DRIVE.......................................................................137 Bearing Carrier Removal.......................................................137 Bearing Removal And Installation..............................................139 Bearing Carrier Installation..................................................140 Front Drive Shaft Removal And Installation....................................142 Rear Drive Shaft Removal And Installation.....................................143 Drive Shaft / CV Joint Handling...............................................145 Outer CV Joint And Boot Removal And Installation..............................146 Inner Plunging Joint And Boot Removal And Installation........................149 Propshaft Removal And Installation............................................152 Propshaft U-Joint Disassembly.................................................152 Propshaft U-Joint Assembly....................................................154 Front Gearcase Operation......................................................157 Front Gearcase Removal And Installation.......................................160 Front Gearcase Parts Identification...........................................162 Front Gearcase Disassembly / Inspection.......................................163 Front Gearcase Assembly.......................................................167 TRAVEL CONTROL PEDAL..............................................................171 Description...................................................................171 Inspection....................................................................171 Removal And Installation......................................................171 Cable Removal And Installation................................................172 MAINFRAME.............................................................................175 ROLL-OVER PROTECTIVE STRUCTURE (ROPS).............................................177 Removal And Installation......................................................177 OPERATOR SEAT.....................................................................183 Seat Base Removal And Installation............................................183 Seat Belt Removal And Installation............................................184 DASH..............................................................................185 Front Access Cover Removal And Installation...................................185 Upper Dash Panel Removal And Installation.....................................185 Lower Dash Panel Removal And Installation.....................................186 Storage Panel Removal And Installation........................................189 BUMPER COVER......................................................................191 Removal And Installation......................................................191 REAR SUSPENSION LINK AND AXLE BRACE...............................................193 Upper Suspension Link Removal And Installation................................193 Lower Suspension Link Removal And Installation................................194 Axle Brace Removal And Installation...........................................195 Rear Axle Bearing Replacement.................................................197 STEERING COLUMN...................................................................199 Description...................................................................199 Tilt Steering Shock Removal And Installation..................................199 Parts Identification..........................................................200 Steering Wheel Removal And Installation.......................................201 Steering Wheel / Upper Steering Shaft Removal And Installation................202 Steering Shaft Bearing Replacement............................................203 STEERING BOX......................................................................205 Removal And Installation......................................................205 FUEL TANK.........................................................................207 Fuel Tank Removal And Installation............................................207 SHOCKS............................................................................209 Rear Shock Removal And Installation...........................................209 Spring Preload Adjustment.....................................................210 Front Shock Removal And Installation..........................................210 Shock Spring Removal And Installation.........................................211 A-ARMS............................................................................213 Lower A-Arm Removal And Installation..........................................213 Upper A-Arm Removal...........................................................214 Upper A-Arm Installation......................................................216 Inspection....................................................................218 Ball Joint Removal And Installation...........................................219 TIE ROD...........................................................................221 Description...................................................................221 Removal And Installation......................................................221 Toe Adjustment Procedure......................................................222 TAILGATE..........................................................................223 Removal And Installation......................................................223 Latch Removal And Installation................................................224 CARGO BOX.........................................................................225 Removal And Installation......................................................225 FENDER............................................................................227 Removal And Installation (Front)..............................................227 Removal And Installation (Rear)...............................................227 Flare Removal And Installation................................................229 FRONT WINDOW......................................................................231 Removal And Installation......................................................231 DOOR..............................................................................233 Removal And Installation......................................................233 DOOR LATCH........................................................................235 Removal And Installation......................................................235 Adjustment....................................................................235 REAR PANEL........................................................................237 Removal And Installation......................................................237 WINDSHIELD WASHER RESERVOIR.......................................................239 Removal And Installation......................................................239 ELECTRICAL SYSTEM AND ANALYSIS........................................................241 ELECTRICAL SCHEMATICS.............................................................245 ELECTRICAL SYSTEM INFORMATION.....................................................247 Glossary Of Electrical Symbols................................................247 Troubleshooting...............................................................250 Description...................................................................251 Fuse And Relay Location.......................................................251 Fusible Links.................................................................253 BATTERY...........................................................................255 Removal And Installation......................................................255 Servicing.....................................................................256 Using A Booster Battery (Jump Starting).......................................257 Battery Terminal Blocks.......................................................259 CHARGING SYSTEM...................................................................261 Current Draw - Key OFF........................................................261 Break Even Test...............................................................261 Alternator Voltage Test.......................................................262 Low Voltage Test..............................................................262 Removal And Installation......................................................263 Alternator Belt Adjustment....................................................264 Alternator Disassembly And Assembly...........................................265 STARTER SYSTEM....................................................................267 Starter System Troubleshooting................................................267 Removal And Installation......................................................268 Starter Disassembly And Assembly..............................................269 Starter Motor Testing.........................................................271 Starter Solenoid Operation....................................................272 FUEL SOLENOID.....................................................................273 Description...................................................................273 Solenoid Location.............................................................273 Fuel Solenoid Pull Coil Testing...............................................273 Fuel Solenoid Hold Coil Testing...............................................273 LIGHTS............................................................................275 Headlight Removal And Installation............................................275 Headlight Adjustment..........................................................276 Taillight / Brake Light Removal And Installation..............................277 ELECTRONIC CONTROL MODULE.........................................................279 Description...................................................................279 Removal And Installation......................................................279 SPEED SENSORS.....................................................................281 Engine Speed Sensor...........................................................281 Vehicle Speed Sensor..........................................................282 SWITCH (HEADLIGHT)................................................................283 Location......................................................................283 Removal And Installation......................................................283 Testing.......................................................................284 SWITCH (BRAKE LIGHT)..............................................................285 Description...................................................................285 Location......................................................................285 Removal And Installation......................................................286 Testing.......................................................................286 SWITCH (AWD / 2WD / TURF).........................................................287 Location......................................................................287 Removal And Installation......................................................287 Testing.......................................................................288 SWITCH (KEY)......................................................................289 Location......................................................................289 Removal And Installation......................................................289 Ignition Key Switch Testing...................................................290 SWITCH (GEAR SELECTOR)............................................................291 Location......................................................................291 Removal And Installation......................................................291 Testing.......................................................................292 SWITCH (PUMP NEUTRAL).............................................................293 Description...................................................................293 Location......................................................................293 Testing.......................................................................293 Removal And Installation......................................................294 GLOW PLUGS........................................................................295 Location......................................................................295 Removal And Installation......................................................295 Testing.......................................................................296 TEMPERATURE SENSOR................................................................297 Description...................................................................297 Testing.......................................................................297 Removal And Installation......................................................298 Fan Control Circuit Operation / Testing.......................................298 Fan Control Circuit Bypass Test...............................................298 DIFFERENTIAL SOLENOID.............................................................299 Description...................................................................299 Removal And Installation......................................................299 DIFFERENTIAL SOLENOID (REAR RELAY)................................................301 Description...................................................................301 Removal And Installation......................................................301 Differential Solenoid Circuit Operation.......................................302 OIL PRESSURE SENSOR...............................................................303 Location......................................................................303 Testing.......................................................................303 Removal And Installation......................................................304 HYDRAULIC OIL SWITCH..............................................................305 Description...................................................................305 Location......................................................................305 Testing.......................................................................305 Removal And Installation......................................................305 BACK-UP ALARM SYSTEM..............................................................307 Description...................................................................307 Location......................................................................307 Inspecting....................................................................308 Removal And Installation......................................................309 HYDRAULIC TEMPERATURE SENSOR......................................................311 Location......................................................................311 Testing.......................................................................311 Removal And Installation......................................................312 INSTRUMENT CLUSTER................................................................313 Information Display...........................................................313 Pinouts.......................................................................315 Information Display Area......................................................316 Diagnostic Trouble Codes......................................................321 Removal And Installation......................................................323 HVAC SYSTEM.......................................................................325 Description...................................................................325 A/C Switch....................................................................325 Blower Switch.................................................................326 Temperature Control...........................................................326 FUEL SENDER.......................................................................327 Testing.......................................................................327 DIAGNOSTIC TESTING................................................................329 Digital Wrench™ Diagnostic Software...........................................329 Digital Wrench™ Diagnostic Connector..........................................330 Digital Wrench™ SmartLink Module Kit - MEL1721................................330 Digital Wrench™ Serial Number Location........................................331 Version And Update ID.........................................................331 Updates.......................................................................332 Digital Wrench™ Feature Map...................................................334 Engine Controller Unit Reprograming (Reflash).................................335 Special Tests Menu............................................................340 Data Items....................................................................340 ENGINE SERVICE........................................................................341 ENGINE INFORMATION................................................................345 Description...................................................................345 Specifications................................................................346 Torque Values.................................................................350 Troubleshooting...............................................................351 Troublesh ooting..............................................................351 Accessible Engine Components..................................................358 Engine Removal And Installation...............................................359 Engine Installation Notes.....................................................366 Engine Mount Replacement......................................................366 Compression And Leakage Teat..................................................367 Cylinder Head Diagnostics.....................................................368 Fuel Limiter..................................................................368 Idle Speed Setting............................................................369 Timing Belt Inspection........................................................370 MUFFLER...........................................................................371 Removal And Installation......................................................371 AIR CLEANER.......................................................................373 Housing Removal And Installation..............................................373 ENGINE COOLING SYSTEM.............................................................375 Cooling System Pressure Test..................................................375 Radiator Cap Pressure Test....................................................375 System Bleeding...............................................................376 Radiator Cleaning.............................................................377 Radiator Removal And Installation.............................................378 Cooling Fan Removal And Installation..........................................380 Thermostat Removal And Installation...........................................381 Thermostat Checking...........................................................382 Water Pump Removal And Installation...........................................383 LUBRICATION SYSTEM................................................................385 Oil Pan Removal And Installation..............................................385 Oil Pump Removal..............................................................386 Oil Pump Inspection...........................................................387 Oil Pump Installation.........................................................387 Engine Oil Pressure - Testing.................................................388 FUEL SYSTEM.......................................................................389 Service Notes.................................................................389 Operation.....................................................................389 Initial Priming / Starting Procedure..........................................390 Fuel Line Removal / Installation..............................................390 Fuel Tank Removal.............................................................391 Fuel Tank Installation........................................................392 Fuel Pump.....................................................................393 Location......................................................................395 Fuel Filter / Water Separator Draining........................................395 Fuel Sender Removal And Installation..........................................396 Injector Timing...............................................................398 ENGINE DISASSEMBLY AND INSPECTION.................................................401 Crankcase Vacuum Regulator Valve Removal......................................401 Intake Manifold Removal.......................................................401 Exhaust Manifold Removal......................................................402 Drive Pulley Removal..........................................................402 Flywheel Removal..............................................................403 Timing Belt Removal...........................................................404 Timing Pulleys Removal........................................................405 Water Pump Removal............................................................406 Speed Governor Removal........................................................407 Rocker Arm Cover Removal......................................................407 Fuel Rail Removal.............................................................408 Unit Injector Removal.........................................................409 Rocker Arm Assembly Removal...................................................410 Camshaft Removal..............................................................410 Camshaft Inspection...........................................................411 Cylinder Head Removal.........................................................412 Valve Removal.................................................................412 Valve And Spring Inspection...................................................413 Pre-Combustion Chamber Removal................................................415 Piston and Connecting Rod Removal.............................................416 Piston and Piston Ring Inspection.............................................417 Connecting Rod Inspection.....................................................418 Cylinder Inspection...........................................................419 Crankshaft Removal............................................................420 Crankshaft Inspection.........................................................421 ENGINE ASSEMBLY...................................................................423 Crankshaft Installation.......................................................423 Piston and Connecting Rod Installation........................................424 Oil Pan Installation..........................................................425 Pre-Combustion Chamber Installation...........................................426 Valve Installation............................................................426 Cylinder Head Installation....................................................427 Camshaft Installation.........................................................428 Rocker Arm Assembly Installation..............................................429 Valve / Rocker Arm Clearance..................................................429 Speed Governor Installation...................................................430 Unit Injector Installation....................................................431 Fuel Rail Installation........................................................432 Rocker Arm Cover Installation.................................................432 Oil Pump Installation.........................................................433 Water Pump Installation.......................................................434 Timing Pulleys Installation...................................................434 Timing Belt Installation......................................................435 Flywheel Installation.........................................................438 Drive Pulley Installation.....................................................438 Starter Installation..........................................................439 Exhaust Manifold Installation.................................................440 Intake Manifold Installation..................................................440 Crankcase Vacuum Regulator Valve Installation.................................441 ENGINE SPEED CONTROL..............................................................443 Cable Removal And Installation................................................443 HYDRAULIC SYSTEM......................................................................445 HYDRAULIC / HYDROSTATIC SCHEMATICS................................................447 HYDRAULIC SYSTEM INFORMATION......................................................449 Glossary Of Hydraulic / Hydrostatic Symbols...................................449 Troubleshooting...............................................................453 HYDRAULIC RESERVOIR...............................................................455 Description...................................................................455 Removal And Installation......................................................456 STEERING VALVE....................................................................459 Removal And Installation......................................................459 Parts Identification..........................................................460 Disassembly...................................................................461 Assembly......................................................................467 MANIFOLD VALVE....................................................................473 Description...................................................................473 Two-Speed Pressure Testing....................................................473 Steering Relief Valve Testing.................................................474 Removal And Installation......................................................475 Parts Identification..........................................................476 Disassembly...................................................................477 Assembly......................................................................481 HYDRAULIC / HYDROSTATIC FILTER....................................................485 Description...................................................................485 Housing Removal And Installation..............................................486 OIL COOLER........................................................................487 Removal And Installation......................................................487 GEAR PUMP.........................................................................489 Removal And Installation......................................................489 Parts Identification..........................................................491 Disassembly And Assembly......................................................492 HYDROSTATIC SYSTEM....................................................................497 HYDROSTATIC SYSTEM INFORMATION....................................................499 Troubleshooting...............................................................499 Description...................................................................500 HYDROSTATIC DRIVE MOTOR...........................................................501 Description...................................................................501 Removal And Installation......................................................502 Parts Identification..........................................................505 Disassembly...................................................................506 Assembly......................................................................513 CHARGE PRESSURE...................................................................519 Description...................................................................519 Testing.......................................................................520 HYDROSTATIC PUMP..................................................................521 Description...................................................................521 Drive Relief Pressure Testing.................................................521 Removal And Installation......................................................522 Hydrostatic Travel Control Adjustments........................................531 Performance Checks Worksheet..................................................538 Coupler Removal And Installation..............................................539 Parts Identification..........................................................540 Parts Identification..........................................................541 Disassembly...................................................................542 Inspection....................................................................553 Assembly......................................................................555 HEATING, VENTILATION AND AIR CONDITIONING (HVAC)......................................565 AIR CONDITIONING SYSTEM FLOW (S/N B3C216999 & BELOW)..............................567 Description...................................................................567 Chart.........................................................................568 Components....................................................................569 Safety Equipment..............................................................572 AIR CONDITIONING SYSTEM FLOW (S/N B3C217001 & ABOVE)..............................573 Description...................................................................573 Chart.........................................................................574 Components....................................................................575 Safety Equipment..............................................................579 REGULAR MAINTENANCE...............................................................581 Compressor Drive Belt Inspection..............................................581 Condenser.....................................................................581 Air Conditioning Service Chart................................................582 A/C Evaporator Coil Filter (S/N B3C216999 & Below)............................583 A/C Evaporator Coil Filter (S/N B3C217001 & Above)............................583 TROUBLESHOOTING...................................................................585 Blower Motor Does Not Operate.................................................585 Blower Motor Operates Normally But Air Flow Is Insufficient...................585 Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....585 The Compressor Does Not Operate At All Or Operates Improperly.................586 Gauge Pressure Related Troubleshooting........................................587 Temperature / Pressure Chart..................................................589 Poor A/C Performance..........................................................590 HVAC Repair And Leaks.........................................................590 Electrical System.............................................................591 Engine Coolant Bypassing The Heater Valve.....................................600 Heater Valve Not Opening Or Closing...........................................601 SYSTEM CHARGING AND RECLAMATION...................................................603 Refrigerant Identification....................................................603 Reclamation And Charging With Recovery / Charging Unit........................604 COMPRESSOR........................................................................607 Belt Adjustment...............................................................607 Belt Replacement..............................................................607 Removal And Installation......................................................608 Oil...........................................................................609 Oil Check.....................................................................610 Clutch Disassembly And Assembly...............................................611 CONDENSER.........................................................................615 Removal And Installation......................................................615 RECEIVER / DRIER..................................................................617 Receiver / Drier Removal And Installation.....................................617 Pressure Relief Valve Removal And Installation................................618 Pressure Switch Removal And Installation......................................619 EVAPORATOR / HEATER UNIT (S/N B3C216999 & BELOW)..................................621 Removal And Installation......................................................621 EVAPORATOR / HEATER UNIT (S/N B3C217001 & ABOVE)..................................625 Removal And Installation......................................................625 THERMOSTAT (S/N B3C216999 & BELOW)................................................629 Description...................................................................629 Removal And Installation......................................................630 THERMOSTAT (S/N B3C217001 & ABOVE)................................................633 Description...................................................................633 Removal And Installation......................................................634 EXPANSION VALVE (S/N B3C216999 & BELOW)...........................................637 Removal And Installation......................................................637 EXPANSION VALVE (S/N B3C217001 & ABOVE)...........................................639 Removal And Installation......................................................639 EVAPORATOR COIL (S/N B3C216999 & BELOW)...........................................641 Removal And Installation......................................................641 EVAPORATOR COIL (S/N B3C217001 & ABOVE)...........................................643 Removal And Installation......................................................643 HEATER COIL (S/N B3C216999 & BELOW)...............................................645 Removal And Installation With A/C.............................................645 HEATER COIL (S/N B3C217001 & ABOVE)...............................................647 Removal And Installation With A/C.............................................647 BLOWER FAN (S/N B3C216999 & BELOW)................................................649 Removal And Installation......................................................649 BLOWER FAN (S/N B3C217001 & ABOVE)................................................653 Removal And Installation......................................................653 HEATER VALVE (S/N B3C216999 & BELOW)..............................................657 Removal And Installation......................................................657 Disassembly And Assembly......................................................657 HEATER VALVE (S/N B3C217001 & ABOVE)..............................................659 Removal And Installation......................................................659 SPECIFICATIONS........................................................................661 (3600) UTILITY VEHICLE SPECIFICATIONS.............................................663 Dimensions (S/N B3C216999 & Below)............................................663 Dimensions (S/N B3C217001 & Above)............................................664 Performance...................................................................665 Controls......................................................................665 Engine........................................................................666 Electrical....................................................................666 Hydraulic System..............................................................666 Drive System..................................................................667 Fluid And Capacities..........................................................667 Tires.........................................................................667 TECHNICAL SERVICE GUIDE SPECIFICATIONS............................................669 Engine........................................................................669 Engine Torques................................................................669 Cooling System................................................................669 TORQUE SPECIFICATIONS FOR BOLTS...................................................671 Torque For General SAE Bolts..................................................671 Torque For General Metric Bolts...............................................672 CONVERSIONS.......................................................................673 Decimal And Millimeter Equivalent Chart.......................................673 U.S. To Metric Conversion Chart...............................................674 SERVICE TOOLS REQUIRED............................................................675 Hydraulic Tools...............................................................675 Transmission / Clutch / Drive Tools...........................................676 Engine Tools..................................................................680 HVAC Tools....................................................................684 ALPHABETICAL INDEX....................................................................685
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