Bobcat 3650 Utility Vehicle Service Manual SN B3C311001 & Above – PDF DOWNLOAD

Description

Bobcat 3650 Utility Vehicle Service Manual SN B3C311001 & Above – PDF DOWNLOAD

FILE DETAILS:

Bobcat 3650 Utility Vehicle Service Manual SN B3C311001 & Above – PDF DOWNLOAD

Language : English
Pages : 786
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Bobcat 3650 Utility Vehicle Service Manual SN B3C311001 & Above – PDF DOWNLOAD

FOREWORD

This manual is for the Utility Vehicle mechanic. It provides necessary servicing and adjustment procedures for the Utility Vehicle 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 SN B3C311001 & 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 (3650)............................................. 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..................................................................... 26
	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.......................................................... 53
		Adding Front Gearcase Fluid................................................... 53
		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................................................ 56
		Mounting...................................................................... 57
		Tire Pressure................................................................. 57
	SPARK ARRESTER MUFFLER............................................................ 59
		Cleaning Procedure............................................................ 59
	UTILITY VEHICLE STORAGE AND RETURN TO SERVICE..................................... 61
		Storage....................................................................... 61
		Return To Service............................................................. 61
	STOPPING THE ENGINE AND LEAVING THE UTILITY VEHICLE............................... 63
		Procedure..................................................................... 63
		Emergency Exit (When Equipped With Cab)....................................... 64
	RELIEVING HYDRAULIC PRESSURE...................................................... 65
		Procedure..................................................................... 65
	SEAT BELT......................................................................... 67
		Inspection And Maintenance.................................................... 67
	LUBRICATING THE UTILITY VEHICLE................................................... 69
		Lubrication Locations......................................................... 69
DRIVE SYSTEM.......................................................................... 71
	BRAKE............................................................................. 73
		General Specifications........................................................ 73
		Torque Specifications......................................................... 73
		System Service Notes.......................................................... 74
		Noise Troubleshooting......................................................... 75
		System Troubleshooting........................................................ 76
		Hydraulic Brake System Operation.............................................. 77
		System Parts Identification................................................... 78
		Master Cylinder Removal And Installation...................................... 79
		Foot Brake Pedal Removal And Installation..................................... 80
		Bleeding / Fluid Removal And Installation..................................... 81
		Brake Inspection.............................................................. 83
		Brake Pad Inspection.......................................................... 83
		Burnishing.................................................................... 84
	BRAKE (FRONT)..................................................................... 85
		Pad Removal................................................................... 85
		Pad Inspection................................................................ 86
		Pad Assembly / Installation................................................... 87
		Caliper Removal............................................................... 88
		Caliper Parts Identification.................................................. 89
		Caliper Disassembly........................................................... 90
		Caliper Inspection............................................................ 91
		Caliper Assembly.............................................................. 92
		Caliper Installation.......................................................... 92
		Disc Runout................................................................... 93
		Disc Inspection............................................................... 93
		Disc Removal And Installation................................................. 94
	BRAKE (REAR)...................................................................... 95
		Pad Removal................................................................... 95
		Pad Inspection................................................................ 96
		Pad Installation.............................................................. 96
		Caliper Removal............................................................... 97
		Caliper Parts Identification.................................................. 98
		Caliper Disassembly........................................................... 99
		Caliper Inspection............................................................100
		Caliper Assembly..............................................................101
		Caliper Installation..........................................................101
		Disc Runout...................................................................102
		Disc Inspection...............................................................102
		Disc Removal And Installation.................................................103
	TRANSMISSION......................................................................105
		Shift Lever Removal And Installation..........................................105
		Shift Cable Adjustment........................................................106
		Shift Cable Removal And Installation..........................................107
		Removal And Installation......................................................109
		Parts Identification..........................................................118
		Differential Operation........................................................122
		Transmission Disassembly......................................................123
		Snorkel Shaft Removal / Disassembly...........................................126
		Transmission Shaft Service....................................................128
		Planetary Differential Disassembly............................................130
		Planetary Differential Assembly...............................................133
		Transmission Assembly.........................................................137
	FINAL DRIVE.......................................................................141
		Bearing Carrier Removal.......................................................141
		Bearing Removal And Installation..............................................143
		Bearing Carrier Installation..................................................144
		Front Drive Shaft Removal And Installation....................................146
		Rear Drive Shaft Removal And Installation.....................................147
		Drive Shaft / CV Joint Handling...............................................149
		Outer CV Joint And Boot Removal And Installation..............................150
		Inner Plunging Joint And Boot Removal And Installation........................153
		Propshaft Removal And Installation............................................156
		Propshaft U-Joint Disassembly.................................................157
		Propshaft U-Joint Assembly....................................................158
		Front Gearcase Operation......................................................161
		Front Gearcase Removal And Installation.......................................164
		Front Gearcase Parts Identification...........................................166
		Front Gearcase Disassembly / Inspection.......................................167
		Front Gearcase Assembly.......................................................171
	TRAVEL CONTROL PEDAL..............................................................175
		Description...................................................................175
		Inspection....................................................................175
		Removal And Installation......................................................175
		Cable Removal And Installation................................................176
	PTO...............................................................................179
		Drive Belt Removal And Installation...........................................179
		Drive Pulley Removal And Installation.........................................180
		Drive Belt Tensioner Removal And Installation.................................181
		Clutch Removal And Installation...............................................182
		Gear Box Removal And Installation.............................................183
		Parts Identification..........................................................184
		Gearbox Disassembly And Assembly..............................................185
MAINFRAME.............................................................................189
	ROLL-OVER PROTECTIVE STRUCTURE (ROPS).............................................191
		Removal And Installation......................................................191
	OPERATOR SEAT.....................................................................197
		Seat Base Removal And Installation............................................197
		Seat Belt Removal And Installation............................................198
	DASH..............................................................................199
		Front Access Cover Removal And Installation...................................199
		Upper Dash Panel Removal And Installation.....................................199
		Lower Dash Panel Removal And Installation.....................................200
		Storage Panel Removal And Installation........................................203
	BUMPER COVER......................................................................205
		Removal And Installation......................................................205
	REAR SUSPENSION LINK AND AXLE BRACE...............................................207
		Upper Suspension Link Removal And Installation................................207
		Lower Suspension Link Removal And Installation................................208
		Axle Brace Removal And Installation...........................................209
		Rear Axle Bearing Replacement.................................................211
	STEERING COLUMN...................................................................213
		Description...................................................................213
		Tilt Steering Shock Removal And Installation..................................213
		Parts Identification..........................................................214
		Steering Wheel Removal And Installation.......................................215
		Steering Wheel / Upper Steering Shaft Removal And Installation................216
		Steering Shaft Bearing Replacement............................................218
	STEERING BOX......................................................................219
		Removal And Installation......................................................219
	FUEL TANK.........................................................................221
		Fuel Tank Removal And Installation............................................221
	SHOCKS............................................................................225
		Rear Shock Removal And Installation...........................................225
		Front Shock Removal And Installation..........................................226
		Shock Spring Removal And Installation.........................................227
		Spring Preload Adjustment.....................................................228
	A-ARMS............................................................................229
		Lower A-Arm Removal And Installation..........................................229
		Upper A-Arm Removal...........................................................230
		Upper A-Arm Installation......................................................233
		Inspection....................................................................235
		Ball Joint Removal And Installation...........................................236
	TIE ROD...........................................................................239
		Description...................................................................239
		Removal And Installation......................................................239
		Toe Adjustment Procedure......................................................240
	TAILGATE..........................................................................241
		Removal And Installation......................................................241
		Latch Removal And Installation................................................242
	CARGO BOX.........................................................................243
		Removal And Installation......................................................243
	FENDER............................................................................245
		Removal And Installation (Front)..............................................245
		Removal And Installation (Rear)...............................................245
		Flare Removal And Installation................................................247
	ATTACHMENT ARM....................................................................249
		Removal And Installation......................................................249
	FRONT MOUNT.......................................................................251
		Removal And Installation......................................................251
	FRONT WINDOW......................................................................253
		Removal And Installation......................................................253
	DOOR..............................................................................255
		Removal And Installation......................................................255
	DOOR LATCH........................................................................257
		Removal And Installation......................................................257
		Adjustment....................................................................257
	REAR PANEL........................................................................259
		Removal And Installation......................................................259
	WINDSHIELD WASHER RESERVOIR.......................................................261
		Removal And Installation......................................................261
	ROOF..............................................................................263
		Removal And Installation......................................................263
ELECTRICAL SYSTEM AND ANALYSIS........................................................265
	ELECTRICAL SCHEMATICS.............................................................269
	ELECTRICAL SYSTEM INFORMATION.....................................................271
		Glossary Of Electrical Symbols................................................271
		Description...................................................................274
		Troubleshooting...............................................................275
		Fuse And Relay Location.......................................................276
		Fusible Links.................................................................278
	BATTERY...........................................................................279
		Removal And Installation......................................................279
		Servicing.....................................................................280
		Using A Booster Battery (Jump Starting).......................................280
		Battery Terminal Blocks.......................................................283
	CHARGING SYSTEM...................................................................285
		Current Draw - Key OFF........................................................285
		Break Even Test...............................................................285
		Alternator Voltage Test.......................................................286
		Low Voltage Test..............................................................286
		Removal and Installation......................................................287
		Belt Adjustment...............................................................288
		Alternator Disassembly And Assembly...........................................289
	STARTER SYSTEM....................................................................291
		Starter System Troubleshooting................................................291
		Removal And Installation......................................................292
		Starter Disassembly And Assembly..............................................293
		Starter Motor Testing.........................................................295
		Starter Solenoid Operation....................................................296
		Starter Solenoid Bench Test...................................................296
	STOP SOLENOID.....................................................................297
		Description...................................................................297
		Solenoid Location.............................................................297
		Fuel Solenoid Pull Coil Testing...............................................297
		Fuel Solenoid Hold Coil Testing...............................................297
	LIGHTS............................................................................299
		Headlight Removal And Installation............................................299
		Headlight Adjustment..........................................................299
		Taillight / Brake Light Removal And Installation..............................300
	ELECTRONIC CONTROL MODULE.........................................................301
		Description...................................................................301
		Removal And Installation......................................................301
	SPEED SENSORS.....................................................................303
		Engine Speed Sensor...........................................................303
		Vehicle Speed Sensor..........................................................304
	SWITCH (HEADLIGHT)................................................................305
		Location......................................................................305
		Removal And Installation......................................................305
		Testing.......................................................................306
	SWITCH (BRAKE LIGHT)..............................................................307
		Description...................................................................307
		Location......................................................................307
		Removal And Installation......................................................308
		Testing.......................................................................308
	SWITCH (AWD / 2WD / TURF).........................................................309
		Location......................................................................309
		Removal And Installation......................................................309
		Testing.......................................................................310
	SWITCH (KEY)......................................................................311
		Location......................................................................311
		Removal And Installation......................................................311
		Ignition Key Switch Testing...................................................312
	SWITCH (GEAR SELECTOR)............................................................313
		Location......................................................................313
		Removal And Installation......................................................313
		Testing.......................................................................314
	SWITCH (JOYSTICK LOCK)............................................................315
		Removal And Installation......................................................315
		Testing.......................................................................316
	SWITCH (TILT LOCK)................................................................317
		Removal And Installation......................................................317
		Testing.......................................................................318
	SWITCH (PUMP NEUTRAL).............................................................319
		Description...................................................................319
		Location......................................................................319
		Testing.......................................................................319
		Removal And Installation......................................................320
	GLOW PLUGS........................................................................321
		Location......................................................................321
		Testing.......................................................................321
		Removal And Installation......................................................321
	TEMPERATURE SENSOR................................................................323
		Description...................................................................323
		Testing.......................................................................323
		Removal And Installation......................................................324
		Fan Control Circuit Operation / Testing.......................................324
		Fan Control Circuit Bypass Test...............................................324
	DIFFERENTIAL SOLENOID.............................................................325
		Description...................................................................325
		Removal And Installation......................................................325
	DIFFERENTIAL SOLENOID (REAR RELAY)................................................327
		Description...................................................................327
		Removal And Installation......................................................327
		Differential Solenoid Circuit Operation.......................................327
	OIL PRESSURE SENSOR...............................................................329
		Description...................................................................329
		Location......................................................................329
		Testing.......................................................................330
		Removal And Installation......................................................330
	HYDRAULIC OIL SWITCH..............................................................331
		Description...................................................................331
		Location......................................................................331
		Testing.......................................................................332
		Removal And Installation......................................................332
	BACK-UP ALARM SYSTEM..............................................................333
		Description...................................................................333
		Location......................................................................333
		Inspecting....................................................................333
		Removal And Installation......................................................334
	HYDRAULIC TEMPERATURE SENSOR......................................................335
		Location......................................................................335
		Testing.......................................................................335
		Removal And Installation......................................................336
	SWITCH (PTO ENGAGEMENT)...........................................................337
		Description...................................................................337
		Location......................................................................337
		Testing.......................................................................338
		Removal And Installation......................................................339
	INSTRUMENT CLUSTER................................................................341
		Information Display...........................................................341
		Pinouts.......................................................................343
		Information Display Area......................................................344
		Diagnostic Trouble Codes......................................................349
		Removal And Installation......................................................351
	HVAC SYSTEM.......................................................................353
		Description...................................................................353
		AC Switch.....................................................................353
		Blower Switch.................................................................354
		Temperature Control...........................................................354
	FUEL SENDER.......................................................................355
		Testing.......................................................................355
	DIAGNOSTIC TESTING................................................................357
		Digital Wrench™ Diagnostic Software...........................................357
		Digital Wrench™ Diagnostic Connector..........................................358
		Digital Wrench™ SmartLink Module Kit - MEL1721................................358
		Serial Number Location........................................................359
		Version And Update ID.........................................................359
		Updates.......................................................................360
		Digital Wrench™ Feature Map...................................................362
		Engine Controller Unit Reprograming (Reflash).................................363
		Special Tests Menu............................................................368
		Data Items....................................................................368
ENGINE SERVICE........................................................................369
	ENGINE INFORMATION................................................................373
		Description...................................................................373
		Specifications................................................................374
		Torque Values.................................................................378
		Troubleshooting...............................................................379
		Starting Trouble- shooting Problem............................................379
		Accessible Engine Components..................................................386
		Engine Removal And Installation...............................................387
		Engine Installation Notes.....................................................395
		Engine Mount Replacement......................................................395
		Compression And Leakage Test..................................................396
		Cylinder Head Diagnostics.....................................................397
		Fuel Limiter..................................................................397
		Idle Speed Setting............................................................397
		Timing Belt Inspection........................................................398
	ENGINE SPEED CONTROL LEVER........................................................399
		Description...................................................................399
		Inspection....................................................................399
		Hand Lever Removal And Installation...........................................399
		Cable Removal And Installation................................................403
	MUFFLER...........................................................................405
		Removal And Installation......................................................405
	AIR CLEANER.......................................................................407
		Housing Removal And Installation..............................................407
	ENGINE COOLING SYSTEM.............................................................409
		Cooling System Pressure Test..................................................409
		Radiator Cap Pressure Test....................................................409
		System Bleeding...............................................................410
		Radiator Cleaning.............................................................411
		Radiator Removal And Installation.............................................412
		Cooling Fan Removal And Installation..........................................414
		Thermostat Removal And Installation...........................................415
		Thermostat Checking...........................................................416
		Water Pump Removal And Installation...........................................417
	LUBRICATION SYSTEM................................................................419
		Oil Pan Removal And Installation..............................................419
		Oil Pump Removal..............................................................420
		Oil Pump Inspection...........................................................421
		Oil Pump Installation.........................................................421
		Engine Oil Pressure - Testing.................................................422
	FUEL SYSTEM.......................................................................423
		Service Notes.................................................................423
		Operation.....................................................................423
		Initial Priming / Starting Procedure..........................................424
		Fuel Line Removal / Installation..............................................424
		Fuel Tank Removal.............................................................425
		Fuel Tank Installation........................................................426
		Fuel Pump.....................................................................427
		Location......................................................................428
		Fuel Filter / Water Separator Draining........................................428
		Fuel Sender...................................................................429
		Injector Timing...............................................................430
	ENGINE DISASSEMBLY AND INSPECTION.................................................433
		Crankcase Vacuum Regulator Valve Removal......................................433
		Intake Manifold Removal.......................................................433
		Exhaust Manifold Removal......................................................434
		Drive Pulley Removal..........................................................434
		Flywheel Removal..............................................................435
		Timing Belt Removal...........................................................436
		Timing Pulleys Removal........................................................437
		Water Pump Removal............................................................438
		Speed Governor Removal........................................................438
		Rocker Arm Cover Removal......................................................439
		Fuel Rail Removal.............................................................440
		Unit Injector Removal.........................................................440
		Rocker Arm Assembly Removal...................................................441
		Camshaft Removal..............................................................442
		Camshaft Inspection...........................................................443
		Cylinder Head Removal.........................................................444
		Valve Removal.................................................................444
		Valve And Spring Inspection...................................................445
		Pre-Combustion Chamber Removal................................................447
		Piston and Connecting Rod Removal.............................................448
		Piston and Piston Ring Inspection.............................................449
		Connecting Rod Inspection.....................................................450
		Cylinder Inspection...........................................................451
		Crankshaft Removal............................................................452
		Crankshaft Inspection.........................................................453
	ENGINE ASSEMBLY...................................................................455
		Crankshaft Installation.......................................................455
		Piston and Connecting Rod Installation........................................457
		Oil Pan Installation..........................................................458
		Pre-Combustion Chamber Installation...........................................458
		Valve Installation............................................................459
		Cylinder Head Installation....................................................460
		Camshaft Installation.........................................................461
		Rocker Arm Assembly Installation..............................................461
		Valve / Rocker Arm Clearance..................................................462
		Speed Governor Installation...................................................463
		Unit Injector Installation....................................................464
		Fuel Rail Installation........................................................465
		Rocker Arm Cover Installation.................................................465
		Oil Pump Installation.........................................................466
		Water Pump Installation.......................................................467
		Timing Pulleys Installation...................................................468
		Timing Belt Installation......................................................469
		Flywheel Installation.........................................................471
		Drive Pulley Installation.....................................................471
		Starter Installation..........................................................472
		Exhaust Manifold Installation.................................................472
		Intake Manifold Installation..................................................473
		Crankcase Vacuum Regulator Valve Installation.................................474
HYDRAULIC SYSTEM......................................................................475
	HYDRAULIC / HYDROSTATIC SCHEMATICS................................................477
	HYDRAULIC SYSTEM INFORMATION......................................................479
		Glossary Of Hydraulic / Hydrostatic Symbols...................................479
		Troubleshooting...............................................................483
	CYLINDER (LIFT)...................................................................485
		Testing.......................................................................485
		Removal And Installation......................................................486
		Parts Identification..........................................................487
		Disassembly...................................................................488
		Assembly......................................................................491
	CYLINDER (TILT)...................................................................497
		Testing.......................................................................497
		Removal And Installation......................................................498
		Parts Identification..........................................................499
		Disassembly...................................................................500
		Assembly......................................................................503
	HYDRAULIC CONTROL VALVE...........................................................509
		Main Relief Valve Testing.....................................................509
		Port Relief Valve Testing.....................................................510
		Removal And Installation......................................................511
		Parts Identification..........................................................515
		Disassembly...................................................................516
		Assembly......................................................................526
	AUXILIARY CONTROL VALVE...........................................................535
		Port Relief Valve Testing (If Equipped).......................................535
		Removal And Installation......................................................535
		Parts Identification..........................................................537
		Disassembly...................................................................538
		Assembly......................................................................545
	HYDRAULIC RESERVOIR...............................................................553
		Description...................................................................553
		Removal And Installation......................................................553
	FRONT AUXILIARY HYDRAULIC COUPLER.................................................557
		Removal And Installation......................................................557
	STEERING VALVE....................................................................559
		Removal And Installation......................................................559
		Parts Identification..........................................................560
		Disassembly...................................................................561
		Assembly......................................................................567
	MANIFOLD VALVE....................................................................573
		Description...................................................................573
		Two-Speed Pressure Testing....................................................573
		Steering Relief Valve Testing.................................................574
		Removal And Installation......................................................575
		Parts Identification..........................................................576
		Disassembly...................................................................577
		Assembly......................................................................581
	HYDRAULIC / HYDROSTATIC FILTER....................................................585
		Description...................................................................585
		Housing Removal And Installation..............................................586
	OIL COOLER........................................................................587
		Removal And Installation......................................................587
	GEAR PUMP.........................................................................589
		Removal And Installation......................................................589
		Parts Identification..........................................................591
		Disassembly And Assembly......................................................592
HYDROSTATIC SYSTEM....................................................................597
	HYDROSTATIC SYSTEM INFORMATION....................................................599
		Troubleshooting...............................................................599
		Description...................................................................600
	HYDROSTATIC DRIVE MOTOR...........................................................601
		Description...................................................................601
		Removal And Installation......................................................601
		Parts Identification..........................................................604
		Disassembly...................................................................605
		Assembly......................................................................613
	CHARGE PRESSURE...................................................................619
		Description...................................................................619
		Testing.......................................................................620
	HYDROSTATIC PUMP..................................................................621
		Description...................................................................621
		Drive Relief Pressure Testing.................................................621
		Removal And Installation......................................................622
		Hydrostatic Travel Control Adjustments........................................630
		Performance Checks Worksheet..................................................638
		Coupler Removal And Installation..............................................639
		Parts Identification..........................................................640
		Disassembly...................................................................642
		Inspection....................................................................652
		Assembly......................................................................654
HEATING, VENTILATION AND AIR CONDITIONING (HVAC)......................................665
	AIR CONDITIONING SYSTEM FLOW (S/N B3C316999 & Below)..............................667
		Description...................................................................667
		Chart.........................................................................668
		Components....................................................................669
		Safety Equipment..............................................................672
	AIR CONDITIONING SYSTEM FLOW (S/N B3C317001 & Above)..............................673
		Description...................................................................673
		Chart.........................................................................674
		Components....................................................................675
		Safety Equipment..............................................................679
	REGULAR MAINTENANCE...............................................................681
		Compressor Drive Belt Inspection..............................................681
		Condenser.....................................................................681
		Air Conditioning Service Chart................................................682
		A/C Evaporator Coil Filter (S/N B3C316999 & Below)............................683
		A/C Evaporator Coil Filter (S/N B3C317001 & Above)............................683
	TROUBLESHOOTING...................................................................685
		Blower Motor Does Not Operate.................................................685
		Blower Motor Operates Normally But Air Flow Is Insufficient...................685
		Insufficient Cooling Although Air Flow And Compressor Operation Are Normal....685
		The Compressor Does Not Operate At All Or Operates Improperly.................686
		Gauge Pressure Related Troubleshooting........................................687
		Temperature / Pressure Chart..................................................689
		Poor A/C Performance..........................................................690
		HVAC Repair And Leaks.........................................................690
		Electrical System.............................................................691
		Engine Coolant Bypassing The Heater Valve.....................................700
		Heater Valve Not Opening Or Closing...........................................701
	SYSTEM CHARGING AND RECLAMATION...................................................703
		Refrigerant Identification....................................................703
		Reclamation And Charging With Recovery / Charging Unit........................704
	COMPRESSOR........................................................................707
		Belt Adjustment...............................................................707
		Belt Replacement..............................................................707
		Removal And Installation......................................................708
		Oil...........................................................................709
		Oil Check.....................................................................710
		Clutch Disassembly And Assembly...............................................711
	CONDENSER.........................................................................715
		Removal And Installation......................................................715
	RECEIVER / DRIER..................................................................717
		Receiver / Drier Removal And Installation.....................................717
		Pressure Relief Valve Removal And Installation................................718
		Pressure Switch Removal And Installation......................................718
	EVAPORATOR / HEATER UNIT (S/N B3C316999 & BELOW)..................................719
		Removal And Installation......................................................719
	EVAPORATOR / HEATER UNIT (S/N B3C317001 & ABOVE)..................................723
		Removal And Installation......................................................723
	THERMOSTAT (S/N B3C316999 & BELOW)................................................727
		Description...................................................................727
		Removal And Installation......................................................728
	THERMOSTAT (S/N B3C317001 & ABOVE)................................................731
		Description...................................................................731
		Removal And Installation......................................................732
	EXPANSION VALVE (S/N B3C316999 & BELOW)...........................................735
		Removal And Installation......................................................735
	EXPANSION VALVE (S/N B3C317001 & ABOVE)...........................................737
		Removal And Installation......................................................737
	EVAPORATOR COIL (S/N B3C316999 & BELOW)...........................................739
		Removal And Installation......................................................739
	EVAPORATOR COIL (S/N B3C317001 & ABOVE)...........................................741
		Removal And Installation......................................................741
	HEATER COIL (S/N B3C316999 & BELOW)...............................................743
		Removal And Installation With A/C.............................................743
	HEATER COIL (S/N B3C317001 & ABOVE)...............................................745
		Removal And Installation With A/C.............................................745
	BLOWER FAN (S/N B3C316999 & BELOW)................................................747
		Removal And Installation......................................................747
	BLOWER FAN (S/N B3C317001 & ABOVE)................................................751
		Removal And Installation......................................................751
	HEATER VALVE (S/N B3C316999 & BELOW)..............................................755
		Removal And Installation......................................................755
		Disassembly And Assembly......................................................755
	HEATER VALVE (S/N B3C317001 & ABOVE)..............................................757
		Removal And Installation......................................................757
SPECIFICATIONS........................................................................759
	UTILITY VEHICLE SPECIFICATIONS....................................................761
		(3650) Dimensions (S/N B3C316999 & Below).....................................761
		(3650) Dimensions (S/N B3C317001 & Above).....................................762
		Performance...................................................................763
		Controls......................................................................763
		Engine........................................................................764
		Electrical....................................................................764
		Hydraulic System..............................................................765
		Power Take-Off (PTO) System...................................................765
		Drive System..................................................................766
		Fluid And Capacities..........................................................766
		Tires.........................................................................766
	TECHNICAL SERVICE GUIDE SPECIFICATIONS............................................767
		Engine........................................................................767
		Engine Torques................................................................767
		Cooling System................................................................767
		Utility Vehicle Torques.......................................................768
		Hydraulic / Hydrostatic System................................................768
	TORQUE SPECIFICATIONS FOR BOLTS...................................................769
		Torque For General SAE Bolts..................................................769
		Torque For General Metric Bolts...............................................770
	CONVERSIONS.......................................................................771
		Decimal And Millimeter Equivalent Chart.......................................771
		U.S. To Metric Conversion Chart...............................................772
	SERVICE TOOLS REQUIRED............................................................773
		Hydraulic Tools...............................................................773
		Transmission / Clutch / Drive Tools...........................................774
		Engine Tools..................................................................778
		HVAC Tools....................................................................782
ALPHABETICAL INDEX....................................................................783

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