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Bobcat 3650 Utility Vehicle Service Manual (SN AVW411001-AVW499999)

Format: PDF (Printable Document)

File Language: English

File Pages: 736

File Size: 20.90 MB (Speed Download Link)

Brand: Bobcat

Model: 3650 Utility Vehicle

Book No: 6990367

Serial No: SN AVW411001-AVW499999

Type of Document: Service Manual

Categories: ,

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Bobcat 3650 Utility Vehicle Service Manual (SN AVW411001-AVW499999)

The Bobcat 3650 is a diesel utility vehicle that hauls tools, tows trailers, and runs front and rear hydraulics around farms, jobsites, and rental yards. The service manual is what I pull when a 3650 in our fleet is down and I need real specs and procedures, not just where the switches are. Buyers use this to keep an out-of-warranty machine working, plan repairs, and cut downtime by fixing it right the first time.

What this manual helps you do

  • Diagnose no-start, low power, or smoking issues on the small diesel engine, then plan parts and labor.
  • Trace and troubleshoot hydraulic and hydrostatic problems like weak lift, slow drive, or overheating oil.
  • Check, test, and repair the 4WD, driveline, and brake systems when you have noise, vibration, or no-move complaints.
  • Follow step-by-step teardown and reassembly for cylinders, drive components, steering, and suspension parts.
  • Verify wiring, chase shorts or opens, and replace sensors or controllers using proper electrical diagrams.

Who this is for

This is for a shop mechanic, field tech, serious owner-operator, or rental fleet that needs to repair a Bobcat 3650 Utility Vehicle by serial number. If you only want basic controls, safety, and daily checks, you want the operator's handbook instead, not this service manual.

FAQ

Q: Is this a searchable PDF, and are the wiring diagrams readable?

A: Yes, these manuals are normally searchable PDFs, and the wiring diagrams are laid out so you can zoom in and read pin labels and wire colors.

Q: Will this cover my exact 3650?

A: It covers Bobcat 3650 Utility Vehicles in the serial range AVW411001 through AVW499999. If your plate is outside that, you need a different manual.

Q: Is this the right document if I'm planning major repairs?

A: Yes, this is the workshop-level service manual, meant for real teardown, testing, and adjustment work, not just basic operation.

Bottom line: If you own or maintain a 3650 in that serial range and you're doing your own repairs, this is the manual you want. If you just operate the machine, it's overkill.

📘 Show Index

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
  • 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)
    • RELIEVING HYDRAULIC PRESSURE
      • Procedure
  • 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
      • Clutch Brake Adjusting
      • 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
    • 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
    • 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)
    • CHARGING SYSTEM
      • Current Draw – Key OFF
      • Break Even Test
      • Alternator Voltage Test
      • Low Voltage Test
      • Removal And Installation
      • Alternator 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
      • 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
    • 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
      • AC 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
      • 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
      • Hand Lever Removal And Installation
      • Cable Removal And Installation
  • HYDRAULIC SYSTEM
    • HYDRAULIC 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
      • 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
    • priority 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
      • 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
      • (3650) Dimensions
      • 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

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