Barko 495B - SE Service Manual Download Page 2

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Service Manual

Last Updated - 9/28/2016

495B SE (S)

TABLE OF CONTENTS

INTRODUCTION 4

ABBREVIATIONS AND SYMBOLS 5

KNOW YOUR MACHINE 7

SAFETY SUMMARY 8

FIRE PREVENTION 13

INSTALLATION OF FIRE EXTINGUISHER BRACKET

MODEL DESCRIPTION

SAFETY WHILE SERVICING

PREVENTIVE MAINTENANCE

SPECIAL NEW-MACHINE INSTRUCTIONS

SERVICE SCHEDULE

LUBRICATION POINTS

FLUID SPECIFICATIONS

GENERAL TORQUE SPECIFICATIONS

HYDRAULIC DRAWING

HYDRAULIC SERVO DRAWING

HYDRAULIC SCHEMATIC

HYDRAULIC DRAWING TANDEM

HYDRAULIC SERVO TANDEM

HYDRAULIC SCHEMATIC TANDEM

HYDRAULIC PRESSURE SETTINGS (495ML) 35

MACHINE FUNCTION SPEEDS 35

HYDRAULIC PRESSURE ADJUSTMENTS 36

HYDRAULIC RESERVOIR MAINTENANCE 41

HYDRAULIC FILTER MAINTENANCE 42

ELIMINATING AIR FROM THE SYSTEM 44

HYDRAULIC FITTINGS, HOSES & TUBING 45

HYDRAULIC CYLINDER MAINTENANCE 46

HYDRAULIC COLLECTOR MAINTENANCE 48

SWING MOTOR MAINTENANCE (DANFOSS) 52

SWING MOTOR GEARBOX MAINTENANCE (T1/02) 55

ELEC. SCHEMATIC - 460V 3PH 60HZ 100HP 57

ELEC. SCHEMATIC - 575V 3PH 60HZ 100HP 58

ELEC. SCHEMATIC - 380V 3PH 50HZ 125HP 59

ELECTRICAL SYSTEM MAINTENANCE 60

ELECTRIC COLLECTOR MAINTENANCE 65

AIR CONDITIONER MAINTENANCE 67

ENGINE MAINTENANCE 79

PUMP DRIVE MAINTENANCE 80

AIR CLEANER MAINTENANCE 84

TURNTABLE BEARING MAINTENANCE 89

Summary of Contents for 495B - SE

Page 1: ...OTE The operating and safety instructions for a Slasher Saw Attachment or Carrier Lower are not included in this manual See Slasher Saw or Carrier manufacturer s information NOTE The Grapple Service a...

Page 2: ...NDEM 33 HYDRAULIC SCHEMATIC TANDEM 34 HYDRAULIC PRESSURE SETTINGS 495ML 35 MACHINE FUNCTION SPEEDS 35 HYDRAULIC PRESSURE ADJUSTMENTS 36 HYDRAULIC RESERVOIR MAINTENANCE 41 HYDRAULIC FILTER MAINTENANCE...

Page 3: ...Introduction...

Page 4: ...some of the thousands of injuries and deaths caused by industrial accidents each year A professional operator should also be familiar with the information contained in other applicable sources such as...

Page 5: ...in the forward operating position a c air conditioner AC Articulated Carrier Art Car adj adjust or adjusting appl application AR As Required assy assembly BC Back of Cab b m bill of material brg beari...

Page 6: ...fuse action to protect the machine and the operator from overloading When overloaded the machine can become stressed to a level where part fractures cause death se vere injury or property damage This...

Page 7: ...being operated in an unsafe manner 6 Never use a boom or attachment for a work platform or personnel carrier Serious injury or death may result 7 When machine is not operating or when leaving cab boom...

Page 8: ...e owner s responsibility See Mounting Instructions for recommended procedures WARNING When using a Slasher Saw Attachment be sure to get proper safety and operating manuals from Slasher manufacturer R...

Page 9: ...e sulting in machine being operated in an unsafe manner Never use a boom attachment for a work platform or personnel carrier An unstable machine can cause death severe injury or property damage Do not...

Page 10: ...hen mounting or dismounting Never jump on or off machine Do not rush Walk do not run Mechanically connected controls will cause movement of components at all times even if pump or engine is not operat...

Page 11: ...or severe injury This is a 12 volt negative ground electrical system Always wear seat belt when operating or running ma chine Check the Air Cleaner Assembly daily for cracks loose clamps or any other...

Page 12: ...and snow affect the machine stability Irregular terrain must be traveled at slower speeds Direction of travel Avoid operating the machine across the slope When possible travel up or down slopes Place...

Page 13: ...system and hydraulic system Clean as often as necessary to help prevent overheating and combustion The electrical system battery electrical connections etc can be a source of arcs or sparks if damaged...

Page 14: ...MODEL DESCRIPTION Hydraulic Oil Reservoir Shouding Power Unit Pumps Cab Stick Boom Cylinder Stick Boom Main Boom Cylinder Counterweight Exhaust Main Boom Head Assembly Platform Control Deck Grapple Ha...

Page 15: ...Maintenance...

Page 16: ...n any structural member unless specifi cally authorized by Barko Hydraulics Any unauthorized welding or welding procedures will void the warranty and may cause death severe injury property damage or s...

Page 17: ...re after the first 100 hours of operation 1 Do a complete inspection of the loader Rectify any problems replace any damaged parts 2 Check torque retorque if necessary Turntable Bearing Mounting Bolts...

Page 18: ...Service Manual Last Updated 9 28 2016 495B SE S 18 SERVICE SCHEDULE...

Page 19: ...Service Manual 495B SE S 19 Last Updated 9 28 2016 SERVICE SCHEDULE CONTINUED...

Page 20: ...Service Manual Last Updated 9 28 2016 495B SE S 20 SERVICE SCHEDULE CONTINUED...

Page 21: ...Service Manual 495B SE S 21 Last Updated 9 28 2016 SERVICE SCHEDULE CONTINUED...

Page 22: ...Service Manual Last Updated 9 28 2016 495B SE S 22 SERVICE SCHEDULE CONTINUED...

Page 23: ...boxes gear fluid see Swing Motor Gearbox Maintenance section in Service Manual approx 5 07 quarts 4 8 Liters if lube reservoir is used maintain it at half full LUBRICATION POINTS PERFORM DAILY 3 1 1 8...

Page 24: ...lity to resist oxidation and prevent varnish formation and deposits that foul systems Anti wear properties to prevent scuffing and exccesive wear at high speeds and high pressures Good viscosity index...

Page 25: ...LUBRICANTS Conditions in certain geographical areas may require special lubricants and lubrication practices which do not appear in this manual LUBRICANT STORAGE The machine can operate at top efficie...

Page 26: ...nd Nuts 600 Ft Lbs 814 Nm Valve Bank Studs Nuts Tighten in a clockwise pattern so that all nuts are tightened equally without binding on the valve bank Final torque should be K170 valves 44 Ft Lbs 60...

Page 27: ...154 171 92 102 5 8 212 240 127 144 3 4 376 420 226 252 7 8 606 668 364 400 1 909 995 545 597 1 1 8 1288 1444 773 866 1 1 4 1817 2012 1090 1207 1 3 8 2382 2712 1430 1627 1 1 2 3161 3557 1897 GRADE 8 SA...

Page 28: ...Hydraulic...

Page 29: ...Service Manual 495B SE S 29 Last Updated 9 28 2016 HYDRAULIC DRAWING 603 01594...

Page 30: ...Service Manual Last Updated 9 28 2016 495B SE S 30 HYDRAULIC SERVO DRAWING 603 01593...

Page 31: ...Service Manual 495B SE S 31 Last Updated 9 28 2016 HYDRAULIC SCHEMATIC 607 00185...

Page 32: ...Service Manual Last Updated 9 28 2016 495B SE S 32 HYDRAULIC DRAWING TANDEM 603 01574...

Page 33: ...Service Manual 495B SE S 33 Last Updated 9 28 2016 HYDRAULIC SERVO TANDEM 603 01573...

Page 34: ...Service Manual Last Updated 9 28 2016 495B SE S 34 HYDRAULIC SCHEMATIC TANDEM 607 00184...

Page 35: ...d of main boom cylinder 4000 PSI 276 Bar at the Port Relief Main Boom down rod end of main boom cylinder 1800 PSI 124 Bar at the Port Relief Stick Boom up butt end of secondary boom cylinder 4000 PSI...

Page 36: ...just pressure loosen jam nut on pressure control block located on pump with 1 2 wrench Adjust pressure by turning screw in or out with a 5 32 allen wrench Retighten jam nut prior to taking pressure re...

Page 37: ...keep dirt and dust out if cap is to tight it will add to system pressure Adjust pressures and reconnect hoses Repeat for other pump Standby pressure Pump compensator Torque Control 1 Install an elect...

Page 38: ...e to 425 PSI by turning screw in or out with a 5 32 allen wrench turn screw clockwise to increase counterclockwise to decrease 5 Tighten jam nut 6 Stall saw or plug pressure line 7 Run engine at full...

Page 39: ...adjust installagaugeontheloadsensetestportlocatedonthepump seePumpAdjustmentsforlocation of test port Remove the acorn nut and loosen the jam nut 13 mm wrench Using a 4 mm Allen wrench turn the adjust...

Page 40: ...adjust the pressure install a gauge on the load sense test port located on the pump Adjust pressure at the load sense adjustment screw on the load sense relief on the valve bank inlet cover Pressure s...

Page 41: ...nnels oil filling equipment the oil filler opening and above all the hydraulic oil itself must be kept absolutely clean Dirt in the hydraulic system can cause serious damage to pumps valves and cylind...

Page 42: ...sket from inside new element and install in groove in filter head 4 Apply oil to new gasket NOTE On a new machine the filter elements must be changed after the first 100 hours of operating time and th...

Page 43: ...has an indicator to show when filter needs servicing Check indicator daily to ensure proper service intervals CHANGING FILTER ELEMENT 1 Unscrew filter bowl from filter head 2 Replace old element with...

Page 44: ...ric pressure air may be drawn in where fluid will not necessarily leak out 5 Fluid level too low This can cause vortexing at pump inlet in reservoir thus drawing in air 6 Air trapped in filter with no...

Page 45: ...s aeration in the fluid but also provides the risk of contamination entering the fluid and components with the air The easiest way to effectively reduce and possibly eliminate this problem is to use a...

Page 46: ...maged replace them 8 Install new seals ensure order is as shown in diagram NOTE Special pliers part number 412 00409 can be used to aid in assembly see photo on next page Install item 10 before item 8...

Page 47: ...O RING 1 1 3 6 2 7 8 10 9 11 5 4 2 6 NOTE Follow order and orientation of seals shown in drawing Expansion ring on item 8 must point towards pressurized end of cylinder with item 10 behind it Dependin...

Page 48: ...disconnected cap off the load sense line that runs from the LSP port to port 4 on the collector a seal leak between the pressure port and load sense port will cause the pump to stay stroked 3 8 JIC c...

Page 49: ...553 02044 See Figure 3 Find a clean work area to perform this procedure 1 Remove retaining plate cap screws retaining plate dust shield o ring and nylon thrust washer Separate the spool and housing by...

Page 50: ...back up o ring that you installed Do not stop during this process because the stretched seal will want to go back to its original shape making it more difficult to install without damage NOTE If any...

Page 51: ...the spool until at least the second seal is inserted into the bore Using a plastic mallet gently and slowly tap the spool into the housing until it appears to be almost all the way home 15 Then flip t...

Page 52: ...ing tool for bushing can be ordered Bushing for 1 1 4 DIA can be ordered DISASSEMBLY REFER TO FIGURE 1 1 Remove parallel key item 8 from non splined shaft if used 2 Put motor in main holding tool with...

Page 53: ...aulic oil and grease rubber parts with vaseline REASSEMBLY 1 Place motor housing in main holding tool with flange uppermost Grease check valves item 11 check valves must have new o rings and place the...

Page 54: ...al on a 1 1 4 splined shaft 15 Turn gearwheel set counterclockwise until cardan shaft and gearwheel start to mesh 15 degrees See Figure 2 16 Turn gearwheel rim so that holes made for screws line up 17...

Page 55: ...ug located in the top of the oil expansion tank See Figure 1 If a lube reservoir is used keep adding fluid to the lube reservoir until gearbox is full and lube reservoir remains at half full The fille...

Page 56: ...Electrical...

Page 57: ...Service Manual 495B SE S 57 Last Updated 9 28 2016 ELEC SCHEMATIC 460V 3PH 60HZ 100HP 903 00106...

Page 58: ...Service Manual Last Updated 9 28 2016 495B SE S 58 ELEC SCHEMATIC 575V 3PH 60HZ 100HP 903 00149...

Page 59: ...Service Manual 495B SE S 59 Last Updated 9 28 2016 ELEC SCHEMATIC 380V 3PH 50HZ 125HP 903 00225...

Page 60: ...ment see ALTERNATOR DRIVE BELT ADJUSTMENT information Loose wire connections Be sure all wires are tightly connected Broken or open wires Replace any wires that are damaged or worn Proper electrolyte...

Page 61: ...er cable to positive terminal of extra battery Connect other end of same jumper cable to positive terminal of machine battery 6 Connect end of second jumper cable to negative terminal of extra battery...

Page 62: ...ny metal Sparks may occur causing damage to battery and personal injury ALTERNATOR DRIVE BELT ADJUSTMENT 1 Loosen alternator adjusting bolt and mounting bolt See Figure 1 2 Move alternator along adjus...

Page 63: ...M 6 The ammeter reading must be within 10 percent of rated amperage marked on alternator case 7 If reading is correct alternator is good If reading is more or less than 10 percent of rated amperage ch...

Page 64: ...damaged 2 Battery connections are dirty of loose 3 Battery is damaged 4 The ground connection is not making a good contact 5 The alternator is damaged 6 The engine is locked 7 The starter has damage 8...

Page 65: ...times between the brush and the brass ring and is especially important if an orbiting condition develops as the equipment ages COLLECTOR MAINTENANCE Under normal operating conditions the self cleaning...

Page 66: ...arm spring assemblies Because of their small size they can be broken if forced up or down In the correctly installed position the possibility of breakage is minimal LUBRICATION Electric collectors wi...

Page 67: ...and the National Institute for Automotive Service Excellence ASE are approved by the Environmental Protection Agency EPA as organizations with approved independent testing and certification programs...

Page 68: ...8 10f CONDENSER temperatures are not ambient temperatures Add to ambient 35 40 F for proper heat transfer then refer to pressure chart Example 90 F ambient temp 40 Conditions will vary for different s...

Page 69: ...Service Manual 495B SE S 69 Last Updated 9 28 2016 AIR CONDITIONER MAINTENANCE CONTINUED Barko Magnum Plus Series...

Page 70: ...Service Manual Last Updated 9 28 2016 495B SE S 70 AIR CONDITIONER MAINTENANCE CONTINUED 72 87 5 520 5 72 86 72 87 6 6 3 5 7 8675 7 21...

Page 71: ...Service Manual 495B SE S 71 Last Updated 9 28 2016 AIR CONDITIONER MAINTENANCE CONTINUED...

Page 72: ...Service Manual Last Updated 9 28 2016 495B SE S 72 AIR CONDITIONER MAINTENANCE CONTINUED...

Page 73: ...Service Manual 495B SE S 73 Last Updated 9 28 2016 AIR CONDITIONER MAINTENANCE CONTINUED...

Page 74: ...Service Manual Last Updated 9 28 2016 495B SE S 74 AIR CONDITIONER MAINTENANCE CONTINUED...

Page 75: ...Service Manual 495B SE S 75 Last Updated 9 28 2016 AIR CONDITIONER MAINTENANCE CONTINUED 1 2 3 4 5 6 2 7 8...

Page 76: ...Last Updated 9 28 2016 495B SE S 76 AIR CONDITIONER MAINTENANCE CONTINUED LDJQRVLQJ DQ SDQVLRQ 9DOYH 6 VWHP RZ 6LGH LJK 6LGH 6LJKW ODVV YDSRUDWRU 2XWOHW XFW 7HPSHUDWXUH RZ 6LGH LJK 6LGH 6 PSWRPV LDJQ...

Page 77: ...5 29 4 94 9 91 8 25 31 7 6 9 2 3 90 32 2 103 9 99 8 20 28 9 3 7 0 6 95 35 0 113 5 108 3 15 26 1 0 0 2 4 100 37 8 123 6 117 2 10 23 3 1 9 4 5 105 40 6 134 3 126 6 5 20 6 4 1 6 7 110 43 3 145 6 136 4 0...

Page 78: ...Maintenance...

Page 79: ...Cummins diesel engine Complete specifications operating instructions and maintenance and lubrication information will be found in the engine manufacturer s manuals which ship with the machine These ma...

Page 80: ...y at the same time checking for fluid leaks Because the lubricant system is the heart of the unit it is especially important that the fluid be kept clean The following procedures should be followed 1...

Page 81: ...6 After all driven gears and their bearings have been removed position gear box so that the engine adaptor is facing up Remove place bolts and lift engine adaptor up from gear box Lift pinion gear and...

Page 82: ...el housings involving more than 4 bolt holes be sure cord gasket lap joint falls behind one hole location which will be used for a bolt or stud fastener Do not lap ends behind an unused bolt hole Remo...

Page 83: ...djusting yoke to right or clockwise until operating lever requires a distinct pressure to engage A new clutch requires several adjustments until friction discs are worn in See Figure 5 For cold weathe...

Page 84: ...AGE IS DUE TO CARELESS SERVICE PROCEDURES By following the steps shown below and on the next few pages you can avoid unnecessary dust contamination to the engine The following steps should be taken on...

Page 85: ...RS Measure the restriction of the Air Cleaner with a service gauge or a water manometer at the restriction tap provided in the Air Cleaner the transfer pipe or the blower intake Replace the element on...

Page 86: ...not firmly sealed or that a dust leak exists Make certain the cause of that leak isidentifiedandrectifiedbeforereplacingthe element 5 PRESS YOUR FRESH GASKET TO SEE IF IT SPRINGS BACK Make sure your...

Page 87: ...gine If the element is not going to be changed and reassembled immediately cover the opening The only way to be sure nothing got in is to be sure nothing gets in THE IMPORTANT DON TS TO ALWAYS REMEMBE...

Page 88: ...Structural...

Page 89: ...ise a steady increase of bearing clearance which accelerates towards the end of the bearing life The last item bearing clearance can be measured and is a good means of determining the bearing conditio...

Page 90: ...et dial indicator 4 Balance the machine so as to have zero moment load on the bearing This is done by adjusting the boom angle Zero moment is when the upper race is at its lowest position at both fron...

Page 91: ...110 114 118 122 90 079 091 098 114 118 122 126 100 079 091 102 114 122 124 126 110 094 102 118 126 128 130 120 098 106 122 126 130 134 130 102 110 126 130 134 138 140 114 126 134 136 138 150 118 130 1...

Page 92: ...f machine s Operator s Manual Loose or overtorqued bolts can cause death severe injury or property damage Maintain proper bolt torque Visually check bolts daily Check torque every 100 hours BEARING LU...

Page 93: ...Trouble Shooting...

Page 94: ...pair any leaks Drain engine oil and fill with heavier weight engine oil Engine overheats Low coolant level Loose worn or broken fan belt Radiator plugged Air filter elements plugged Fill to correct le...

Page 95: ...oil viscosity Excessive load Pump not receiving hydraulic oil Damaged line Any or all of the following Replace dirty filters Clogged inlet line Clean reservoir breather vent Fill reservoir to proper l...

Page 96: ...oil Clean and tighten connections Replace engine oil Refer to Fuel and Lubricants Gauges do not work Gauge sender needs service Loose gauge ground connection Replace sender Check ground connection Ti...

Page 97: ...system not operational Repair or replace sources of leaks and blocks Repair or replace as needed Machine steering in opposite direction if applicable Lines to cylinders connected to wrong ports at st...

Page 98: ...ame non skid mat l 1 163 01115 INSTALL DRAWING platform non skid mat l 1 539 00868 NON SKID MATERIAL 6 wide AR 539 00950 NON SKID MATERIAL 12 wide AR NOTE This section of the manual is used for the de...

Page 99: ...1 Banks Avenue Superior WI 54880 phone 715 395 6700 fax 800 772 2448 website www barko com email parts barko com...

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