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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

Содержание 495B - SE

Страница 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...

Страница 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...

Страница 3: ...Introduction...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 15: ...Maintenance...

Страница 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...

Страница 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...

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

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 28: ...Hydraulic...

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

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

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 56: ...Electrical...

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 78: ...Maintenance...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 88: ...Structural...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 93: ...Trouble Shooting...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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