Bobcat 3650 Utility Vehicle Service Manual 6990367 (02-16) – PDF DOWNLOAD

Description

Bobcat 3650 Utility Vehicle Service Manual 6990367 (02-16) – PDF DOWNLOAD

FILE DETAILS:

Bobcat 3650 Utility Vehicle Service Manual 6990367 (02-16) – PDF DOWNLOAD

Language : English
Pages : 736
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat 3650 Utility Vehicle Service Manual 6990367 (02-16) – PDF DOWNLOAD

S/N AVW411001 & Above
S/N AVW420001 & Above

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 3650 Utility Vehicle Service Manual 6990367 (02-16) – 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
		Chart......................................................................... 29
	AIR CLEANER SERVICE............................................................... 31
		Pre-Filter Element............................................................ 31
		Replacing Filter Element...................................................... 32
	ENGINE COOLING SYSTEM............................................................. 33
		Checking Level................................................................ 33
		Cleaning...................................................................... 34
		Removing And Replacing Coolant................................................ 35
	FUEL SYSTEM....................................................................... 37
		Fuel Specifications........................................................... 37
		Biodiesel Blend Fuel.......................................................... 37
		Filling The Fuel Tank......................................................... 38
		Fuel Filter................................................................... 38
		Removing Air From The Fuel System............................................. 39
		Filling A Portable Fuel Container............................................. 39
	ENGINE LUBRICATION SYSTEM......................................................... 41
		Checking And Adding Engine Oil................................................ 41
		Engine Oil Chart.............................................................. 41
		Removing And Replacing Oil And Filter......................................... 42
	HYDRAULIC / HYDROSTATIC SYSTEM.................................................... 45
		Checking Fluid................................................................ 45
		Hydraulic Fluid............................................................... 45
		Adding Fluid.................................................................. 45
		Removing And Replacing Hydraulic / Hydrostatic Filter......................... 46
		Removing And Replacing Hydraulic / Hydrostatic Fluid.......................... 47
	GEARCASE.......................................................................... 49
		Checking Transmission Fluid................................................... 49
		Transmission Fluid............................................................ 49
		Adding Transmission Fluid..................................................... 49
		Removing And Replacing Transmission Fluid..................................... 50
		Checking Front Gearcase Fluid................................................. 50
		Front Gearcase Fluid.......................................................... 51
		Adding Front Gearcase Fluid................................................... 51
		Removing And Replacing Front Gearcase Fluid................................... 51
	TIRE MAINTENANCE.................................................................. 53
		Tires......................................................................... 53
		Tire Tread Depth.............................................................. 53
		Axle And Wheel Nut Torque..................................................... 53
		Wheel Removal And Installation................................................ 53
		Mounting...................................................................... 54
		Tire Pressure................................................................. 54
	SPARK ARRESTER MUFFLER............................................................ 55
		Cleaning Procedure............................................................ 55
	UTILITY VEHICLE STORAGE AND RETURN TO SERVICE..................................... 57
		Storage....................................................................... 57
		Return To Service............................................................. 57
	STOPPING THE ENGINE AND LEAVING THE UTILITY VEHICLE............................... 59
		Procedure..................................................................... 59
		Emergency Exit (When Equipped With Cab)....................................... 60
	RELIEVING HYDRAULIC PRESSURE...................................................... 61
		Procedure..................................................................... 61
DRIVE SYSTEM.......................................................................... 63
	BRAKE............................................................................. 65
		General Specifications........................................................ 65
		Torque Specifications......................................................... 65
		System Service Notes.......................................................... 66
		Noise Troubleshooting......................................................... 67
		System Troubleshooting........................................................ 68
		Hydraulic Brake System Operation.............................................. 69
		System Parts Identification................................................... 70
		Master Cylinder Removal And Installation...................................... 71
		Foot Brake Pedal Removal And Installation..................................... 72
		Bleeding / Fluid Removal And Installation..................................... 73
		Brake Inspection.............................................................. 75
		Brake Pad Inspection.......................................................... 75
		Burnishing.................................................................... 75
	BRAKE (FRONT)..................................................................... 77
		Pad Removal................................................................... 77
		Pad Inspection................................................................ 78
		Pad Assembly / Installation................................................... 79
		Caliper Removal............................................................... 80
		Caliper Parts Identification.................................................. 81
		Caliper Disassembly........................................................... 82
		Caliper Inspection............................................................ 83
		Caliper Assembly.............................................................. 84
		Caliper Installation.......................................................... 84
		Disc Runout................................................................... 85
		Disc Inspection............................................................... 86
		Disc Removal And Installation................................................. 86
	BRAKE (REAR)...................................................................... 89
		Pad Removal................................................................... 89
		Pad Inspection................................................................ 90
		Pad Installation.............................................................. 90
		Caliper Removal............................................................... 91
		Caliper Parts Identification.................................................. 92
		Caliper Disassembly........................................................... 93
		Caliper Inspection............................................................ 94
		Caliper Assembly.............................................................. 95
		Caliper Installation.......................................................... 95
		Disc Runout................................................................... 96
		Disc Inspection............................................................... 96
		Disc Removal And Installation................................................. 97
	TRANSMISSION...................................................................... 99
		Shift Lever Removal And Installation.......................................... 99
		Shift Cable Adjustment........................................................100
		Shift Cable Removal And Installation..........................................101
		Removal And Installation......................................................103
		Parts Identification..........................................................110
		Differential Operation........................................................114
		Transmission Disassembly......................................................115
		Snorkel Shaft Removal / Disassembly...........................................118
		Transmission Shaft Service....................................................120
		Planetary Differential Disassembly............................................122
		Planetary Differential Assembly...............................................125
		Transmission Assembly.........................................................129
	FINAL DRIVE.......................................................................133
		Bearing Carrier Removal.......................................................133
		Bearing Removal And Installation..............................................135
		Bearing Carrier Installation..................................................136
		Front Drive Shaft Removal And Installation....................................139
		Rear Drive Shaft Removal And Installation.....................................140
		Drive Shaft / CV Joint Handling...............................................142
		Outer CV Joint And Boot Removal And Installation..............................143
		Inner Plunging Joint And Boot Removal And Installation........................146
		Propshaft Removal And Installation............................................149
		Propshaft U-Joint Disassembly.................................................150
		Propshaft U-Joint Assembly....................................................151
		Front Gearcase Operation......................................................152
		Front Gearcase Removal And Installation.......................................155
		Front Gearcase Parts Identification...........................................157
		Front Gearcase Disassembly / Inspection.......................................158
		Front Gearcase Assembly.......................................................162
	TRAVEL CONTROL PEDAL..............................................................165
		Description...................................................................165
		Inspection....................................................................165
		Removal And Installation......................................................165
		Cable Removal And Installation................................................166
	PTO...............................................................................169
		Drive Belt Removal And Installation...........................................169
		Drive Pulley Removal And Installation.........................................170
		Drive Belt Tensioner Removal And Installation.................................171
		Clutch Removal And Installation...............................................172
		Clutch Brake Adjusting........................................................173
		Gear Box Removal And Installation.............................................174
		Parts Identification..........................................................175
		Gearbox Disassembly And Assembly..............................................176
MAINFRAME.............................................................................179
	ROLL-OVER PROTECTIVE STRUCTURE (ROPS).............................................181
		Removal And Installation......................................................181
	OPERATOR SEAT.....................................................................185
		Seat Base Removal And Installation............................................185
		Seat Belt Removal And Installation............................................186
	DASH..............................................................................187
		Front Access Cover Removal And Installation...................................187
		Upper Dash Panel Removal And Installation.....................................187
		Lower Dash Panel Removal And Installation.....................................187
		Storage Panel Removal And Installation........................................190
	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.................................................196
	STEERING COLUMN...................................................................197
		Description...................................................................197
		Tilt Steering Shock Removal And Installation..................................197
		Parts Identification..........................................................198
		Steering Wheel Removal And Installation.......................................199
		Steering Wheel / Upper Steering Shaft Removal And Installation................200
		Steering Shaft Bearing Replacement............................................201
	STEERING BOX......................................................................203
		Removal And Installation......................................................203
	FUEL TANK.........................................................................205
		Fuel Tank Removal And Installation............................................205
	SHOCKS............................................................................209
		Rear Shock Removal And Installation...........................................209
		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 And Installation..........................................214
		Inspection....................................................................214
		Ball Joint Removal And Installation...........................................215
	TIE ROD...........................................................................217
		Description...................................................................217
		Removal And Installation......................................................217
		Toe Adjustment Procedure......................................................218
	TAILGATE..........................................................................219
		Removal And Installation......................................................219
		Latch Removal And Installation................................................220
	CARGO BOX.........................................................................221
		Removal And Installation......................................................221
	FENDER............................................................................223
		Removal And Installation (Front)..............................................223
		Removal And Installation (Rear)...............................................223
		Flare Removal And Installation................................................225
	ATTACHMENT ARM....................................................................227
		Removal And Installation......................................................227
	FRONT MOUNT.......................................................................229
		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
	ROOF..............................................................................241
		Removal And Installation......................................................241
ELECTRICAL SYSTEM AND ANALYSIS........................................................243
	ELECTRICAL SCHEMATICS.............................................................247
	ELECTRICAL SYSTEM INFORMATION.....................................................249
		Glossary Of Electrical Symbols................................................249
		Description...................................................................252
		Troubleshooting...............................................................253
		Fuse And Relay Location.......................................................254
		Fusible Links.................................................................256
	BATTERY...........................................................................257
		Removal And Installation......................................................257
		Servicing.....................................................................258
		Using A Booster Battery (Jump Starting).......................................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
		Starter Solenoid Bench Test...................................................272
	STOP 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..........................................................275
		Tail Light / Brake Light Removal And Installation.............................276
	ELECTRONIC CONTROL MODULE.........................................................277
		Description...................................................................277
		Removal And Installation......................................................277
	SPEED SENSORS.....................................................................279
		Engine Speed Sensor...........................................................279
		Vehicle Speed Sensor..........................................................280
	SWITCH (HEADLIGHT)................................................................281
		Location......................................................................281
		Removal And Installation......................................................281
		Testing.......................................................................281
	SWITCH (BRAKE LIGHT)..............................................................283
		Description...................................................................283
		Location......................................................................283
		Removal And Installation......................................................283
		Testing.......................................................................283
	SWITCH (AWD / 2WD / TURF).........................................................285
		Location......................................................................285
		Removal And Installation......................................................285
		Testing.......................................................................285
	SWITCH (KEY)......................................................................287
		Location......................................................................287
		Removal And Installation......................................................287
		Ignition Key Switch Testing...................................................287
	SWITCH (GEAR SELECTOR)............................................................289
		Location......................................................................289
		Removal And Installation......................................................289
		Testing.......................................................................289
	SWITCH (JOYSTICK LOCK)............................................................291
		Removal And Installation......................................................291
		Testing.......................................................................292
	SWITCH (TILT LOCK)................................................................293
		Removal And Installation......................................................293
		Testing.......................................................................294
	SWITCH (PUMP NEUTRAL).............................................................295
		Description...................................................................295
		Location......................................................................295
		Testing.......................................................................295
		Removal And Installation......................................................296
	GLOW PLUGS........................................................................297
		Location......................................................................297
		Testing.......................................................................297
		Removal And Installation......................................................297
	TEMPERATURE SENSOR................................................................299
		Description...................................................................299
		Testing.......................................................................299
		Removal And Installation......................................................299
		Fan Control Circuit Operation / Testing.......................................300
		Fan Control Circuit Bypass Test...............................................300
	DIFFERENTIAL SOLENOID.............................................................301
		Description...................................................................301
		Removal And Installation......................................................301
	DIFFERENTIAL SOLENOID (REAR RELAY)................................................303
		Description...................................................................303
		Removal And Installation......................................................303
		Differential Solenoid Circuit Operation.......................................303
	OIL PRESSURE SENSOR...............................................................305
		Location......................................................................305
		Removal And Installation......................................................305
	HYDRAULIC OIL SWITCH..............................................................307
		Description...................................................................307
		Location......................................................................307
		Testing.......................................................................307
		Removal And Installation......................................................307
	BACK-UP ALARM SYSTEM..............................................................309
		Description...................................................................309
		Location......................................................................309
		Inspecting....................................................................309
		Removal And Installation......................................................310
	HYDRAULIC TEMPERATURE SENSOR......................................................311
		Location......................................................................311
		Testing.......................................................................311
		Removal And Installation......................................................311
	SWITCH (PTO ENGAGEMENT)...........................................................313
		Description...................................................................313
		Location......................................................................313
		Testing.......................................................................313
		Removal And Installation......................................................314
	INSTRUMENT CLUSTER................................................................315
		Information Display...........................................................315
		Pinouts.......................................................................317
		Information Display Area......................................................317
		Diagnostic Trouble Codes......................................................322
		Removal And Installation......................................................324
	HVAC SYSTEM.......................................................................325
		Description...................................................................325
		AC Switch.....................................................................325
		Blower Switch.................................................................325
		Temperature Control...........................................................325
	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
		Serial Number Location........................................................331
		Version And Update ID.........................................................331
		Updates.......................................................................332
		Digital Wrench™ Feature Map...................................................333
		Engine Controller Unit Reprograming (Reflash).................................334
		Special Tests Menu............................................................339
		Data Items....................................................................339
ENGINE SERVICE........................................................................341
	ENGINE INFORMATION................................................................345
		Description...................................................................345
		Specifications................................................................346
		Torque Values.................................................................352
		Troubleshooting...............................................................353
		Engine Removal And Installation...............................................360
		Engine Mount Replacement......................................................365
		Compression - Checking........................................................365
	MUFFLER...........................................................................367
		Removal And Installation......................................................367
	AIR CLEANER.......................................................................369
		Housing Removal And Installation..............................................369
	ENGINE COOLING SYSTEM.............................................................371
		Cooling System Pressure Test..................................................371
		Radiator Cap Pressure Test....................................................371
		System Bleeding...............................................................372
		Radiator Cleaning.............................................................372
		Radiator Removal And Installation.............................................373
		Water Pump Weep Hole..........................................................377
		Water Pump Removal And Installation...........................................377
		Thermostat Removal............................................................379
		Thermostat Checking...........................................................379
	LUBRICATION SYSTEM................................................................381
		Oil Pan Removal And Installation..............................................381
		Oil Pump Removal And Installation.............................................381
		Oil Pump Disassembly And Assembly.............................................382
		Oil Pump Inspection...........................................................382
		Engine Oil Pressure - Testing.................................................384
	FUEL SYSTEM.......................................................................385
		Operation.....................................................................385
		Priming The Fuel System.......................................................385
		Fuel Lines / Vent Line........................................................386
		Fuel Pick-Up Screen...........................................................387
		Fuel Sender Tests.............................................................387
		Fuel Pick-Up / Sending Unit Removal And Installation..........................388
		Fuel Transfer Pump Operation..................................................390
		Fuel Pump Test................................................................390
		Fuel Pump Removal And Installation............................................391
		Draining Water From The Fuel Filter / Water Separator.........................392
		Fuel Filter / Water Separator Replacement.....................................392
		High-Pressure Fuel Injection Lines Removal And Installation...................393
		Fuel Return Line Removal And Installation.....................................394
		Stop Solenoid.................................................................395
		Fuel Injection Pump Removal...................................................396
		Fuel Injection Pump Installation..............................................398
		Fuel Injection Pump Assembly Installation.....................................400
		Injection Pump Timing.........................................................401
		Fuel Injector Removal And Installation........................................406
		Nozzle Spraying Condition.....................................................408
		Fuel Injector Disassembly.....................................................410
		Fuel Injector Assembly........................................................411
		Fuel Injector Nozzle Pressure - Checking......................................411
	CYLINDER HEAD.....................................................................413
		Intake And Exhaust Valves.....................................................413
		Valve Clearance Adjustment....................................................418
		Cylinder Head Removal And Installation........................................420
		Cylinder Head Disassembly And Assembly........................................421
		Cylinder Head - Servicing.....................................................426
		Valve Guide - Checking........................................................426
		Reconditioning The Valve And Valve Seat.......................................427
		Valve Spring..................................................................428
		Valve Tappets.................................................................429
		Rocker Arm And Shaft - Checking...............................................430
		Push Rod Alignment - Checking.................................................430
	CRANKSHAFT AND PISTONS............................................................431
		Piston And Connecting Rod Removal And Installation............................431
		Piston And Connecting Rod - Servicing.........................................438
		Cylinder Bore - Checking......................................................441
		Crankshaft And Bearings Removal...............................................442
		Crankshaft And Bearings Installation..........................................444
		Crankshaft And Bearings - Servicing...........................................446
		Honing And Boring.............................................................448
	CAMSHAFT AND TIMING GEARS.........................................................449
		Timing Gearcase Cover Removal And Installation................................449
		Timing Gears Backlash - Checking..............................................450
		Timing Gears Removal..........................................................451
		Timing Gears Installation.....................................................452
		Idler Gear And Camshaft Removal And Installation..............................453
		Camshaft - Servicing..........................................................455
		Idler Gear And Shaft - Servicing..............................................456
	ENGINE SPEED CONTROL..............................................................457
		Hand Lever Removal And Installation...........................................457
		Cable Removal And Installation................................................460
HYDRAULIC SYSTEM......................................................................463
	HYDRAULIC SCHEMATICS..............................................................465
	HYDRAULIC SYSTEM INFORMATION......................................................467
		Glossary Of Hydraulic / Hydrostatic Symbols...................................467
		Troubleshooting...............................................................471
	CYLINDER (LIFT)...................................................................473
		Testing.......................................................................473
		Removal And Installation......................................................474
		Parts Identification..........................................................475
		Disassembly...................................................................476
		Assembly......................................................................479
	CYLINDER (TILT)...................................................................485
		Testing.......................................................................485
		Removal And Installation......................................................486
		Parts Identification..........................................................487
		Disassembly...................................................................488
		Assembly......................................................................491
	HYDRAULIC CONTROL VALVE...........................................................497
		Main Relief Valve Testing.....................................................497
		Port Relief Valve Testing.....................................................498
		Removal And Installation......................................................499
		Parts Identification..........................................................503
		Disassembly...................................................................504
		Assembly......................................................................514
	AUXILIARY CONTROL VALVE...........................................................523
		Removal And Installation......................................................523
		Parts Identification..........................................................524
		Disassembly...................................................................525
		Assembly......................................................................532
	HYDRAULIC RESERVOIR...............................................................539
		Description...................................................................539
		Removal And Installation......................................................539
	FRONT AUXILIARY HYDRAULIC COUPLER.................................................543
		Removal And Installation......................................................543
	STEERING VALVE....................................................................545
		Removal And Installation......................................................545
		Parts Identification..........................................................546
		Disassembly...................................................................547
		Assembly......................................................................553
	priority VALVE....................................................................559
		Description...................................................................559
		Two-Speed Pressure Testing....................................................559
		Steering Relief Valve Testing.................................................560
		Removal And Installation......................................................561
		Parts Identification..........................................................562
		Disassembly...................................................................563
		Assembly......................................................................567
	HYDRAULIC / HYDROSTATIC FILTER....................................................571
		Description...................................................................571
		Housing Removal And Installation..............................................572
	OIL COOLER........................................................................573
		Removal And Installation......................................................573
	GEAR PUMP.........................................................................575
		Removal And Installation......................................................575
		Parts Identification..........................................................577
		Disassembly And Assembly......................................................578
HYDROSTATIC SYSTEM....................................................................583
	HYDROSTATIC SYSTEM INFORMATION....................................................585
		Troubleshooting...............................................................585
		Description...................................................................586
	HYDROSTATIC DRIVE MOTOR...........................................................587
		Description...................................................................587
		Removal And Installation......................................................587
		Parts Identification..........................................................590
		Disassembly...................................................................591
		Assembly......................................................................599
	CHARGE PRESSURE...................................................................605
		Description...................................................................605
		Testing.......................................................................605
	HYDROSTATIC PUMP..................................................................607
		Description...................................................................607
		Drive Relief Pressure Testing.................................................607
		Removal And Installation......................................................608
		Hydrostatic Travel Control Adjustments........................................616
		Performance Checks Worksheet..................................................625
		Coupler Removal And Installation..............................................627
		Parts Identification..........................................................628
		Disassembly...................................................................629
		Inspection....................................................................639
		Assembly......................................................................641
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)......................................651
	AIR CONDITIONING SYSTEM FLOW......................................................653
		Description...................................................................653
		Chart.........................................................................654
		Components....................................................................655
		Safety Equipment..............................................................658
	REGULAR MAINTENANCE...............................................................659
		Compressor Drive Belt Inspection..............................................659
		Condenser.....................................................................659
		Air Conditioning Service Chart................................................660
		A/C Evaporator Coil...........................................................661
	TROUBLESHOOTING...................................................................663
		Blower Motor Does Not Operate.................................................663
		Blower Motor Operates Normally But Air Flow Is Insufficient...................663
		Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....663
		The Compressor Does Not Operate At All Or Operates Improperly.................664
		Gauge Pressure Related Troubleshooting........................................665
		Temperature / Pressure Chart..................................................667
		Poor A/C Performance..........................................................668
		HVAC Repair And Leaks.........................................................668
		Electrical System.............................................................669
		Engine Coolant Bypassing The Heater Valve.....................................676
		Heater Valve Not Opening Or Closing...........................................676
	SYSTEM CHARGING AND RECLAMATION...................................................677
		Refrigerant Identification....................................................677
		Reclamation And Charging With Recovery / Charging Unit........................678
	COMPRESSOR........................................................................681
		Belt Adjustment...............................................................681
		Belt Replacement..............................................................681
		Removal And Installation......................................................682
		Oil...........................................................................683
		Oil Check.....................................................................684
		Clutch Disassembly And Assembly...............................................685
	CONDENSER.........................................................................689
		Removal And Installation......................................................689
	RECEIVER / DRIER..................................................................691
		Receiver / Drier Removal And Installation.....................................691
		Pressure Relief Valve Removal And Installation................................692
		Pressure Switch Removal And Installation......................................692
	EVAPORATOR / HEATER UNIT..........................................................693
		Removal And Installation......................................................693
	THERMOSTAT........................................................................697
		Description...................................................................697
		Removal And Installation......................................................698
	EXPANSION VALVE...................................................................701
		Removal And Installation......................................................701
	EVAPORATOR COIL...................................................................703
		Removal And Installation......................................................703
	HEATER COIL.......................................................................705
		Removal And Installation With A/C.............................................705
	BLOWER FAN........................................................................707
		Removal And Installation......................................................707
	HEATER VALVE......................................................................711
		Removal And Installation......................................................711
		Disassembly And Assembly......................................................711
SPECIFICATIONS........................................................................713
	UTILITY VEHICLE SPECIFICATIONS....................................................715
		(3650) Dimensions.............................................................715
		Performance...................................................................716
		Controls......................................................................716
		Engine........................................................................717
		Electrical....................................................................717
		Hydraulic System..............................................................718
		Power Take-Off (PTO) System...................................................718
		Drive System..................................................................719
		Fluid And Capacities..........................................................719
		Tires.........................................................................719
	TECHNICAL SERVICE GUIDE SPECIFICATIONS............................................721
		Engine........................................................................721
		Engine Torques................................................................721
		Cooling System................................................................721
		Utility Vehicle Torques.......................................................722
		Hydraulic / Hydrostatic System................................................722
	TORQUE SPECIFICATIONS FOR BOLTS...................................................723
		Torque For General SAE Bolts..................................................723
		Torque For General Metric Bolts...............................................724
	CONVERSIONS.......................................................................725
		Decimal And Millimeter Equivalent Chart.......................................725
		U.S. To Metric Conversion Chart...............................................726
	SERVICE TOOLS REQUIRED............................................................727
		Hydraulic Tools...............................................................727
		Transmission / Clutch / Drive Tools...........................................728
		Engine Tools..................................................................731
		HVAC Tools....................................................................734
ALPHABETICAL INDEX....................................................................735

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