Winch, Hoisting With

EN
Service Manual
Hoisting Winch with Jib
Jib + Hoist 1000 kg: S/N AK3F00101 & Above

Jib + Hoist 600 kg: S/N AK3G00101 & Above
6989514-EN (6-10) Printed in Belgium Bobcat Company 2010

Original instructions
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MAINTENANCE SAFETY
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operators Handbook and
WARNING
WARNING 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. W-2003-0807
Safety Alert Symbol: This symbol with a warning statement, means: Warning, be alert! Your safety is
involved! Carefully read the message that follows.
CORRECT
P-90216
Never service attachments / implements without

instructions. See Operation & Maintenance Manual and
Attachment / Implement Service Manual.
Cleaning and maintenance are required daily.
Never service or adjust attachment / implement with the

engine running unless instructed to do so in manual.
Always lower the attachment / implement to the ground

before lubricating or servicing.
Avoid contact with leaking hydraulic fluid or diesel fuel

under pressure. It can penetrate skin or eyes.
Stop, cool and clean engine of flammable materials before

checking fluids.
Keep body, loose objects and clothing away from moving

parts, electrical contacts, hot parts and exhaust.
Safety glasses are needed for eye protection from electrical

arcs, battery acid, compressed springs, fluids under
pressure and flying debris or when tools are used. Use eye
protection approved for type of welding.
MSW30-0409
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ALPHABETICAL INDEX
CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-10-1
ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
FLUIDS AND LUBRICANTS TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1
HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
HYDRAULIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-1
HYDRAULIC VALVES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-30-1
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20-1
HOISTING WINCH WITH JIB SPECIFICATIONS . . . . . . . . . . . . . . . . . SPEC-10-1
KIT PRESENCE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-10-1
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-30-1
MAIN HYDRAULIC MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-1
QUICK COUPLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-1
REDUCTION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-20-1
ROLLER GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-30-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-40-1
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-1
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-10-1
ALPHA-01 Hoisting Winch with Jib Service Manual

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ALPHA-02 Hoisting Winch with Jib Service Manual
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CONTENTS
SAFETY AND
SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III MAINTENANCE
ATTACHMENT DELIVERY REPORT . . . . . . . . . . . . . . . . . . . . . . . . III
HYDRAULIC
IDENTIFICATION AND MACHINE SIGNS (DECALS) . . . . . . . . . . . IV
SYSTEM
SAFETY AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . 10-01
HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01 MAIN

FRAME
FRAME
MAIN FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-01
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01 ELECTRICAL

SYSTEM
SPECIFICATIONS AND SCHEMATICS . . . . . . . . . . . . . . . . SPEC-01
I Hoisting Winch with Jib Service Manual

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II Hoisting Winch with Jib Service Manual
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SERIAL NUMBER LOCATION ATTACHMENT DELIVERY REPORT
Figure 1 Figure 2
S36756 P-20022
Always use the serial number (Item 1) [Figure 1] of the The Attachment Delivery Report must be completed by
hoisting winch with jib when requesting service the dealer and signed by the owner or operator when the
information or when ordering parts. Early or later models hoisting winch with jib is delivered. An explanation of the
(identification made by number) may use a different form must be given to the owner. Make sure it is entirely
procedure in doing a specific service operation. completed [Figure 2].
III Hoisting Winch with Jib Service Manual

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IDENTIFICATION AND MACHINE SIGNS (DECALS)
SUPPORT HYDRAULIC QUICK TACH

HOLDER HOSES
SUPPORT HOOK
BLOCK
S36753
6809609
JIB + HOIST 1.0T
7191321
7186116
7130143
7186118 7186115 EM5079
IV Hoisting Winch with Jib Service Manual

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IDENTIFICATION AND MACHINE SIGNS (DECALS) (CONTD)
6809609
JIB + HOIST 0.6T
7186116
7130143
7186118 7186115
7191322 EM6703
V Hoisting Winch with Jib Service Manual

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VI Hoisting Winch with Jib Service Manual
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SAFETY AND MAINTENANCE
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Hydraulic System Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-1
Cable Deterioration And Replacement Criteria (as per ISO 4309) 10-20-3 SAFETY AND
Cable Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20-2 MAINTENANCE
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
Lubrication Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-30-1
SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
10-01 Hoisting Winch with Jib Service Manual

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TROUBLESHOOTING
PROBLEM CAUSE CORRECTION

Winch function not working No auxiliary hydraulic pressure Check if boom head hydraulics are ON
and all controls (radio control) are
working.
Defective electrical switch Check if Kit Presence Switch makes
contact with tab on quick-tach. Re-
position if needed.
Replace switch.
Defective Rated Capacity switch Check if Rated Capacity switch is
activated without load. Re-position if
needed.
Replace switch.
Defective hydraulic valve Check if Lower Limit Valve is working.
Replace if needed.
Check if Upper Limit Valve is working.
Replace if needed.
Defective solenoid valve Check if solenoids are working.
Replace if needed.
Clogged orifices (located in the Clean the orifices.
hydraulic motor fittings)
Defective Main Hydraulic Manifold Replace Main Hydraulic Manifold.
Cable is stuck Check cable for kinks or loops.
Replace if needed.
Jib is not in horizontal position Level out the attachment.
10-10-1 Hoisting Winch with Jib Service Manual

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INSPECTION Figure 10-20-3
Hydraulic System Inspection
Figure 10-20-1 1
1 2
S36723
Check the working of the Lower Limit Valve (Item 1)

S36743
S37004 [Figure 10-20-3]. (See Operation & Maintenance Manual
for correct procedure.)
Check the tightness of hydraulic connections on the

hoisting winch with jib (Item 1) and hydraulic quick
couplers (Item 2) [Figure 10-20-1].
Figure 10-20-2
S36742
Check the working of the Upper Limit Valve (Item 1)

[Figure 10-20-2]. (See Operation & Maintenance Manual
for correct procedure.)

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INSPECTION (CONTD) Figure 10-20-6
Cable Inspection 1
Figure 10-20-4
3 S36741
2
Check the condition of the cable (Item 1) and its correct
S36740 winding around the drum (Item 2) [Figure 10-20-6].
Check the cable (Item 1) [Figure 10-20-6] for broken

Check that the pulley (Item 1) of the hook rotates freely. strands and wear, stretching, deformation and rusting in
the winding area. See Cable Deterioration And
Check that the lifting hook (Item 2) [Figure 10-20-4] Replacement Criteria (as per ISO 4309) on Page 10-20-3
rotates freely.
NOTE: Replace the cable with a certified replacement
Check that the safety tab (Item 3) [Figure 10-20-4] is cable provided by Bobcat Company.
intact and positions itself correctly.
Figure 10-20-5
1
S36742
Check the condition of the fixed eyelet socket (Item 1)

[Figure 10-20-5].

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INSPECTION (CONTD) Protrusion of the steel
Cable Deterioration And Replacement Criteria (as per core, generally llinked to
ISO 4309) basket deformation.
Replace this cable
Replace the cable in case of breakage of 19 strands along immediately.
a length of 7.1 in. (180 mm) for 0.24 in. (6 mm) diameter
cable. The wires of a single
strand have loosened
Cables should be replaced when: although inspection of a
section of cable has
the cable diameter, even at just one point, is 7% shown that the
smaller than the nominal diameter; deformation can be seen
at regular intervals,
the cable appears permanently crushed, twisted or normally equal to the lay
bent; pitch. This defect must be
kept under control.
the core can be seen even at just one point; More serious example of
the previous defect with
while in tension, there are one or more loose strands. protrusion on the inner
wires of the strands.
NOTE: Replace the cable with a certified replacement Major localised defect
cable provided by Bobcat Company. caused by applying shock
loads. Replace this cable
The photos below show examples of deterioration of immediately.
cables, describing the cause and replacement conditions.
Confined increase of
diameter of a long lay
Broken wires out of
cable, caused by
position in two strands of
distortion of the metal
a regular lay cable.
core caused by dynamic
Replace this cable.
load. There are also
traced of corrosion and
major wear of the
Major wear and high external wires. Replace
number of broken wires in this cable immediately.
a regular lay cable.
Confined increase of
Replace this cable
diameter of the cable,
immediately.
due to the protrusion of
Broken wires in a single the textile core between
strand and slight wear in the external strands.
a long lay cable. In this Replace this cable.
case, remove the broken
Major kink causing
wires to make the cable
fibrecore protrusion.
smooth.
Replace this cable
Broken wires in several immediately.
strands, close to a return
sheave (sometimes
hidden by the sheave).
Wire cable which has
Replace this cable.
been twisted during
Broken wires in two installation and use. Now
strands due to bending subject to localised wear
fatigue, linked to major and lengthening of the
localized wear. Replace strands. Replace this
this cable. cable.
Birdcage in a multilayer Confined reduction in the
(non rotating) type of cable diameter because
cable caused by forced the outer strands tend to
rotation around small fill the volume of the
grooves or excessive fleet textile core which has
angle. Replace this cable been destroyed. Replace
immediately. this cable immediately

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INSPECTION (CONTD) Continuous flattening;
metal wires which begin
Cable Deterioration And Replacement Criteria (as per
to loosen, with a
ISO 4309) (Contd)
reduction of diameter that
can be estimated at
Flattened section caused approximately 40%.
by local crushing due to Replace this cable
mechanical action; this immediately.
causes a lack of
equilibrium in the strands. Start of surface corrosion.
There are also broken
wires. Replace this cable.
Flattened section of a
multistrand cable caused
by mechanical action on a
long section caused by
incorrect unwinding from
a winch. Note the
increased lay pitch of the Highly perforated surface
external strands with and completely loosened
unbalanced tension in wires. Serious reduction
load conditions. Replace in diameter with space
this cable. between the wires of
more than half their
Example of major
diameter. Replace this
bending. Replace this
cable immediately.
cable.
Example of major internal
corrosion. Clear reduction
Typical example of a of the area of many
cable which has come out external wires of the
of the groove of a sheave strands, in the contact
and has been trapped area of the core, the high
with resulting deformation level of compression, the
and flattening, with local lack of space between the
wear and many broken strands and the ensuing
wires. Replace this rope reduction in the diameter
immediately. of the cable. Replace this
cable immediately.
Cumulative effects of
several deterioration Helical distortion is a
factors. Note the major distortion where the
wear of the external longitudinal axis of the
wires, which has caused cable has a helical shape.
loosening of the wires In this condition the cable
resulting in basket must be inspected
deformation; the risk here continuously. There may
is that the cable could be be wear and broken wires
expulsed from the in the event of prolonged
sheave. Replace this use. Replace the cable if
cable immediately. the deformation exceeds
the value set in UNI ISO
Slight flattening of
4309/84.
external wires. Small
reduction of the cable
diameter.

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LUBRICATION Lubrication Locations
Chart Lubricate more frequently in case of saline or corrosive

environment.
NOTE: Always clean the grease fittings before
injecting grease. Apply lubricant until extra Lubricate the following locations on the hoisting winch
grease shows. Remove all tracks of grease with jib:
after lubrication.
Figure 10-30-1
LUBRICATION
TYPE OF LUBRICANT 1
LOCATIONS
Reduction gear Bobcat SAE 85W/90 - API GL5
(from -12C to +50C)*
Hook rotation Bobcat SAE 15W/40
(from -20C to +40C)*
Cable Thin film of lubricant with
penetration properties,
resistant to corrosion and
wash-out (Bobcat P/N
6987718)
* See FLUIDS AND LUBRICANTS TABLE on Page S36741

SPEC-50-1
Lubricate the cable (Item 1) [Figure 10-30-1]. (See Chart

on Page 10-30-1.)
Figure 10-30-2
S36740
Lubricate the hook (Item 1) [Figure 10-30-2]. (See Chart

on Page 10-30-1.)

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SERVICE SCHEDULE
Maintenance work must be done at regular intervals. Failure to do so will result in excessive wear and early failures. The
service schedule is a guide for correct maintenance of the Bobcat Hoisting Winch with Jib.
Instructions are necessary before operating or servicing machine. Read and
understand the Operation & Maintenance Manual, Operators Handbook and signs
(decals) on machine. Follow warnings and instructions in the manuals when
WARNING 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. W-2003-0903
SERVICE SCHEDULE HOURS

[3]
ITEM SERVICE REQUIRED
daily 50 100 250 1000
Cable Check the cable.
Check the fixed eyelet socket.
Check correct winding of cable.
Block pulley Check free rotation of block pulley (where applicable).
Hook Check free rotation of hook.
Safety tab Check if safety tab of hook is intact and functions properly.
Limit valves Check the working of the limit valves.
Hook stem Lubricate with engine oil (See Chart on Page 10-30-1).
Reduction gear oil Change the reduction gear oil (See
Chart on Page 10-30-1). [1] [2]
Cable Lubricate the cable (See Chart on Page 10-30-1).
[1] Perform service first time, then as indicated in chart.

[2] Check level.
[3] Or every 12 months.

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HYDRAULIC SYSTEM
HYDRAULIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-4
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-5 HYDRAULIC
Manifold Removal And Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1 SYSTEM
Parts Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-3
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1
HYDRAULIC VALVES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

Brake Engagement Safety Valve Disassembly And Assembly . . . . . . . 20-30-2
Brake Engagement Safety Valve Removal And Installation . . . . . . . . . 20-30-1
Lower Limit Valve Disassembly And Assembly . . . . . . . . . . . . . . . . . . 20-30-11
Lower Limit Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . 20-30-10
Rated Capacity Limiting Relief Valve Disassembly And Assembly . . . . 20-30-6
Rated Capacity Limiting Relief Valve Removal And Installation . . . . . . 20-30-6
Upper Limit Valve Disassembly And Assembly . . . . . . . . . . . . . . . . . . . 20-30-8
Upper Limit Valve Removal And Installation . . . . . . . . . . . . . . . . . . . . . 20-30-8
Winch Motor Authorization Valve Disassembly And Assembly . . . . . . . 20-30-5
Winch Motor Authorization Valve Removal And Installation . . . . . . . . . 20-30-3
MAIN HYDRAULIC MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

Disassembly And Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-2
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1
QUICK COUPLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1

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QUICK COUPLERS Figure 20-10-1
Removal and Installation

1
2
IMPORTANT
When repairing hydrostatic and hydraulic systems,
clean the work area before disassembly and keep all
parts clean. Always use caps and plugs on hoses,
tubelines and ports to keep dirt out. Dirt can quickly
damage the system.
I-2003-0888
S36755
IMPORTANT 1
3
Contain and dispose of any oil leakage in an

environmentally safe manner.
I-2066-0395
3
S7182
Remove the male (Item 1) and female (Item 2) [Figure

20-10-1] quick coupler from the hoses.
Remove the connectors (Item 3) [Figure 20-10-1] from

the quick couplers.

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MAIN HYDRAULIC MANIFOLD Figure 20-20-2
Removal and Installation
IMPORTANT
damage the system.
I-2003-0888 1
S36678
Remove the tubeline (Item 1) [Figure 20-20-2].
IMPORTANT Figure 20-20-3

I-2066-0395
Figure 20-20-1
1
S36679
Remove the tubelines (Item 1) [Figure 20-20-3].
1 2
S36677
Remove tubeline (Item 1) and hose (Item 2) [Figure 20-

20-1].

29 of 82
MAIN HYDRAULIC MANIFOLD (CONTD) Disassembly And Assembly
Removal And Installation (Contd) Figure 20-20-5
Figure 20-20-4
1 2
S36681
S36680
Remove the two O-rings (Item 1) [Figure 20-20-5] from
the safety valve.
Remove the two bolts (Item 1) [Figure 20-20-4].
Figure 20-20-6
Installation: Tighten the bolts to 36 - 50 ft.-lb. (49 - 68
Nm) torque. 3
6
Remove the main hydraulic manifold (Item 2) [Figure 20- 1 5
20-4].
2
S36682
Remove the fittings (Items 1, 2, 3, 4, 5 and 6) [Figure 20-

20-6] respectively from the V1, V2, C3, C4, C5 and D
ports.
NOTE: The tee fitting (Item 5) [Figure 20-20-6] contains

an orifice. Mark orientation of the fitting for
assembly.
Installation: Tighten fittings (Item 1 and 2) to 44.2 - 48.7

ft.-lb. (60 - 66 Nm) torque. Tighten fittings (Item 3, 4) to
11 - 12.5 lb.-ft. (15 - 17 Nm) torque. Tighten fitting (Item
5, 6) [Figure 20-20-6] to 40.6 - 44.6 ft.-lb. (55 - 60,5 Nm)
torque.

30 of 82
MAIN HYDRAULIC MANIFOLD (CONTD) Figure 20-20-9
Disassembly And Assembly (Contd)
Figure 20-20-7
1
1
S36608
Remove the seal washer (Item 1) [Figure 20-20-9] from

S36606 the fittings of the C5 and D port.
Figure 20-20-10
Remove the O-ring (Item 1) [Figure 20-20-7] from the
fitting of the C3 port.
Figure 20-20-8
1
1
S36684
Remove the washer (Item 1) and O-ring (Item 2) [Figure

S36607 20-20-10] from the fittings of the C5 and D port.

fittings of the V1 and V2 ports.

31 of 82
Figure 20-20-11
2
S36604
1

S36683 plug.
Figure 20-20-14
Remove the plug (Item 1) [Figure 20-20-11] from the
manifold.
Installation: Tighten the plug to 35.4 - 44.3 in.-lb. (4 - 5

1
Nm) torque.
Remove the relief valve (Item 2) [Figure 20-20-11] from

the manifold.
Installation: Tighten the relief valve to 33.2 - 36.9 ft.-lb.

(45 - 50 Nm) torque.
Figure 20-20-12
4
S36609
3
2
Remove the plug (Item 1) [Figure 20-20-14] from the D
1 port.
5
Installation: Tighten the plug to 11.1 - 12.5 in.-lb. (15 - 17
Nm) torque.
S36603
Remove the piston rod (Item 1), piston (Item 2), spring
(Item 3) and spring retainer (Item 4) [Figure 20-20-12]
from the manifold.

relief valve.

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Figure 20-20-15
1
3
2
4 1
S36611
6
Remove the two allen screws (Item 1) and the orifice (Item
5
S36610 2) [Figure 20-20-16] from the C5 port.
Installation: Tighten the allen screws one by one to 35.4 -

Remove the spring (Item 1), ball (Item 2) and ball retainer 44.3 in.-lb. (4 - 5 Nm) torque.
(Item 3) [Figure 20-20-15] from the D port.
Remove the O-ring (Item 4) and backup ring (Item 5)

[Figure 20-20-15] from the plug.

ball retainer.

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HYDRAULIC VALVES Figure 20-30-2
Brake Engagement Safety Valve Removal And

Installation
1
2
1 S36699
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly 2
damage the system.
I-2003-0888 S36698
Remove the bolt and washer (Item 1) [Figure 20-30-2]

from the bracket.
IMPORTANT Remove the manifold and bracket (Item 2) [Figure 20-30-

2].
environmentally safe manner. Figure 20-30-3
I-2066-0395
Figure 20-30-1 1
2
1
1 2
S36698
S36700
2 4
3
Remove the bolts and lock nuts (Item 1) [Figure 20-30-3]
S36697 from the bracket.
Remove the solenoid connector (Item 1) [Figure 20-30- Installation: Tighten the two bolts and nuts to 72 - 84 ft.-
1]. lb. (8 - 9 Nm).
Remove the solenoid nut (Item 2) and the solenoid (Item Remove the bracket (Item 2) [Figure 20-30-3] from the
3) [Figure 20-30-1]. manifold.
Remove the tubelines (Item 4) [Figure 20-30-1].

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HYDRAULIC VALVES (CONTD) Figure 20-30-6
Brake Engagement Safety Valve Disassembly And

Assembly
2
Clean the outside of the manifold before disassembly.
IMPORTANT
tubelines and ports to keep dirt out. Dirt can quickly S36703
damage the system.

I-2003-0888
Remove washer (Item 1) and replace O-ring (Item 2)
[Figure 20-30-6] from the fitting.
Figure 20-30-4
Figure 20-30-7
2
1
1
1
S36701
S36704
Remove the fittings (Item 1) [Figure 20-30-4].

Replace the O-rings (Item 1) [Figure 20-30-7].
Figure 20-30-5
Remove the solenoid stem (Item 2) [Figure 20-30-7].
S36702
Remove washer (Item 1) and replace O-ring (Item 2)

[Figure 20-30-5] from the fitting.

36 of 82
HYDRAULIC VALVES (CONTD) Winch Motor Authorization Valve Removal And
Installation
Brake Engagement Safety Valve Disassembly And
Assembly (Contd) Figure 20-30-9
Figure 20-30-8
1
1
S36706
S36705
Remove solenoid connector (Item 1) [Figure 20-30-9].
Replace the O-rings (Item 1) and backup ring (Item 2) Figure 20-30-10
[Figure 20-30-8] on the solenoid stem.
S36707
Remove nut (Item 1) and solenoid (Item 2) [Figure 20-30-

10].

37 of 82
Winch Motor Authorization Valve Removal And

Installation (Contd)
Figure 20-30-11 2
1
S36710
1 Remove the two bolts, washers and locking nuts (Item 1)

[Figure 20-30-13].
S36708
Installation: Tighten the two bolts and locking nuts to 11 -
16 ft.-lb. (15 - 22 Nm).
Remove the hoses (Item 1) [Figure 20-30-11].
Remove the manifold (Item 2) [Figure 20-30-13].
Figure 20-30-12
S36709
Remove the two tubelines (Item 1) [Figure 20-30-12].

38 of 82
Winch Motor Authorization Valve Disassembly And

Assembly
Figure 20-30-14
S36714
Remove the solenoid stem (Item 1) [Figure 20-30-16]

from the manifold.
S36711
Figure 20-30-17
Remove the fittings (Item 1) [Figure 20-30-14] from the

manifold.
1
Figure 20-30-15
2
1 2
S36713
Replace the O-rings (Item 1) and backup ring (Item 2)

[Figure 20-30-17] on the solenoid and solenoid stem.
S36712
Remove washer (Item 1) and O-ring (Item 2) [Figure 20-

30-15] from the fittings.

39 of 82
HYDRAULIC VALVES (CONTD) Rated Capacity Limiting Relief Valve Disassembly
And Assembly
Rated Capacity Limiting Relief Valve Removal And
Installation Clean all parts in solvent and dry with compressed air. Do
not use cloth or paper because small pieces of material
Remove the Manifold. can get into the system and cause damage.
Figure 20-30-18
1
IMPORTANT
damage the system.
I-2003-0888
2 Figure 20-30-19
S36715
1
Remove the bolts and washers (Item 1) [Figure 20-30-

18].
Installation: Tighten the bolts to 36 - 50 ft.-lb. (49 - 68

Nm) torque.
Remove the pressure relief manifold (Item 2) [Figure 20-

30-18].
S36716

manifold.
Figure 20-30-20
S36718
Replace the O-ring (item 1) [Figure 20-30-20] on the

fitting.

40 of 82
Pressure Relief Manifold Disassembly And Assembly

(Contd)
Figure 20-30-21
1
S36719
Replace the O-ring (Item 1) [Figure 20-30-23] on the

pressure relief valve.
S36607

fitting.
Figure 20-30-22
S36717
Remove the pressure relief valve (Item 1) [Figure 20-30-

22].
NOTE: Breaking of tamper paint requires recalibration

of Rated Capacity Relief Valve.
Installation: Tighten the pressure relief valve to 33.2 -

36.9 ft.-lb. (45 - 50 Nm) torque.

41 of 82
HYDRAULIC VALVES (CONTD) Upper Limit Valve Disassembly And Assembly
Upper Limit Valve Removal And Installation Clean all parts in solvent and dry with compressed air. Do
Figure 20-30-24 can get into the system and cause damage.
1
IMPORTANT
damage the system.
1
I-2003-0888
S36720 Figure 20-30-26
1
Remove the hoses (Item 1) [Figure 20-30-24] from the
manifold.
Figure 20-30-25
S36722

manifold.
1 Figure 20-30-27
S36721
Remove the two bolts and washers (Item 1) [Figure 20-

30-25].
Installation: Tighten the bolts to 11 - 16 ft.-lb. (15 - 22 1

Nm) torque.
Remove the manifold (Item 2) [Figure 20-30-25].
S36718

fitting.

42 of 82
Upper Limit Valve Disassembly And Assembly

(Contd)
Figure 20-30-28 2
S36660
Remove the spring (Item 1) and spool (Item 2) [Figure

20-30-30] from the manifold.
S36658
Figure 20-30-31
Replace the washer (Item 1) and O-ring (Item 2) [Figure

20-30-28] on the fitting.
1 2
3
Figure 20-30-29
S36661
Replace the dust ring (Item 1), two backup rings (Item 2)
and two O-rings (Item 3) [Figure 20-30-31] on the
S36659 manifold.
NOTE: One backup ring and O-ring are hidden.

Remove the valve (Item 1) [Figure 20-30-29] from the
manifold.
Installation: Tighten the valve to 33.2 - 36.9 ft.-lb. (45 - 50

Nm) torque.

43 of 82
HYDRAULIC VALVES (CONTD) Lower Limit Valve Removal And Installation
Upper Limit Valve Disassembly And Assembly Figure 20-30-34

(Contd)
Figure 20-30-32
2
1 2
1
S36723
S36662 Loosen the spring (Item 1) [Figure 20-30-34].
Remove the two tubelines (Item 2) [Figure 20-30-34].

Remove the plug (Item 1) [Figure 20-30-32] from the
manifold. Figure 20-30-35
Installation: Tighten the plug to 11 - 16 ft.-lb. (15 - 22

Nm) torque.
2
Figure 20-30-33
2
1 1
3
S36724
S36663 Installation: Tighten the bolts to 11 - 16 ft.-lb. (15 - 22

Nm) torque.
Remove the spring (Item 1) and ball (Item 2) [Figure 20- Remove the manifold (Item 2) [Figure 20-30-35].
30-33] from the manifold.

plug.

44 of 82
Lower Limit Valve Disassembly And Assembly

2
Clean all parts in solvent and dry with compressed air. Do 1
2
can get into the system and cause damage.
IMPORTANT
parts clean. Always use caps and plugs on hoses, S36668

damage the system.
I-2003-0888
Replace the dust ring (Item 1), two backup rings (Item 2)
and two O-rings (Item 3) [Figure 20-30-38] on the
manifold.
Figure 20-30-36
NOTE: One backup ring and O-ring are hidden.
Figure 20-30-39
S36666
1
Remove the valve (Item 1) [Figure 20-30-36] from the
manifold. S36669
Installation: Tighten the valve to 33.2 - 36.9 ft.-lb. (45 - 50

Nm) torque. Remove the two fittings (Item 1) [Figure 20-30-39] from
the manifold.
Figure 20-30-37
S36667
Remove the spring (Item 1) and spool (Item 2) [Figure

20-30-37] from the manifold.

45 of 82
HYDRAULIC VALVES (CONTD)
Lower Limit Valve Disassembly And Assembly

(Contd)
Figure 20-30-40
S36670
Replace the O-ring (Item 1) [Figure 20-30-40] on the two

fittings.

46 of 82
HYDRAULIC MOTOR Manifold Removal And Installation
Removal And Installation Figure 20-40-2
IMPORTANT
damage the system.
I-2003-0888
2
S36685
IMPORTANT Remove the two tubelines (Item 1) [Figure 20-40-2].
Contain and dispose of any oil leakage in an Remove the hose (Item 2) [Figure 20-40-2].
I-2066-0395 Figure 20-40-3
Mark the outside of the hydraulic motor for ease of 1 2

assembly.
Figure 20-40-1
1
2
1 S36686
1 Installation: Tighten the bolts to 36 - 50 ft.-lb. (49 - 68

S36685 Nm) torque.
Remove seven bolts and washers (Item 1) [Figure 20-40- Remove the manifold (Item 2) [Figure 20-40-3].
1].
Installation: Evenly tighten the bolts (Item 1) [Figure 20-

40-1] to 22.1 ft.-lb. (30 Nm) torque. Check that all seals
are in position. Tighten the bolts in a crisscross pattern to
a final torque of 33.2 ft.-lb. (45 Nm).
Carefully remove the hydraulic motor (Item 2) [Figure 20-

40-1].

47 of 82
HYDRAULIC MOTOR (CONTD) Figure 20-40-6
Manifold Removal And Installation (Contd)
Figure 20-40-4
S36689
1
S36687 fitting.
Figure 20-40-7
Remove the fittings (Item 1) [Figure 20-40-4].
Figure 20-40-5
S36690
S36388 Replace four O-rings (Item 1) [Figure 20-40-7] on the

manifold.
Replace the O-ring (Item 1) [Figure 20-40-5] on two

fittings.

48 of 82
HYDRAULIC MOTOR (CONTD)
Parts Identification
1. Screw
2. Washer
3. Cover
4. Seal
5. Disc
6. Plate
7. Shaft
8. Housing 1
9. Bearing 2
10. Seal 3
11. Shaft 7
4
12. Ring
13. Label 5
14. Bearing
4
10
6
11 4
13
9 8
14
14
13 EM6734

49 of 82
Disassembly And Assembly 1
NOTE: Disassembly of the hydraulic motor will void

motor warranty.
Clean the outside of the hydraulic motor before

disassembly.
Mark the outside of the hydraulic motor for ease of

assembly.
IMPORTANT S36692
Remove the wear plate (Item 1) [Figure 20-40-9].

Figure 20-40-10
damage the system. 1
I-2003-0888 2
Figure 20-40-8
S36693
Remove the splined shaft (Item 1) [Figure 20-40-10].
Installation: Fixate the splined shaft with petroleum jelly.

S36691

hydraulic motor base.

50 of 82

1
Figure 20-40-11
S36696

S36694 gerotor.
Installation: Always use new O-rings and seals when

Replace the O-ring (Item 1) [Figure 20-40-11] on the assembling the hydraulic motor. Lubricate all seals and O-
gerotor. rings with clean hydraulic fluid before installation.
Put the wear plate (Item 1) [Figure 20-40-11] back on the Inspection
gerotor.
Clean all parts in solvent and dry with compressed air. Do
Turn over the hydraulic motor. not use cloth or paper because small pieces of material
can get into the system and cause damage.
Figure 20-40-12
Inspect the gerotor for wear and scratches.
1
Inspect the wear plate.
S36695
Remove the end cap (Item 1) [Figure 20-40-12].

51 of 82
52 of 82
MAIN FRAME
CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
Removal And Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-10-1
MAIN FRAME
REDUCTION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-20-1
ROLLER GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-30-1


53 of 82
54 of 82
CABLE Figure 30-10-3
Removal And Installation

1
Figure 30-10-1
S36750
Remove the end of the cable (Item 1) [Figure 30-10-3]

S36623 from its socket.
Figure 30-10-4
Loosen the spring (Item 1) [Figure 30-10-1].
Figure 30-10-2
S36751
1
S36748 Remove the wedge (Item 1) [Figure 30-10-4].
Unwind the cable (Item 1) [Figure 30-10-2] fully and

deposit on a clean, vast area free of dust and sand.
NOTE: Unwind the cable onto a drum to keep clear of

dust or to work in small areas.
NOTE: Avoid bending or twisting the cable while

unwinding.
Installation: Rewind the cable in sections, removing

impurities present and lubricate using the prescribed
lubricant. While rewinding the cable, keep it taut. Make
sure the coils are close together without overlapping. If
needed, unwind the cable partly then resume winding.

55 of 82
CABLE (CONTD)
Removal And Installation (Contd)
Figure 30-10-5
S36752
Pull out the end of the cable (Item 1) [Figure 30-10-5].

56 of 82
REDUCTION GEAR Figure 30-20-3
Removal And Installation 2
Remove the cable. (See Removal And Installation on

Page 30-10-1.)
Figure 30-20-1 1
2 1
S36726
Remove the two bolts and washers (Item 1) [Figure 30-

1 20-3].
Remove the two bolts and washers on the other side.

S36725
Installation: Tighten the bolts to 88.5 ft.-lb. (120 Nm)
torque.
Remove the four bolts and washers (Item 1) [Figure 30-
20-1]. Remove the bracket (Item 2) [Figure 30-20-3].
Installation: Tighten the four bolts to 53 - 62 in.-lb. (8 - 9 Figure 30-20-4

Nm) torque.
Remove the cover (Item 2) [Figure 30-20-1].

1
Figure 30-20-2
S36727
Support the winch drum with a hoist (Item 1) [Figure 30-

20-4].
S36723
Remove the spring (Item 1) [Figure 30-20-2].
Remove the bolt and locking nut (Item 2) [Figure 30-20-

2].
Installation: Tighten the bolt and locking nut to 53 - 62

in.-lb. (8 - 9 Nm) torque.

57 of 82
REDUCTION GEAR (CONTD) Figure 30-20-7
Removal And Installation (Contd)
Figure 30-20-5 1
S36729
1 Remove the snap ring (Item 1) [Figure 30-20-7].

1 S36728
Remove the bearing (Item 2) [Figure 30-20-7].
Remove four bolts and washers (Item 1) [Figure 30-20-5] Figure 30-20-8
from the right side of the frame.
Installation: Tighten the bolts to 88.5 ft.-lb. (120 Nm) 2

torque.
Figure 30-20-6
3
1
1 S36730
Place the winch drum on blocks [Figure 30-20-8].
Remove eight bolts and washers (Item 1) [Figure 30-20-

S36727 8].
Installation: Apply Loctite #243 and tighten the bolts to

Move the winch drum to the right side of the frame 11 - 16 ft.-lb. (15 - 22 Nm) torque.
[Figure 30-20-6].
Remove the drum (Item 2) [Figure 30-20-8].
Remove the roller (Item 1) [Figure 30-20-6].
Remove the bottom plate (Item 3) [Figure 30-20-8].
Remove the winch drum.

58 of 82
REDUCTION GEAR (CONTD) Figure 30-20-10
Removal And Installation (Contd) 1
Figure 30-20-9
2
1
2 1
1
S36732
Remove the eight bolts and washers (Item 1) [Figure 30-

1 20-10].
S36731
Installation: Tighten the bolts to 51.6 ft.-lb. (70 Nm)

Remove the bolts (Item 1) [Figure 30-20-9]. torque.
Remove the manifold (Item 2) [Figure 30-20-9]. Remove the reduction gear (Item 2) [Figure 30-20-10].

59 of 82
60 of 82
ROLLER GUIDE Figure 30-30-3

2
Figure 30-30-1
1
2 1
S36733
1
Support the roller with a wooden block [Figure 30-30-3].

S36725
Remove the snap ring (Item 1) [Figure 30-30-3] from the
roller.
Remove the four bolts and washers (Item 1) [Figure 30-
30-1]. Remove the roller (Item 2) [Figure 30-30-3].
Installation: Tighten the four bolts to 53 - 62 in.-lb. (8 - 9 Figure 30-30-4

Nm) torque.
Remove the cover (Item 2) [Figure 30-30-1]. 2

Figure 30-30-2
1
1
S36734
Remove the snap ring (Item 1) [Figure 30-30-4] from the

roller.
S36726
Remove the roller (Item 2) [Figure 30-30-4].
Remove the spring (Item 1) [Figure 30-30-2].
Remove the bolt and locking nut (Item 2) [Figure 30-30-

2].

61 of 82
62 of 82
ELECTRICAL SYSTEM
KIT PRESENCE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-10-1

RATED CAPACITY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-20-1

ELECTRICAL
SYSTEM

63 of 82
64 of 82
KIT PRESENCE SWITCH
Figure 40-10-1
2 1
S36735
Remove tie strap (Item 1) [Figure 40-10-1].
Disconnect the switch connector (Item 2) [Figure 40-10-

1].
Remove the two bolts and locking nuts (Item 3) [Figure

40-10-1].
Installation: Tighten the bolts and locking nuts to 19.5 -

24.8 in.-lb. (2,2 - 2,8 Nm) torque.
Remove the cover and switch (Item 4) [Figure 40-10-1].
NOTE: Mark position of switch (Item 4) [Figure 40-10-

1] before removal.

65 of 82
66 of 82
RATED CAPACITY SWITCH
NOTE: Adjusting the Rated Capacity Switch position

is not recommended. Moving or replacing the
Rated Capacity switch requires recalibration
by a qualified technician.
Figure 40-10-1
S36736
Remove tie strap (Item 1) [Figure 40-10-1].
Disconnect the switch connector (Item 2) [Figure 40-10-

1].
Figure 40-20-2
1 1
S36737
Remove the two bolts and locking nuts (Item 1) [Figure

40-20-2].
Installation: Tighten the bolts and locking nuts to 19.5 -

24.8 in.-lb. (2,2 - 2,8 Nm) torque.
Remove the cover and switch (Item 2) [Figure 40-20-2].
NOTE: Recalibrate the Rated Capacity Switch upon

installation.
40-20-1 Jibd Winch Service Manual

67 of 82
40-20-2 Jibd Winch Service Manual
68 of 82
SPECIFICATIONS AND SCHEMATICS
ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1
FLUIDS AND LUBRICANTS TABLE. . . . . . . . . . . . . . . . . . . . . SPEC-50-1
HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1
HOISTING WINCH WITH JIB SPECIFICATIONS . . . . . . . . . . SPEC-10-1

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-1
Operational Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-10-3
TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . SPEC-40-1 SPECIFICATIONS

Torque For General Metric Bolts . . . . . . . . . . . . . . . . . . . . . SPEC-40-2 AND
Torque For General SAE Bolts . . . . . . . . . . . . . . . . . . . . . . SPEC-40-1 SCHEMATICS
SPEC-01 Hoisting Winch with Jib Service Manual

69 of 82
SPEC-02 Hoisting Winch with Jib Service Manual
70 of 82
HOISTING WINCH WITH JIB SPECIFICATIONS
Dimensions
All dimensions are shown in SI units.
Where applicable, specifications conform to EN and ISO standards and are subject to change without notice
JIB + HOIST 0.6T

EM5081
Width A 31.3 in. (795 mm)

Length B 155.5 in. (3951 mm)
Total Length C 158.2 in. (4019 mm)
Height D 37.5 in. (952 mm)
SPEC-10-1 Hoisting Winch with Jib Service Manual

71 of 82
HOISTING WINCH WITH JIB SPECIFICATIONS (CONTD)
Dimensions (Contd)
All dimensions are shown in SI units.
Where applicable, specifications conform to EN and ISO standards and are subject to change without notice
JIB + HOIST 1.0T

EM6733
Width A 31.3 in. (795 mm)

Length B 155.5 in. (3951 mm)
Total Length C 158.2 in. (4019 mm)
Height D 37.5 in. (952 mm)

72 of 82
HOISTING WINCH WITH JIB SPECIFICATIONS (CONTD)
Specifications
Jib + Hoist 1.0T Jib + Hoist 0.6T

Weight 844 lbs (383 kg) 763 lbs (346 kg)
Max Hydraulic Pressure 2170 PSI (15 MPa) 2680 PSI (18,5 bar)
Max. Hydraulic flow 13 gal/min (50 l/min)
Operational Specifications
Jib + Hoist 1.0T Jib + Hoist 0.6T

Cable length 184 ft. (56 m) 131 ft. (40 m)
Max. hoist speed 144 ft./min (44 m/min) 290 ft./min (89 m/min)
Rated hoist capacity 2200 lbs (1000 kg) 1320 lbs (600 kg)
Technical Specifications
Max. pressure on gear motor 2900.8 PSI (20 MPa)

Motor drain pressure 725.2 PSI (5 MPa)
Min. brake opening pressure 348.1 - 420.6 PSI (2,4 - 2,9 MPa)

73 of 82
74 of 82
HYDRAULIC SCHEMATIC
1. Rated Capacity Limiting Relief Valve

2. Upper Limit Valve
3. Main Hydraulic Manifold
4. Lower Limit Valve
5. Gear Motor with Brake
6. Brake Engagement Safety Valve
7. Winch Motor Authorization Valve EM5074

75 of 82
76 of 82
ELECTRICAL SCHEMATIC
KIT PRESENCE SWITCH
RATED OPERATING CAPACITY SWITCH
WINCH MOTOR AUTHORIZATION SWITCH
BRAKE ENGAGEMENT SAFETY SWITCH
EM5077

77 of 82
78 of 82
TORQUE SPECIFICATIONS FOR BOLTS
Torque For General SAE Bolts
The following table shows standard torque specifications for bolts with zinc phosphate coating. Bolts that have zinc
phosphate coating are specified by the letter H following the part number.
Thread
SAE Grade 5 SAE Grade 8
Size
INCH. .250 80-90 110-120
LBS. (9,0-10,2) (12,4-13,6)
(Nm) .3125 180-200 215-240
(20,3-22,6) (24,2-27-1)
FOOT .375 25-28 35-40
LBS. (34-38) (47-54)
(Nm) .4375 40-45 60-65
(54-61) (81-88)
.500 65-70 90-100
(88-95) (122-136)
.5625 90-100 125-140
(122-136) (170-190)
.625 125-140 175-190
(170-190) (240-260)
.750 220-245 300-330
(300-330) (410-450)
.875 330-360 475-525
(450-490) (645-710)
1.000 475-525 725-800
(645-710) (985-1085)
1.125 650-720 1050-1175
(880-975) (1425-1600)
1.250 900-1000 1475-1625
(1200-1360) (2000-2200)
1.375 1200-1350 2000-2200
(1630-1830) (2720-2980)
1.500 1500-1650 2600-2850
(2040-2240) (3530-3870)
1.625 2000-2800 3450-3800
(2720-2980) (4680-5150)
1.750 2500-2750 4300-4800
(3390-3730) (5830-6500)
1.875 3150-3500 5500-6100
(4270-4750) (7450-8300)
2.000 3800-4200 6500-7200
(5150-5700) (8800-9800)

79 of 82
TORQUE SPECIFICATIONS FOR BOLTS (CONT'D)
Torque For General Metric Bolts
THREAD SIZE MATERIAL

(DIA. X PITCH) HEAD MARK 4 HEAD MARK 7 HEAD MARK 10
M 5 x 0.8 3-4 ft.-lb.
(4-5 Nm)
M 6 x 1.0 6-7 ft.-lb. 6-9 ft.-lb.
(8-9 Nm) (8-12 Nm)
M 8 x 1.25 6-9 ft.-lb. 11-16 ft.-lb. 18-25 ft.-lb.
(8-12 Nm) (15-22 Nm) (24-34 Nm)
M 10 x 1.25 13-18 ft.-lb. 22-30 ft.-lb. 36-50 ft.-lb.
(18-24 Nm) (30-41 Nm) (49-68 Nm)
M 12 x 1.25 22-30 ft.-lb. 40-54 ft.-lb. 69-87 ft.-lb.
(30-41 Nm) (54-73 Nm) (94-118 Nm)
M 14 x 1.25 36-50 ft.-lb. 58-80 ft.-lb. 116-137 ft.-lb.
(49-68 Nm) (79-108 Nm) (157-186 Nm)

80 of 82
Hoisting Winch with Jib Service Manual
All Bobcat Equipment Only for TLS, Wheeled EXC and AL
ENGINE / LOADER TRANSMISSION HYDRAULIC/ ANTIFREEZE AXLE / TRANSMISSION BRAKE FLUID
HYDROSTATIC COOLANT
Bobcat Brake Fluid

Bobcat Brake Fluid
Transmission Oil
Transmission Oil
(Roto TLS only)

Hydraulic/Hydrostatic
Hydraulic/Hydrostatic
Engine Power
Engine Power
Engine Power
Engine Power
Bio Hydraulic
Bobcat Axle /
Bobcat Axle /
Superior SH
SAE 10W/30
SAE 15W/40
SAE 20W/50
SAE 85W/90
PG Coolant
PG Coolant
EG Coolant
EG Coolant
SAE 0W/30
Concentrated
Concentrated
4 Seasons
ISO 100
Bobcat
Bobcat
Bobcat
Bobcat
Bobcat
Bobcat
Bobcat
Bobcat
Bobcat
Bobcat
Premixed
LHM
Packaging Lineart
5L
6987500A 6904840A 6904841A 6987501A 6904842A 6904843A 6987646A 6904844A 6987596A 6987597A 6987602A 6904845A 6904846A 6987667A
SPEC-50-1
Can
25 L
6987500B 6904840B 6904841B 6987501B 6904842B 6904843B 6987646B 6904844B 6987596B 6987597B 6987602B 6904845B 6987667B
Container
209 L
6987500C 6904840C 6904841C 6987501C 6904842C 6904843C 6987646C 6904844C 6987596C 6987597C 6987602C 6904845C 6987667C
Drum
FLUIDS AND LUBRICANTS TABLE
1000 L
6987500D 6904840D 6904841D 6987501D 6904842D 6904843D 6987646D 6904844D 6987596D 6987597D 6987602D 6904845D 6987667D
Tank
Bobcat Multi-Purpose Grease 6903122
400 gr
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Winch, Hoisting With

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Winch, Hoisting With

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EN

Jib + Hoist 1000 kg: S/N AK3F00101 & Above

6989514-EN (6-10) Printed in Belgium Bobcat Company 2010

Never service attachments / implements without

Cleaning and maintenance are required daily.

Never service or adjust attachment / implement with the

Always lower the attachment / implement to the ground

Avoid contact with leaking hydraulic fluid or diesel fuel

Stop, cool and clean engine of flammable materials before

Keep body, loose objects and clothing away from moving

Safety glasses are needed for eye protection from electrical

ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-30-1

FLUIDS AND LUBRICANTS TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-50-1

HYDRAULIC SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPEC-20-1

HYDRAULIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-40-1

HYDRAULIC VALVES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-30-1

HOISTING WINCH WITH JIB SPECIFICATIONS . . . . . . . . . . . . . . . . . SPEC-10-1

KIT PRESENCE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40-10-1

MAIN HYDRAULIC MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-20-1

QUICK COUPLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-10-1

REDUCTION GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-20-1

ROLLER GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30-30-1

SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-40-1

TORQUE SPECIFICATIONS FOR BOLTS . . . . . . . . . . . . . . . . . . . . . . . SPEC-40-1

ALPHA-01 Hoisting Winch with Jib Service Manual

HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-01 MAIN

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40-01 ELECTRICAL

I Hoisting Winch with Jib Service Manual

III Hoisting Winch with Jib Service Manual

SUPPORT HYDRAULIC QUICK TACH

7186118 7186115 EM5079

IV Hoisting Winch with Jib Service Manual

V Hoisting Winch with Jib Service Manual

SERVICE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40-1

10-01 Hoisting Winch with Jib Service Manual

PROBLEM CAUSE CORRECTION

10-10-1 Hoisting Winch with Jib Service Manual

Hydraulic System Inspection

Check the working of the Lower Limit Valve (Item 1)

Check the tightness of hydraulic connections on the

Check the working of the Upper Limit Valve (Item 1)

10-20-1 Hoisting Winch with Jib Service Manual

Check the cable (Item 1) [Figure 10-20-6] for broken

Check the condition of the fixed eyelet socket (Item 1)

10-20-2 Hoisting Winch with Jib Service Manual

10-20-3 Hoisting Winch with Jib Service Manual

10-20-4 Hoisting Winch with Jib Service Manual

Chart Lubricate more frequently in case of saline or corrosive

* See FLUIDS AND LUBRICANTS TABLE on Page S36741

Lubricate the cable (Item 1) [Figure 10-30-1]. (See Chart

Lubricate the hook (Item 1) [Figure 10-30-2]. (See Chart

10-30-1 Hoisting Winch with Jib Service Manual

SERVICE SCHEDULE HOURS

[1] Perform service first time, then as indicated in chart.

10-40-1 Hoisting Winch with Jib Service Manual

HYDRAULIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-40-1

HYDRAULIC VALVES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-30-1

MAIN HYDRAULIC MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-20-1

QUICK COUPLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-10-1

20-01 Hoisting Winch with Jib Service Manual

Removal and Installation

Contain and dispose of any oil leakage in an

Remove the male (Item 1) and female (Item 2) [Figure

Remove the connectors (Item 3) [Figure 20-10-1] from