Bobcat Hoisting Winch Service Repair Manual Instant Download

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B0bcat
Service Manual Hoisting Winch
EN
Winch Hoist 4T S/N AK3D00101 Above Winch Hoist
3.5T S/N AK3E00101 Above
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Printed in Belgium Original instructions
6 Bobcat Company 201D
6989513-EN (6-10)
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MAINTENANCE SAFETY Instructions are necessary
before operating or servicing machine. Read and
understand the Operation Maintenance Manual,
Operator's Handbook and signs (decals) on
machine. Follow warnings and instructions in the
manuals when making repairs, adjustments or
servicing. Check for correct function after
adjustments, repairs or service. Untrained
operators and failure to follow instructions can
cause injury or death. 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 P90216
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 pans 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.
MSW90-0409
3
ALPHABETICAL INDEX CABLE .........................
........................... 30-40-1 CABLE GUIDE
PULLEY.......................................
30-10-1 CAGE .....................................
................ 30-50-1 ELECTRICAL SCHEMATIC
.................................
SPEC-30-1 FLUIDS AND LUBRICANTS
TABLE........................... SPEC-50-1
INSPECTION .......................................
........ 10-20-1 HYDRAULIC MOTOR
.........................................
20-40-1 HYDRAULIC SCHEMATIC ......................
............ SPEC-20-1 HYDRAULIC VALVES
.........................................
20-30-1 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
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TROUBLESHOOTING ..................................
...... 10-10-1 HOISTING WINCH SPECIFICATIONS......
................... SPEC-10-1
ALPHA-01
Hoisting Winch Service Manual
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CONTENTS
SAFETY AND MAINTENANCE
SERIAL NUMBER LOCATION
III
III IV 10-01
ATTACHMENT DELIVERY REPORT
HYDRAULIC SYSTEM
IDENTIFICATION AND MACHINE SIGNS (DECALS)
SAFETY AND MAINTENANCE
MAIN FRAME
HYDRAULIC SYSTEM
20-01
MAIN FRAME .
30-01
ELECTRICAL SYSTEM
ELECTRICAL SYSTEM
40-01
SPECIFICATIONS AND SCHEMATICS
SPEC-01
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SERIAL NUMBER LOCATION
ATTACHMENT DELIVERY REPORT
Figure 1
Figure 2
The Attachment Delivery Report must be completed
by the dealer and signed by the owner or operator
when the hoisting winch is delivered. An
explanation of the form must be given to the
owner. Make sure it is entirely completed Figure
2.
Always use the serial number (Item 1) Figure 1
of the hoisting winch when requesting service
information or when ordering parts. Early or
later models (identification made by number) may
use a different procedure in doing a specific
service operation.
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III
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IDENTIFICATION AND MACHINE SIGNS (DECALS)
QUICKTACH
HYDRAULIC HOSES
SUPPORT
HOOK BLOCK
6809609
7186116
7191320 HOISTING WINCH 3.ST
7186117
6705340
7186118
7191319 (HOISTING WINCH 4T)
7130143
7186115
EMMI78
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Hoisting Winch 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 Cable Inspection
....................................... 10-20-2
SAFETY AND 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
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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
Winch function not working Defective electrical switch Check if Kit Presence Switch makes contact with the tab on the quick-tach. Re-position if needed.
Winch function not working Defective electrical switch Replace switch
Winch function not working Defective hydraulic valve Check if Lower Limit Valve is working. Replace if needed.
Winch function not working Defective hydraulic valve Check if Upper Limit Valve is working. Replace if needed.
Winch function not working Defective solenoid valve Check if solenoids are working. Replace if needed.
Winch function not working Clogged orifices (located in the hydraulic motor fittings) Clean the orifices
Winch function not working Defective Main Hydraulic Manifold. Replace Main Hydraulic Manifold.
Winch function not working Cable is stuck Check cable for kinks or loops. Replace if needed.
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10-10-1
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INSPECTION
Figure 10-20-3
Hydraulic System Inspection Figure 10-20-1
Check the working of the Lower Limit Valve (Item
1) Figure 10-20-3. Check the tightness of
hydraulic connections on the hoisting winch (Item
1) and hydraulic quick couplers (Item 2) Figure
10-20-1. Figure 10-20-2
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Check the working of the Upper Limit Valve (Item
1) Figure 10-20-2.
10-20-1
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INSPECTION (CONT'D) Cable Inspection
Figure 10-20-6
Figure 10-20-4
Check the condition of the fixed socket (Item 1)
Figure 10-20-6.
Figure 10-20-7
Check that the pulley (Item 1) Figure 10-20-4
of the block rotates freely.
Check that the lifting hook (Item 2) Figure
10-20-4 rotates freely. Check that the safety
tab (Item 3) Figure 10-20-4 is intact and
positions itself correctly. Figure 10-20-5
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Check the condition of the cable and its correct
winding around the drum (Item 1) Figure 10-20-7.
Check the cable (Item 1) Figure 10-20-7 for
broken strands and wear, stretching, deformation
and rusting in the winding area. (See Cable
Deterioration And Replacement Criteria (as per
ISO 4309) on Page 10-20- 3.)
536673
NOTE Replace the cable with a certified
replacement cable provided by Bobcat Company.
Check the lateral sliding of the cable guide
pulley (Item 1) on the shaft (Item 2) Figure
10-20-5.
10-20-1
12

• INSPECTION (CONTD)
• Cable Deterioration And Replacement Criteria (as
  per ISO 4309)
• Replace the cable in case of breakage of 10
  strands along a length of 14.2 in. (360 mm) for
  0.47 in. (12 mm) diameter cable.
• Cables should be replaced when
• the cable diameter, even at just one point, is 7
  smaller than the nominal diameter
• the cable appears permanently crushed, twisted or
  bent
• the core can be seen even at just one point
• while in tension, there are one or more loose
  strands.
• NOTE Replace the cable with a certified
  replacement cable provided by Bobcat Company.
• The photos below show examples of deterioration
  of cables, describing the cause and replacement
  conditions.

Protrusion of the steel core, generally Ilinked to basket deformation. Replace this cable immediately.
The wires of a single strand have loosened although inspection of a section of cable has shown that the deformation can be seen at regular intervals, normally equal to the lay pitch. This defect must be kept under control.
More serious example of the previous defect with protrusion on the inner wires of the strands. Major localised defect caused by applying shock loads. Replace this cable immediately.
Confined increase of diameter of a long lay cable, caused by distortion of the metal core caused by dynamic load. There are also traced of corrosion and major wear of the external wires. Replace this cable immediately.
Confined increase of diameter of the cable, due to the protrusion of the textile core between the external strands. Replace this cable.
Major kink causing fibrecore protrusion. Replace this cable immediately.
Wire cable which has been twisted during installation and use. Now subject to localised wear and lengthening of the strands. Replace this cable.
Confined reduction in the cable diameter because the outer strands tend to fill the volume of the textile core which has been destroyed. Replace this cable immediately
Broken wires out of position in two strands of a regular lay cable. Replace this cable.
Major wear and high number of broken wires in a regular lay cable. Replace this cable immediately.
Broken wires in a single strand and slight wear in a long lay cable. In this case, remove the broken wires to make the cable smooth.
Broken wires in several strands, close to a return sheave (sometimes hidden by the sheave). Replace this cable.
Broken wires in two strands due to bending fatigue, linked to major localized wear. Replace this cable.
Birdcage in a multilayer (non rotating) type of cable caused by forced rotation around small grooves or excessive fleet angle. Replace this cable immediately.
10-20-3
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INSPECTION (CONT'D)
Continuous
flattening
metal wires which begin
Cable Deterioration And Replacement Criteria (as
per ISO 4309) (Cont'd)
to loosen, with a
reduction of diameter that
can be estimated at approximately 40. Replace
this cable immediately. Start of surface
corrosion.
Flattened section caused by local crushing due to mechanical action this causes a lack of equilibrium in the strands. 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 external strands with unbalanced tension in load conditions. Replace this cable.
Example of major bending. Replace this cable.
Typical example of a cable which has come out of the groove of a sheave and has been trapped with resulting deformation and flattening, with local wear and many broken wires. Replace this rope immediately.
Cumulative effects of several deterioration factors. Note the major wear of the external wires, which has caused loosening of the wires resulting in basket deformation the risk here is that the cable could be expulsed from the sheave. Replace this cable immediately.
Slight flattening of external wires. Small reduction of the cable diameter.
Highly perforated surface and completely loosened
wires. Serious reduction in diameter with space
between the wires of more than half their
diameter. Replace this cable immediately. Examp
le of major internal corrosion. Clear reduction
of the external strands,
area wires in the
many of the contact
area of the core, the high level of compression,
the lack of space between the strands and the
ensuing reduction in the diameter of the cable.
Replace this
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cable immediately. Helical distortion
distortion where the
longitudinal axis of the cable has a helical
shape. In this condition the cable must be
inspected continuously. There may be wear and
broken wires in the event of prolonged use.
Replace the cable if the deformation exceeds the
value set in UNI ISO 4309/84.
10-20-3
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LUBRICATION ChaM NOTE Always
Lubrication Locations
See Chart on Page 10-30-1 when lubricating the
hoisting winch. Apply the lubricant until extra
grease shows. Lubricate more frequently in case
of saline or corrosive environment. Lubricate the
following locations on the hoisting winch
clean the grease fittings before
injecting grease. Apply lubricant until extra
grease shows. Remove all tracks of grease after
lubrication.
LUBRICATION LOCATIONS TYPE OF LUBRICANT
Cable guide pulley Bobcat lithium-based multipurpose grease
Block pulley Bobcat lithium-based multipurpose grease
Cable guide pulley shaft Bobcat lithium-based multipurpose grease
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)
Figure 10-30-1
Cable guide pulley (1 fitting) (Item 1) Figure
10-30-1 on hoisting winch.
See FLUIDS AND LUBRICANTS TABLE on Page
SPEC-50-1
Shaft (Item 2) Figure 10-30-1 of cable guide
pulley.
NOTE Remove all traces of dust and sand before
lubricating the cable guide shaft (Item 2)
Figure 10-30-1.
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Figure 10-30-2
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Block pulley (1 fitting) (Item 1) Figure
10-30-2 on hook block.
10-30-1
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LUBRICATION (CONT'D) Lubrication Locations
(Cont'd) Figure 10-30-3
Lubricate the hook stem (Item 1) Figure
10-30-3. NOTE Remove all traces of dust and
sand before lubricating the hook stem (Item 1)
Figure 10- 30-3. Figure 10-30-4
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Lubricate the cable (Item 1) Figure
10-30-4. NOTE Unwind and rewind the cable for
lubrication (See Operation Maintenance
Manual for correct procedure).
10-30-2
Hoisting Winch Service Manual
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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. Instructions are
necessary before operating or servicing machine.
Read and understand the Operation Maintenance
Manual, Operator's Handbook and signs (decals) on
machine. Follow warnings and instructions in the
manuals when making repairs, adjustments or
servicing. Check for correct function after
adjustments, repairs or service. Untrained
operators and failure to follow instructions can
cause injury or death. w-zsse-rsor

ITEM SERVICE REQUIRED daily 50 100 250 1000
CBble ChecK the cable.
CBble Check the fixed socket, split pin and clBFFlp.
CBble Check correct winding of cable.
CBble guide pulley Check lateral sliding of pulley.
Dlock pulley Check free rotation of block pulley.
Hook Check free rotation of hook.
SBfety tab ChecK if salery tab of hook is intact Bnd functions propeily.
Llmlt valves Check the working of the limit vBlves.
CBble guide pulley, shaft, block pulley Lubricate with multipurpose lithium based grease (See Chart on Page 10- 30-1).
Hook stem Lubricate with engine oil tsee Chart on Page 10-30-1.
I-reduction geBr all Change the reduction gear oil (See Chart on Page 10-30-1.
CBble 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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10-30-2
Hoisting Winch Service Manual
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the link into your browser. The full manual is
available for immediate download. https//www.ebo
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