Bobcat 3600 Utility Vehicle AVW211001, AVW220001 & Up 6990371 (Preview)
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
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
Chart
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)
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
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
A-ARMS
Lower A-Arm Removal And Installation
Upper A-Arm Removal And 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
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
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)
CHARGING SYSTEM
Current Draw – Key OFF
Break Even Test
Alternator Voltage Test
Low Voltage Test
Removal And Installation
Alternator Belt Adjustment
Alternator Belt Adjustment
Alternator Disassembly And Assembly
STARTER SYSTEM
Starter System Troubleshooting
Removal And Installation
Starter Disassembly And Assembly
Starter Motor Testing
STOP SOLENOID
Description
Solenoid Location
Fuel Solenoid Pull Coil Testing
Fuel Solenoid Hold Coil Testing
LIGHTS
Headlight Removal And Installation
Headlight Adjustment
Taillight / 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 (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
Location
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
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
Digital Wrench™ 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
Engine Removal And Installation
Engine Mount Replacement
Compression – Checking
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
Water Pump Weep Hole
Water Pump Removal And Installation
Thermostat Removal
Thermostat Checking
LUBRICATION SYSTEM
Oil Pan Removal And Installation
Oil Pump Removal And Installation
Oil Pump Disassembly And Assembly
Oil Pump Inspection
Engine Oil Pressure – Testing
FUEL SYSTEM
Operation
Priming The Fuel System
Fuel Lines / Vent Line
Fuel Pick-up Screen
Fuel Sender Tests
Fuel Pick-up / Sending Unit Removal And Installation
Fuel Transfer Pump Operation
Fuel Pump Test
Fuel Pump Removal And Installation
Draining Water From The Fuel Filter / Water Separator
Fuel Filter / Water Separator Replacement
High-Pressure Fuel Injection Lines Removal And Installation
Fuel Return Line Removal And Installation
Stop Solenoid
Fuel Injection Pump Removal
Fuel Injection Pump Installation
Fuel Injection Pump Assembly Installation
Injection Pump Timing
Fuel Injector Removal And Installation
Nozzle Spraying Condition
Fuel Injector Disassembly
Fuel Injector Assembly
Fuel Injector Nozzle Pressure – Checking
CYLINDER HEAD
Intake And Exhaust Valves
Valve Clearance Adjustment
Cylinder Head Removal And Installation
Cylinder Head Disassembly And Assembly
Cylinder Head – Servicing
Valve Guide – Checking
Reconditioning The Valve And Valve Seat
Valve Spring
Valve Tappets
Rocker Arm And Shaft – Checking
Push Rod Alignment – Checking
CRANKSHAFT AND PISTONS
Piston And Connecting Rod Removal And Installation
Piston And Connecting Rod – Servicing
Cylinder Bore – Checking
Crankshaft And Bearings Removal
Crankshaft And Bearings Installation
Crankshaft And Bearings – Servicing
Honing And Boring
CAMSHAFT AND TIMING GEARS
Timing Gearcase Cover Removal And Installation
Timing Gears Backlash – Checking
Timing Gears Removal
Timing Gears Installation
Idler Gear And Camshaft Removal And Installation
Camshaft – Servicing
Idler Gear And Shaft – Servicing
ENGINE SPEED CONTROL
Cable Removal And Installation
HYDRAULIC SYSTEM
HYDRAULIC / HYDROSTATIC SCHEMATICS
HYDRAULIC SYSTEM INFORMATION
Glossary Of Hydraulic / Hydrostatic Symbols
Troubleshooting
HYDRAULIC RESERVOIR
Description
Removal And Installation
STEERING VALVE
Removal And Installation
Parts Identification
Disassembly
Assembly
MANIFOLD VALVE
Description
Two-Speed Pressure 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
Description
Chart
Components
Safety Equipment
REGULAR MAINTENANCE
Compressor Drive Belt Inspection
Condenser
Air Conditioning Service Chart
A/C Evaporator Coil
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
Removal And Installation
THERMOSTAT
Description
Removal And Installation
EXPANSION VALVE
Removal And Installation
EVAPORATOR COIL
Removal And Installation
HEATER COIL
Removal And Installation With A/C
BLOWER FAN
Removal And Installation
HEATER VALVE
Removal And Installation
Disassembly And Assembly
SPECIFICATIONS
UTILITY VEHICLE SPECIFICATIONS
(3600) Dimensions
Performance
Controls
Engine
Electrical
Hydraulic System
Drive System
Fluid And Capacities
Tires
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
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