Bobcat 3650 Utility Vehicle Service Manual 7252958enUS (04-18) (D)

Model Covers:
Bobcat 3650 Utility Vehicle
S/N B3C311001 & Above

File Format: PDF
Size: 36.41 MB
No. of pages: 776
Delivery Method: Instant Download Access your file immediately after purchase.

Table of Contents:
- MAINTENANCE SAFETY
- CONTENTS
- FOREWORD
- FOREWORD
- SAFETY INSTRUCTIONS
- FIRE PREVENTION
- Maintenance
- Operation
- Electrical
- Fueling
- Starting
- Spark Arrester Exhaust System
- Welding And Grinding
- Fire Extinguishers
- SERIAL NUMBER LOCATIONS
- Utility Vehicle Serial Number
- Engine Serial Number
- DELIVERY REPORT
- UTILITY VEHICLE IDENTIFICATION (3650)
- SAFETY AND MAINTENANCE
- LIFTING AND BLOCKING THE UTILITY VEHICLE
- Procedure
- ROLL-OVER PROTECTIVE STRUCTURE (ROPS) / OCCUPANT PROTECTIVE STRUCTURE (OPS)
- Description
- TRANSPORTING THE UTILITY VEHICLE ON A TRAILER
- Loading And Unloading
- Fastening
- TOWING THE UTILITY VEHICLE
- Procedure
- SERVICE SCHEDULE
- Maintenance Intervals
- AIR CLEANER SERVICE
- Pre-Filter Element
- Replacing Filter Element
- ENGINE COOLING SYSTEM
- Checking Level
- Cleaning
- Removing And Replacing Coolant
- FUEL SYSTEM
- Fuel Specifications
- Biodiesel Blend Fuel
- Filling The Fuel Tank
- Fuel Filter
- Removing Air From The Fuel System
- Filling A Portable Fuel Container
- ENGINE LUBRICATION SYSTEM
- Checking And Adding Engine Oil
- Engine Oil Chart
- Removing And Replacing Oil And Filter
- HYDRAULIC / HYDROSTATIC SYSTEM
- Checking Fluid
- Hydraulic Fluid
- Adding Fluid
- Removing And Replacing Hydraulic / Hydrostatic Filter
- Removing And Replacing Hydraulic / Hydrostatic Fluid
- GEARCASE
- Checking Transmission Fluid
- Transmission Fluid
- Adding Transmission Fluid
- Removing And Replacing Transmission Fluid
- Checking Front Gearcase Fluid
- Front Gearcase Fluid
- Adding Front Gearcase Fluid
- Removing And Replacing Front Gearcase Fluid
- TIRE MAINTENANCE
- Tires
- Tire Tread Depth
- Axle And Wheel Nut Torque
- Wheel Removal And Installation
- Mounting
- Tire Pressure
- SPARK ARRESTER MUFFLER
- Cleaning Procedure
- UTILITY VEHICLE STORAGE AND RETURN TO SERVICE
- Storage
- Return To Service
- STOPPING THE ENGINE AND LEAVING THE UTILITY VEHICLE
- Procedure
- Emergency Exit (When Equipped With Cab)
- RELIEVING HYDRAULIC PRESSURE
- Procedure
- SEAT BELT
- Inspection And Maintenance
- LUBRICATING THE UTILITY VEHICLE
- Lubrication Locations
- DRIVE SYSTEM
- BRAKE
- General Specifications
- Torque Specifications
- System Service Notes
- Noise Troubleshooting
- System Troubleshooting
- Hydraulic Brake System Operation
- System Parts Identification
- Master Cylinder Removal And Installation
- Foot Brake Pedal Removal And Installation
- Bleeding / Fluid Removal And Installation
- Brake Inspection
- Brake Pad Inspection
- Burnishing
- BRAKE (FRONT)
- Pad Removal
- Pad Inspection
- Pad Assembly / Installation
- Caliper Removal
- Caliper Parts Identification
- Caliper Disassembly
- Caliper Inspection
- Caliper Assembly
- Caliper Installation
- Disc Runout
- Disc Inspection
- Disc Removal And Installation
- BRAKE (REAR)
- Pad Removal
- Pad Inspection
- Pad Installation
- Caliper Removal
- Caliper Parts Identification
- Caliper Disassembly
- Caliper Inspection
- Caliper Assembly
- Caliper Installation
- Disc Runout
- Disc Inspection
- Disc Removal And Installation
- TRANSMISSION
- Shift Lever Removal And Installation
- Shift Cable Adjustment
- Shift Cable Removal And Installation
- Removal And Installation
- Parts Identification
- Differential Operation
- Transmission Disassembly
- Snorkel Shaft Removal / Disassembly
- Transmission Shaft Service
- Planetary Differential Disassembly
- Planetary Differential Assembly
- Transmission Assembly
- FINAL DRIVE
- Bearing Carrier Removal
- Bearing Removal And Installation
- Bearing Carrier Installation
- Front Drive Shaft Removal And Installation
- Rear Drive Shaft Removal And Installation
- Drive Shaft / CV Joint Handling
- Outer CV Joint And Boot Removal And Installation
- Inner Plunging Joint And Boot Removal And Installation
- Propshaft Removal And Installation
- Propshaft U-Joint Disassembly
- Propshaft U-Joint Assembly
- Front Gearcase Operation
- Front Gearcase Removal And Installation
- Front Gearcase Parts Identification
- Front Gearcase Disassembly / Inspection
- Front Gearcase Assembly
- TRAVEL CONTROL PEDAL
- Description
- Inspection
- Removal And Installation
- Cable Removal And Installation
- PTO
- Drive Belt Removal And Installation
- Drive Pulley Removal And Installation
- Drive Belt Tensioner Removal And Installation
- Clutch Removal And Installation
- Gear Box Removal And Installation
- Parts Identification
- Gearbox Disassembly And Assembly
- MAINFRAME
- ROLL-OVER PROTECTIVE STRUCTURE (ROPS)
- Removal And Installation
- OPERATOR SEAT
- Seat Base Removal And Installation
- Seat Belt Removal And Installation
- DASH
- Front Access Cover Removal And Installation
- Upper Dash Panel Removal And Installation
- Lower Dash Panel Removal And Installation
- Storage Panel Removal And Installation
- BUMPER COVER
- Removal And Installation
- REAR SUSPENSION LINK AND AXLE BRACE
- Upper Suspension Link Removal And Installation
- Lower Suspension Link Removal And Installation
- Axle Brace Removal And Installation
- Rear Axle Bearing Replacement
- STEERING COLUMN
- Description
- Tilt Steering Shock Removal And Installation
- Parts Identification
- Steering Wheel Removal And Installation
- Steering Wheel / Upper Steering Shaft Removal And Installation
- Steering Shaft Bearing Replacement
- STEERING BOX
- Removal And Installation
- FUEL TANK
- Fuel Tank Removal And Installation
- SHOCKS
- Rear Shock Removal And Installation
- Front Shock Removal And Installation
- Shock Spring Removal And Installation
- Spring Preload Adjustment
- A-ARMS
- Lower A-Arm Removal And Installation
- Upper A-Arm Removal
- Upper A-Arm Installation
- Inspection
- Ball Joint Removal And Installation
- TIE ROD
- Description
- Removal And Installation
- Toe Adjustment Procedure
- TAILGATE
- Removal And Installation
- Latch Removal And Installation
- CARGO BOX
- Removal And Installation
- FENDER
- Removal And Installation (Front)
- Removal And Installation (Rear)
- Flare Removal And Installation
- ATTACHMENT ARM
- Removal And Installation
- FRONT MOUNT
- Removal And Installation
- FRONT WINDOW
- Removal And Installation
- DOOR
- Removal And Installation
- DOOR LATCH
- Removal And Installation
- Adjustment
- REAR PANEL
- Removal And Installation
- WINDSHIELD WASHER RESERVOIR
- Removal And Installation
- ROOF
- Removal And Installation
- ELECTRICAL SYSTEM AND ANALYSIS
- ELECTRICAL SCHEMATICS
- ELECTRICAL SYSTEM INFORMATION
- Glossary Of Electrical Symbols
- Description
- Troubleshooting
- Fuse And Relay Location
- Fusible Links
- BATTERY
- Removal And Installation
- Servicing
- Using A Booster Battery (Jump Starting)
- Battery Terminal Blocks
- CHARGING SYSTEM
- Current Draw - Key OFF
- Break Even Test
- Alternator Voltage Test
- Low Voltage Test
- Removal and Installation
- Belt Adjustment
- Alternator Disassembly And Assembly
- STARTER SYSTEM
- Starter System Troubleshooting
- Removal And Installation
- Starter Disassembly And Assembly
- Starter Motor Testing
- Starter Solenoid Operation
- Starter Solenoid Bench Test
- STOP SOLENOID
- Description
- Solenoid Location
- Fuel Solenoid Pull Coil Testing
- Fuel Solenoid Hold Coil Testing
- LIGHTS
- Headlight Removal And Installation
- Headlight Adjustment
- Tail Light / Brake Light Removal And Installation
- ELECTRONIC CONTROL MODULE
- Description
- Removal And Installation
- SPEED SENSORS
- Engine Speed Sensor
- Vehicle Speed Sensor
- SWITCH (HEADLIGHT)
- Location
- Removal And Installation
- Testing
- SWITCH (BRAKE LIGHT)
- Description
- Location
- Removal And Installation
- Testing
- SWITCH (AWD / 2WD / TURF)
- Location
- Removal And Installation
- Testing
- SWITCH (KEY)
- Location
- Removal And Installation
- Ignition Key Switch Testing
- SWITCH (GEAR SELECTOR)
- Location
- Removal And Installation
- Testing
- SWITCH (JOYSTICK LOCK)
- Removal And Installation
- Testing
- SWITCH (TILT LOCK)
- Removal And Installation
- Testing
- SWITCH (PUMP NEUTRAL)
- Description
- Location
- Testing
- Removal And Installation
- GLOW PLUGS
- Location
- Testing
- Removal And Installation
- TEMPERATURE SENSOR
- Description
- Testing
- Removal And Installation
- Fan Control Circuit Operation / Testing
- Fan Control Circuit Bypass Test
- DIFFERENTIAL SOLENOID
- Description
- Removal And Installation
- DIFFERENTIAL SOLENOID (REAR RELAY)
- Description
- Removal And Installation
- Differential Solenoid Circuit Operation
- OIL PRESSURE SENSOR
- Description
- Location
- Testing
- Removal And Installation
- HYDRAULIC OIL SWITCH
- Description
- Location
- Testing
- Removal And Installation
- BACK-UP ALARM SYSTEM
- Description
- Location
- Inspecting
- Removal And Installation
- HYDRAULIC TEMPERATURE SENSOR
- Location
- Testing
- Removal And Installation
- SWITCH (PTO ENGAGEMENT)
- Description
- Location
- Testing
- Removal And Installation
- INSTRUMENT CLUSTER
- Information Display
- Pinouts
- Information Display Area
- Diagnostic Trouble Codes
- Removal And Installation
- HVAC SYSTEM
- Description
- A/C Switch
- Blower Switch
- Temperature Control
- FUEL SENDER
- Testing
- DIAGNOSTIC TESTING
- Digital Wrench Diagnostic Software
- Digital Wrench Diagnostic Connector
- Digital Wrench SmartLink Module Kit - MEL1721
- Serial Number Location
- Version And Update ID
- Updates
- Digital Wrench Feature Map
- Engine Controller Unit Reprograming (Reflash)
- Special Tests Menu
- Data Items
- ENGINE SERVICE
- ENGINE INFORMATION
- Description
- Specifications
- Torque Values
- Troubleshooting
- Starting Trouble- shooting Problem
- Accessible Engine Components
- Engine Removal And Installation
- Engine Installation Notes
- Engine Mount Replacement
- Compression And Leakage Test
- Cylinder Head Diagnostics
- Fuel Limiter
- Idle Speed Setting
- Timing Belt Inspection
- ENGINE SPEED CONTROL LEVER
- Description
- Inspection
- Hand Lever Removal And Installation
- Cable Removal And Installation
- MUFFLER
- Removal And Installation
- AIR CLEANER
- Housing Removal And Installation
- ENGINE COOLING SYSTEM
- Cooling System Pressure Test
- Radiator Cap Pressure Test
- System Bleeding
- Radiator Cleaning
- Radiator Removal And Installation
- Cooling Fan Removal And Installation
- Thermostat Removal And Installation
- Thermostat Checking
- Water Pump Removal And Installation
- LUBRICATION SYSTEM
- Oil Pan Removal And Installation
- Oil Pump Removal
- Oil Pump Inspection
- Oil Pump Installation
- Engine Oil Pressure - Testing
- FUEL SYSTEM
- Service Notes
- Operation
- Initial Priming / Starting Procedure
- Fuel Line Removal / Installation
- Fuel Tank Removal
- Fuel Tank Installation
- Fuel Pump
- Location
- Fuel Filter / Water Separator Draining
- Fuel Sender
- Injector Timing
- ENGINE DISASSEMBLY AND INSPECTION
- Crankcase Vacuum Regulator Valve Removal
- Intake Manifold Removal
- Exhaust Manifold Removal
- Drive Pulley Removal
- Flywheel Removal
- Timing Belt Removal
- Timing Pulleys Removal
- Water Pump Removal
- Speed Governor Removal
- Rocker Arm Cover Removal
- Fuel Rail Removal
- Unit Injector Removal
- Rocker Arm Assembly Removal
- Camshaft Removal
- Camshaft Inspection
- Cylinder Head Removal
- Valve Removal
- Valve And Spring Inspection
- Pre-Combustion Chamber Removal
- Piston and Connecting Rod Removal
- Piston and Piston Ring Inspection
- Connecting Rod Inspection
- Cylinder Inspection
- Crankshaft Removal
- Crankshaft Inspection
- ENGINE ASSEMBLY
- Crankshaft Installation
- Piston and Connecting Rod Installation
- Oil Pan Installation
- Pre-Combustion Chamber Installation
- Valve Installation
- Cylinder Head Installation
- Camshaft Installation
- Rocker Arm Assembly Installation
- Valve / Rocker Arm Clearance
- Speed Governor Installation
- Unit Injector Installation
- Fuel Rail Installation
- Rocker Arm Cover Installation
- Oil Pump Installation
- Water Pump Installation
- Timing Pulleys Installation
- Timing Belt Installation
- Flywheel Installation
- Drive Pulley Installation
- Starter Installation
- Exhaust Manifold Installation
- Intake Manifold Installation
- Crankcase Vacuum Regulator Valve Installation
- HYDRAULIC SYSTEM
- HYDRAULIC / HYDROSTATIC SCHEMATICS
- HYDRAULIC SYSTEM INFORMATION
- Glossary Of Hydraulic / Hydrostatic Symbols
- Troubleshooting
- CYLINDER (LIFT)
- Testing
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- CYLINDER (TILT)
- Testing
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- HYDRAULIC CONTROL VALVE
- Main Relief Valve Testing
- Port Relief Valve Testing
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- AUXILIARY CONTROL VALVE
- Port Relief Valve Testing (If Equipped)
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- HYDRAULIC RESERVOIR
- Description
- Removal And Installation
- FRONT AUXILIARY HYDRAULIC COUPLER
- Removal And Installation
- STEERING VALVE
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- MANIFOLD VALVE
- Description
- Two-Speed Pressure Testing
- Steering Relief Valve Testing
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- HYDRAULIC / HYDROSTATIC FILTER
- Description
- Housing Removal And Installation
- OIL COOLER
- Removal And Installation
- GEAR PUMP
- Removal And Installation
- Parts Identification
- Disassembly And Assembly
- HYDROSTATIC SYSTEM
- HYDROSTATIC SYSTEM INFORMATION
- Troubleshooting
- Description
- HYDROSTATIC DRIVE MOTOR
- Description
- Removal And Installation
- Parts Identification
- Disassembly
- Assembly
- CHARGE PRESSURE
- Description
- Testing
- HYDROSTATIC PUMP
- Description
- Drive Relief Pressure Testing
- Removal And Installation
- Hydrostatic Travel Control Adjustments
- Performance Checks Worksheet
- Coupler Removal And Installation
- Parts Identification
- Disassembly
- Inspection
- Assembly
- HEATING, VENTILATION AND AIR CONDITIONING (HVAC)
- AIR CONDITIONING SYSTEM FLOW (S/N B3C316999 & BELOW)
- Description
- Chart
- Components
- Safety Equipment
- AIR CONDITIONING SYSTEM FLOW (S/N B3C317001 & ABOVE)
- Description
- Chart
- Components
- Safety Equipment
- REGULAR MAINTENANCE
- Compressor Drive Belt Inspection
- Condenser
- Air Conditioning Service Chart
- A/C Evaporator Coil Filter (S/N B3C316999 & Below)
- A/C Evaporator Coil Filter (S/N B3C317001 & Above)
- TROUBLESHOOTING
- Blower Motor Does Not Operate
- Blower Motor Operates Normally But Air Flow Is Insufficient
- Insufficient Cooling Although Air Flow And Compressor Operation Are Normal
- The Compressor Does Not Operate At All Or Operates Improperly
- Gauge Pressure Related Troubleshooting
- Temperature / Pressure Chart
- Poor A/C Performance
- HVAC Repair And Leaks
- Electrical System
- Engine Coolant Bypassing The Heater Valve
- Heater Valve Not Opening Or Closing
- SYSTEM CHARGING AND RECLAMATION
- Refrigerant Identification
- Reclamation And Charging With Recovery / Charging Unit
- COMPRESSOR
- Belt Adjustment
- Belt Replacement
- Removal And Installation
- Oil
- Oil Check
- Clutch Disassembly And Assembly
- CONDENSER
- Removal And Installation
- RECEIVER / DRIER
- Receiver / Drier Removal And Installation
- Pressure Relief Valve Removal And Installation
- Pressure Switch Removal And Installation
- EVAPORATOR / HEATER UNIT (S/N B3C316999 & BELOW)
- Removal And Installation
- EVAPORATOR / HEATER UNIT (S/N B3C317001 & ABOVE)
- Removal And Installation
- THERMOSTAT (S/N B3C316999 & BELOW)
- Description
- Removal And Installation
- THERMOSTAT (S/N B3C317001 & ABOVE)
- Description
- Removal And Installation
- EXPANSION VALVE (S/N B3C316999 & BELOW)
- Removal And Installation
- EXPANSION VALVE (S/N B3C317001 & ABOVE)
- Removal And Installation
- EVAPORATOR COIL (S/N B3C316999 & BELOW)
- Removal And Installation
- EVAPORATOR COIL (S/N B3C317001 & ABOVE)
- Removal And Installation
- HEATER COIL (S/N B3C316999 & BELOW)
- Removal And Installation With A/C
- HEATER COIL (S/N B3C317001 & ABOVE)
- Removal And Installation With A/C
- BLOWER FAN (S/N B3C316999 & BELOW)
- Removal And Installation
- BLOWER FAN (S/N B3C317001 & ABOVE)
- Removal And Installation
- HEATER VALVE (S/N B3C316999 & BELOW)
- Removal And Installation
- Disassembly And Assembly
- HEATER VALVE (S/N B3C317001 & ABOVE)
- Removal And Installation
- SPECIFICATIONS
- UTILITY VEHICLE SPECIFICATIONS
- (3650) Dimensions (S/N B3C316999 & Below)
- (3650) Dimensions (S/N B3C317001 & Above)
- Performance
- Controls
- Engine
- Electrical
- Hydraulic System
- Power Take-Off (PTO) System
- Drive System
- Fluid And Capacities
- Tires
- TECHNICAL SERVICE GUIDE SPECIFICATIONS
- Engine
- Engine Torques
- Cooling System
- Utility Vehicle Torques
- Hydraulic / Hydrostatic System
- TORQUE SPECIFICATIONS FOR BOLTS
- Torque For General SAE Bolts
- Torque For General Metric Bolts
- CONVERSIONS
- Decimal And Millimeter Equivalent Chart
- U.S. To Metric Conversion Chart
- SERVICE TOOLS REQUIRED
- Hydraulic Tools
- Transmission / Clutch / Drive Tools
- Engine Tools
- HVAC Tools
- ALPHABETICAL INDEX