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Barko Hydraulics 495B SD Service Manual

Stationary diesel w/tier 4 engine
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495B SD - STATIONARY DIESEL W/TIER 4 ENGINE
NOTE: 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 and Installation Information is not included in this manual. See separate
Grapple Service and Installation manual which accompanies all grapples from the factory.
The information and illustrations in this manual have been approved as accurate at the time of printing.
However, the manual may contain information on options not present on your loader. The right is reserved
by Barko Hydraulics,LLC to make changes and improvements in it's product at anytime without notice
or obligation.
Service Manual PN# 800-00405
SERVICE MANUAL
Machine
Serial Number
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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Summary of Contents for Barko Hydraulics 495B SD

  • Page 1 The information and illustrations in this manual have been approved as accurate at the time of printing. However, the manual may contain information on options not present on your loader. The right is reserved by Barko Hydraulics,LLC to make changes and improvements in it's product at anytime without notice or obligation.

  • Page 2: Table Of Contents

    Last Updated - 08/31/2016 Operation and Maintenance Manual Table of Contents INTRODUCTION ABBREVIATIONS AND SYMBOLS WARRANTY KNOW YOUR MACHINE SAFETY SUMMARY FIRE PREVENTION 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...

  • Page 4: Introduction

    Model No. Serial No. NOTE: Information in this manual is current at the time of printing. Barko Hydraulics reserves the right to make changes and improvements to it's products and manuals at any time without notice or obligation. 495B ML TM (S)

  • Page 5: Abbreviations And Symbols

    Last Updated - 08/31/2016 Operation and Maintenance Manual ABBREVIATIONS AND SYMBOLS air conditioner j.s. joystick Articulated Carrier (Art. Car.) Lbs. pounds adj. adjust or adjusting LH (lh) left hand appl. application mtg. mounting As Required Not Applicable assy assembly number Back of Cab Not Sold Separately bill of material...

  • Page 6: Warranty

    Pressures in excess of these settings render each and all Barko warranties null and void and constitute an obvious misuse and abuse of our product. Barko Hydraulics, LLC 495B ML TM (S)

  • Page 8: Know Your Machine

    Last Updated - 08/31/2016 Operation and Maintenance Manual KNOW YOUR MACHINE The following is a list of ten important safety precautions and warnings you should read through and understand before operating or servicing your machine. 1. Don't assume that because you know the control functions of other similar machinery, that you can run and/ or service the Barko Loader.

  • Page 9: Safety Summary

    Last Updated - 08/31/2016 Operation and Maintenance Manual SAFETY SUMMARY Failure to fallow safety precautions in this manual can result in death, severe personal injury and/or property damage. Carefully read safety precautions below and within this manual. Heed all decals on machine. - Indicates an immediate hazard which WILL result in severe personal injury or death.
  • Page 10 Last Updated - 08/31/2016 Operation and Maintenance Manual SAFETY SUMMARY CONTINUED... If machine malfunctions during operation, stop machine Falling boom or load will cause death or severe injury. motion as quickly as possible, lower boom to the ground Stay clear if boom or load are not grounded. and shut down the machine.
  • Page 11 Last Updated - 08/31/2016 Operation and Maintenance Manual SAFETY SUMMARY CONTINUED... High pressure hydraulic fluid can penetrate skin causing Improper load handling and/or hydraulic pressure loss death, gangrene or other severe injury. Seek immediate can cause load to impact cab guard, resulting in death or medical help to remove fluid. severe injury. Keep hands and body away from areas ejecting Do not rely on guard alone for personal protection.
  • Page 12 Last Updated - 08/31/2016 Operation and Maintenance Manual SAFETY SUMMARY CONTINUED... Always wear seat belt when operating or running ma- If this machine is equipped with electric motor driven chine. Auxiliary Oil Cooler, be sure battery is disconnected be- fore going near cooler fan. If battery is not disconnect- ed, fan may come on at any time causing severe injury.
  • Page 13 Last Updated - 08/31/2016 Operation and Maintenance Manual SAFETY SUMMARY CONTINUED... Use caution when checking items beyond your reach. Use an approved safety ladder. Do not exceed 15 PSI nozzle pressure when drying parts with compressed air. Do not direct compressed air against human skin.

  • Page 14: Fire Prevention

    Last Updated - 08/31/2016 Operation and Maintenance Manual FIRE PREVENTION This machine may have several components which are at high temperatures under normal operating conditions, such as the engine, exhaust system, brake system and transmission. Clean the machine often. High pressure washing of the machine is suggested every 1000 hours (or 6 months) and always after a spill.

  • Page 15: Model Description

    Last Updated - 08/31/2016 Operation and Maintenance Manual MODEL DESCRIPTION Hydraulic Oil Reservoir - Shouding, Power Unit & Pumps Main Boom Platform/Control Deck Stick Boom Head Assembly Counterweight Exhaust Grapple Hanger Grapple Stick Boom Rotator Grapple Cylinder Cylinders Main Boom Cylinder Grapple Arms...

  • Page 17: Safety While Servicing

    Do not weld on any structural member unless specifi- cally authorized by Barko Hydraulics. Any unauthorized Relieve all hydraulic pressure before breaking any hy- welding or welding procedures will void the warranty, draulic connection, opening the reservoir access cover, and may cause death, severe injury, property damage or or performing any maintenance on the machine.

  • Page 18: Preventive Maintenance

    Last Updated - 08/31/2016 Operation and Maintenance Manual PREVENTIVE MAINTENANCE Preventive maintenance is really just a simple matter of common sense. If you keep any piece of mechanical equipment clean and properly lubricated, and promptly replace any worn or damaged parts, you are going to "prevent" deterioration and promote long life and safe, productive service.

  • Page 19: Service Schedule

    Last Updated - 08/31/2016 Operation and Maintenance Manual SERVICE SCHEDULE 495B ML TM (S)
  • Page 20 Last Updated - 08/31/2016 Operation and Maintenance Manual SERVICE SCHEDULE CONTINUED... 495B ML TM (S)
  • Page 21 Last Updated - 08/31/2016 Operation and Maintenance Manual SERVICE SCHEDULE CONTINUED... 495B ML TM (S)
  • Page 22 Last Updated - 08/31/2016 Operation and Maintenance Manual SERVICE SCHEDULE CONTINUED... 495B ML TM (S)
  • Page 23 Last Updated - 08/31/2016 Operation and Maintenance Manual SERVICE SCHEDULE CONTINUED... 495B ML TM (S)

  • Page 24: Lubrication Points

    Last Updated - 08/31/2016 Operation and Maintenance Manual LUBRICATION POINTS (PERFORM DAILY) Grapple Arms Stabilizer Legs GREASE Grapple Rotator Stabilizer Cylinder Grapple Cylinders 10 Main Boom Cylinder 4 Grapple Hanger (2 fittings) 11 Stick Boom Cylinder HYDRAULIC Turntable Bearing & Pinion 12 Hydraulic Oil Reservoir Stick Boom Pivot 13 Swing Motor Gearbox Main Boom Pivot...

  • Page 25: Fluid Specifications

    Last Updated - 08/31/2016 Operation and Maintenance Manual FLUID SPECIFICATIONS GREASE Use grease shown on chart below, depending on the expected air temperature range. AIR TEMPERATURE RANGE Fahrenheit (F) 104 122 Celsius (C) NLGI NO. 2 HIGH TEMP. /EP NLGI O OR I ARCTIC GREASE HYDRAULIC OIL The following lists some features to look for in an oil.
  • Page 26 Last Updated - 08/31/2016 Operation and Maintenance Manual FLUID SPECIFICATIONS CONTINUED... FUEL STORAGE NOTE: Diesel fuels stored for a long time may form gum or bacteria and plug filters. Keep fuel in a clean container and store in a protected area. Water and sediment must be removed before fuel gets to the engine. Do not use de-icers to remove water from fuel. Do not depend on fuel filters to remove water. NOTE: Keep all dirt, scale, water, or other foreign material out of fuel. Store fuel drums on sides with plug up.
  • Page 27 Last Updated - 08/31/2016 Operation and Maintenance Manual SPECIAL TORQUE SPECIFICATIONS 495ML MAGNUM PLUS TM 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. In critical applications (such as Turntable Bearing Bolts and any grade 8 or grade 9 bolts), once the old bolts and nuts have been loosened, they must be replaced...

  • Page 28: General Torque Specifications

    Last Updated - 08/31/2016 Operation and Maintenance Manual GENERAL TORQUE SPECIFICATIONS See Special Torque Specifications that pertain specifically to this machine. *LUBRICATED DIA. COARSE FINE COARSE FINE 5/16 7/16 Grade 9 bolts must be used with 9/16 Grade 9 washers. GRADE 5 SAE GRADE 5 RECOMMENDED TORQUE FOOT 1-1/8 Do not re-use grade 8 or grade POUNDS 1-1/4...

  • Page 30: Hydraulic Drawing

    Last Updated - 08/31/2016 Operation and Maintenance Manual HYDRAULIC DRAWING 603-01594 495B ML TM (S)

  • Page 31: Hydraulic Servo Drawing

    Last Updated - 08/31/2016 Operation and Maintenance Manual HYDRAULIC SERVO DRAWING 603-01593 495B ML TM (S)

  • Page 32: Hydraulic Schematic

    Last Updated - 08/31/2016 Operation and Maintenance Manual HYDRAULIC SCHEMATIC 607-00185 495B ML TM (S)

  • Page 33: Hydraulic Drawing Tandem

    Last Updated - 08/31/2016 Operation and Maintenance Manual 603-01574 HYDRAULIC DRAWING TANDEM 495B ML TM (S)

  • Page 34: Hydraulic Servo Tandem

    Last Updated - 08/31/2016 Operation and Maintenance Manual HYDRAULIC SERVO TANDEM 603-01573 495B ML TM (S)

  • Page 35: Hydraulic Schematic Tandem

    Last Updated - 08/31/2016 Operation and Maintenance Manual 607-00184 HYDRAULIC SCHEMATIC TANDEM 495B ML TM (S)

  • Page 36: Hydraulic Pressure Settings (495Ml)

    Last Updated - 08/31/2016 Operation and Maintenance Manual HYDRAULIC PRESSURE SETTINGS (495ML) RELIEF VALVES The Relief Valve portion of the control valves in your Barko Loader limit the flow of hydraulic oil, which relieves the excess pressure in the hydraulic system, if for any reason pressure is built up above a predetermined, safe, maximum. CAUTION The relief valve pressure setting has been arrived at by our engineers after considerable experience with and testing of this loader.

  • Page 37: Hydraulic Pressure Adjustments

    Last Updated - 08/31/2016 Operation and Maintenance Manual HYDRAULIC PRESSURE ADJUSTMENTS PUMP ADJUSTMENTS (A11VLO-145) ADJUSTING WORKING PRESSURE (3600 PSI) AND STANDBY PRESSURE (425 PSI) 1. Install an electronic (digital) gauge on the system pressure test port (which is located on the main control valve).
  • Page 38 Last Updated - 08/31/2016 Operation and Maintenance Manual PUMP ADJUSTMENTS (AA11V-095) ADJUSTING WORKING PRESSURE (3600 PSI) AND STANDBY PRESSURE (425 PSI) Note: When setting the working pressure and standby pressure on a double pump system the two pumps must be set at equal pressures for optimal efficiency. The pressure readings from the pump output test port, or the system pressure output test port is the highest pressure from the either pump.
  • Page 39 Last Updated - 08/31/2016 Operation and Maintenance Manual PUMP ADJUSTMENTS (AA11 SAW PUMP) ADJUSTING WORKING PRESSURE (2800 PSI) AND STANDBY PRESSURE (425 PSI) 1. Install an electronic (digital) pressure gauge on the Torque Control Pump Compensator saw pressure test port located next to the pressure port on the pump.
  • Page 40 Last Updated - 08/31/2016 Operation and Maintenance Manual HYDRAULIC PRESSURE ADJUSTMENT CONTINUED... K170 UPPER VALVE ADJUSTMENTS NOTE: The Pilot Filter must be removed and cleaned every 1000 hours. Main Relief - 4000 PSI non-adjustable. Pilot Relief - 450 PSI non-adjustable. Port Reliefs for all boom and swing functions are non-adjustable.
  • Page 41 L90 LOWER VALVE BANK ADJUSTMENTS Last Updated - 08/31/2016 Operation and Maintenance Manual HYDRAULIC PRESSURE ADJUSTMENT CONTINUED... L90 LOWER VALVE BANK ADJUSTMENTS (558-01627) Sections with Feed Reducers: Sections 1 and 3 are equipped with adjustable feed reducers to control pressure. When making adjustments on the feed reducers, install a gauge on the load sense test port located on the pump.

  • Page 42: Hydraulic Reservoir Maintenance

    Last Updated - 08/31/2016 Operation and Maintenance Manual HYDRAULIC RESERVOIR MAINTENANCE The supply source for the hydraulic system, the oil DRAINING THE RESERVOIR reservoir, is located behind the cab. A sight gauge for 1. First, be sure boom is lowered to the ground and checking oil level is located on the reservoir next to the secure.

  • Page 43: Hydraulic Filter Maintenance

    Last Updated - 08/31/2016 Operation and Maintenance Manual HYDRAULIC FILTER MAINTENANCE NOTE: On a new machine the filter elements must be changed after the first 100 hours of operating time and then every 400 hours after that. THE RETURN FILTER (See Figure 1) The Return Filters (565-00116) are welded into the top of the hydraulic oil reservoir. The filter heads must be unbolted, twisted, and lifted off to reveal the filter element which can then be removed and replaced. When maintaining the hydraulic system, keep all parts clean and remove all dirt from the area before you begin disas- sembly.
  • Page 44 Last Updated - 08/31/2016 Operation and Maintenance Manual HYDRAULIC FILTER MAINTENANCE CONTINUED... 5. Screw element on by hand until tight, to seat gasket in groove. 6. Loosen element. 7. Retighten element until it contacts gasket, then tighten 1/2 to 3/4 of a turn. 8.

  • Page 45: Eliminating Air From The System

    Last Updated - 08/31/2016 Operation and Maintenance Manual ELIMINATING AIR FROM THE SYSTEM All hydraulic fluid contains some dissolved air, usually about 10% by volume. Under increased pressure, the fluid will absorb much more air. Aeration in a hydraulic circuit is the presence of free air in places where there ought to be only fluid. Usually the air will be in the form of bubbles dispersed through the fluid. Difficulties with aeration will occur more frequently as flow velocities increase in hydraulic components. This section covers some of the causes of air being introduced into a system and the suggested practices to effectively reduce and eliminate this problem.

  • Page 46: Hydraulic Fittings, Hoses & Tubing

    Last Updated - 08/31/2016 Operation and Maintenance Manual HYDRAULIC FITTINGS, HOSES & TUBING A heavy wall tubing and multi-wire hose network carries the hydraulic oil from the reservoir to the pumps and valves and then to cylinders and motors and finally back to the reservoir. Operating pressure of the hydraulic system varies from model to model. For your loader, consult the Hydraulic Pressure Warning Sheet in this manual.

  • Page 47: Hydraulic Cylinder Maintenance

    Last Updated - 08/31/2016 Operation and Maintenance Manual HYDRAULIC CYLINDER MAINTENANCE Hydraulic cylinders provide force used to operate booms, attachment, and stabilizers. Proper maintenance of cylinders will promote long life and smooth operation. Inspect cylinders daily for leaks or damage and repair or replace as necessary. Lubricate cylinder grease fittings daily. Cylinder shown may not be type used on your machine but is shown as a reference. BUSHING GREASE FITTING...
  • Page 48 Last Updated - 08/31/2016 Operation and Maintenance Manual Piston and Gland shown may not be type used on your machine but are shown as a reference. Piston SEAL PLIERS (PART # 412-00409) BEING USED TO BEND SEAL FOR INSTALLATION. Gland NOTE: Follow order and orientation of seals shown in drawing.

  • Page 49: Hydraulic Collector Maintenance

    Last Updated - 08/31/2016 Operation and Maintenance Manual HYDRAULIC COLLECTOR MAINTENANCE (SYMPTOMS OF A DEFECTIVE COLLECTOR) TROUBLE SHOOTING 1. External leaks on collector. 2. Failure to achieve system pressure (3600 PSI) on the main up and stick boom functions at one half throttle or less.
  • Page 50 Last Updated - 08/31/2016 Operation and Maintenance Manual COLLECTOR TROUBLE SHOOTING CONTINUED... K170 UPPER VALVE BANK Pilot Relief Active Fill (pressure reducing valve) Valve Inlet Cover Outlet Cover Pilot Counter Port Reliefs (with pressure in) Supply Pressure Counter (non-adjustable) Port Valve Pressure Valve...
  • Page 51 Last Updated - 08/31/2016 Operation and Maintenance Manual COLLECTOR TROUBLE SHOOTING CONTINUED... Walk the clean or new thrust washer down the spool from seal groove to flow groove. Install the lower dust shield o-ring onto the spool. Using new clean oil, lightly oil the back-up o-rings, seals, and the stretching mandrel. Install only the first back-up o-ring onto the spool (DO NOT install all of the back-up o-rings at once!). Using your finger tips, (not fingernails) gently work the first seal down onto the stretching mandrel and allow at least 5 minutes before removing. After five minutes on the stretching mandrel, remove the stretched seal. Gently insert the I.D. of the seal into the 1st seal groove and gently walk it into the next seal groove. Then gently work the seal into the 1st flow groove and repeat from flow groove to seal groove and so on until you get it in place over the first back-up o-ring that you installed.
  • Page 52 Last Updated - 08/31/2016 Operation and Maintenance Manual COLLECTOR TROUBLE SHOOTING CONTINUED... 11. Place the clean housing on a clean, firm work surface with the chamfer facing up. 12. Lightly oil the bore of the housing and the seals that are installed on the spool. 13. Install both wear rings. 14. Carefully place the spool into the chamfer. Gently (by hand) apply downward pressure on the spool until at least the second seal is inserted into the bore.

  • Page 53: Swing Motor Maintenance (Danfoss)

    Last Updated - 08/31/2016 Operation and Maintenance Manual SWING MOTOR MAINTENANCE (DANFOSS) TOOLS REQUIRED FOR SERVICING Socket Set. 0.15" screwdriver. 0.08" screwdriver. 3.5 mm screw tap (shortened). Torx spanner, type T30. Main holding tool (horse shoe). - can be ordered. Holding tool for bushing.
  • Page 54 Last Updated - 08/31/2016 Operation and Maintenance Manual SWING MOTOR MAINTENANCE (DANFOSS) CONTINUED... 5. Remove end cover (item 17) sideways. 6. Keeping fingers under gearwheel set (item 16) to prevent parts from falling out, remove gearwheel set and the two o-rings (item 14). 7. Remove cardan shaft (item 10). 8. Remove distributor plate (item 15) and o-ring (also item 14). 9.
  • Page 55 Last Updated - 08/31/2016 Operation and Maintenance Manual SWING MOTOR MAINTENANCE (DANFOSS) CONTINUED... 12. Fill oil in output shaft (item 9) up to brim of internal splines. Then install cardan shaft (item 10). 13. Place greased o-rings (item 14) in grooves of gearwheel (item 16). Place gearwheel with recess in spline holes on same side as smallest screw aperture diameter (step hole) in gearwheel rim.

  • Page 56: Swing Motor Gearbox Maintenance (T1/02)

    Last Updated - 08/31/2016 Operation and Maintenance Manual SWING MOTOR GEARBOX MAINTENANCE (T1/02) RRT-T1/02 SINGLE-STAGE, VERTICALLY MOUNTED GEARBOX: CHECKING FLUID LEVELS An elbow fitting (with an oil expansion tank and an oil breather/filler plug in it) is located in the top side of the gearbox. The oil expansion tank should rise above the very top of the gearbox, and the fluid level should be kept at just less than half way up the expansion tank. See Figure 1. If a separate lube reservoir is used (it is connected to the gearbox with a hose),it must be kept at half full. FLUID TYPE Use EP80-90 Gear Fluid in gearbox and lube reservoir (if used).

  • Page 58: Electrical Schematic

    Last Updated - 08/31/2016 Operation and Maintenance Manual ELECTRICAL SCHEMATIC 495B ML TM (S)

  • Page 59: Electric Drawing Servo

    Last Updated - 08/31/2016 Operation and Maintenance Manual ELECTRIC DRAWING SERVO 495B ML TM (S)

  • Page 60: Electrical System Maintenance

    Last Updated - 08/31/2016 Operation and Maintenance Manual ELECTRICAL SYSTEM MAINTENANCE ELECTRICAL SYSTEM DESCRIPTION This machine has 12 Volt electrical system with alternator, negative ground, and 12 Volt battery. There are two basic circuits in the electrical system: 1. Charging circuit (alternator and battery). 2.
  • Page 61 Last Updated - 08/31/2016 Operation and Maintenance Manual ELECTRICAL SYSTEM MAINTENANCE CONTINUED... USING AN EXTRA BATTERY TO START MACHINE If necessary to use an extra battery and "jumper" cables to start engine, be careful. This is a two-person operation. There must be one person in operator's seat and one person to connect and disconnect battery cables. Lead-acid batteries produce flammable and explosive gases. Keep arcs, sparks, flames and lighted tobacco away from battery.
  • Page 62 Last Updated - 08/31/2016 Operation and Maintenance Manual ELECTRICAL SYSTEM MAINTENANCE CONTINUED... INSTALLING A NEW BATTERY 1. Remove battery cables. Remember position of positive terminal and negative terminal so you can connect them again correctly. 2. Remove battery hold-down bar. Remove battery from compartment. 3.
  • Page 63 Last Updated - 08/31/2016 Operation and Maintenance Manual ELECTRICAL SYSTEM MAINTENANCE CONTINUED... 3. If any of these tests show zero voltage, repair or replace wiring. 4. Check voltage again until correct reading appears. CHECKING ALTERNATOR OUTPUT 1. Disconnect negative battery cable. 2.
  • Page 64 Last Updated - 08/31/2016 Operation and Maintenance Manual ELECTRICAL SYSTEM MAINTENANCE CONTINUED... TROUBLE SHOOTING THE ELECTRICAL SYSTEM The following trouble shooting chart is provided as an assistance in locating and correcting problems which are most common. PROBLEM CAUSE Battery does not hold it's charge. 1, 2, 3, 4, 5 Alternator will not charge.

  • Page 65: Electric Collector Maintenance

    Last Updated - 08/31/2016 Operation and Maintenance Manual ELECTRIC COLLECTOR MAINTENANCE Hex Lock Nuts Acorn Nut Nylon Rub Disk Cap Screw Cover Set Screw-Type Connectors Brush Holding Stud Knife Disconnect Terminals with Plastic Sleeves Outboard Bearing (nylon) Brush/Arm/Spring Assemblies Set Collar (socket screw-type) Core Assembly (has brass rings that brushes ride on) Nylon Bearing...
  • Page 66 Last Updated - 08/31/2016 Operation and Maintenance Manual ELECTRIC COLLECTOR MAINTENANCE CONTINUED... 1. Remove the hex lock nuts and washers at the top of the brush holding stud along with the outboard bearing, if used. This will allow the brush assemblies to be removed. NOTE: Some smaller collectors use cap screws or may be equipped with socket screw-type set collars instead of hex nuts.

  • Page 67: Air Conditioner Maintenance

    Last Updated - 08/31/2016 Operation and Maintenance Manual AIR CONDITIONER MAINTENANCE Air Conditioner components are shown above connected together to illustrate system operation. The components shown are not to scale. The refrigerant and refrigerant oil are clear in color and not visible in this drawing. The small arrows inside the components and connecting hoses show the direction of refrigerant flow. The location of each component is in parenthesis.
  • Page 68 Last Updated - 08/31/2016 Operation and Maintenance Manual AIR CONDITIONER MAINTENANCE CONTINUED... CHECKING/ADDING REFRIGERANT Allow only certified personnel to service the heater/air conditioner system. The chart below shows relative temperatures and pressures for the system. Generally, for most Barko machines, 3 pounds of refrigerant is required for the system to operate properly. However, use the chart below to determine the exact amount. R-134a Temperature Pressure Chart TEMP F.
  • Page 69 Last Updated - 08/31/2016 Operation and Maintenance Manual AIR CONDITIONER MAINTENANCE CONTINUED... Barko Magnum Plus Series                         ...
  • Page 70 Last Updated - 08/31/2016 Operation and Maintenance Manual AIR CONDITIONER MAINTENANCE CONTINUED... 495B ML TM (S)
  • Page 71 Last Updated - 08/31/2016 Operation and Maintenance Manual AIR CONDITIONER MAINTENANCE CONTINUED... 495B ML TM (S)
  • Page 72 Last Updated - 08/31/2016 Operation and Maintenance Manual AIR CONDITIONER MAINTENANCE CONTINUED...      495B ML TM (S)
  • Page 73 Last Updated - 08/31/2016 Operation and Maintenance Manual AIR CONDITIONER MAINTENANCE CONTINUED... 495B ML TM (S)
  • Page 74 Last Updated - 08/31/2016 Operation and Maintenance Manual AIR CONDITIONER MAINTENANCE CONTINUED...               495B ML TM (S)
  • Page 75 Last Updated - 08/31/2016 Operation and Maintenance Manual AIR CONDITIONER MAINTENANCE CONTINUED... 495B ML TM (S)
  • Page 76 Last Updated - 08/31/2016 Operation and Maintenance Manual AIR CONDITIONER MAINTENANCE CONTINUED...                             ...
  • Page 77 Last Updated - 08/31/2016 Operation and Maintenance Manual AIR CONDITIONER MAINTENANCE CONTINUED... Typical Manifold Gauge Set PRESSURE TEMPERATURE CHART °F °C HFC 134a CFC-12 °F °C HFC 134a CFC-12 -51.1 21.8 19.0 12.8 51.1 52.0 -48.3 20.4 17.3 15.6 57.3 57.7 -45.6 18.7...

  • Page 79: Engine Maintenance

    Last Updated - 08/31/2016 Operation and Maintenance Manual ENGINE MAINTENANCE The standard source of power for the hydraulic system in this machine is a 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 manuals may also include information on other, similar, engines.

  • Page 80: Pump Drive Maintenance

    Last Updated - 08/31/2016 Operation and Maintenance Manual PUMP DRIVE MAINTENANCE (FOR FUNK PUMP DRIVES) TWO, THREE AND FOUR PAD PUMP DRIVES 2 PAD PUMP DRIVE 3 PAD PUMP DRIVE 4 PAD PUMP DRIVE Figure 1 LUBRICANT RECOMMENDATIONS AND FLUID CHANGING PROCEDURES Lubricant Type: EP 80-90 gear fluid (except for direct drive models).
  • Page 81 Last Updated - 08/31/2016 Operation and Maintenance Manual PUMP DRIVE MAINTENANCE CONTINUED... 6. Clean all magnetic drain plugs before replacing. 7. Always use clean fluid in clean containers. 8. Do not overfill. This will result in overheating and possible malfunction of the unit. 9. Fill with EP 80-90 gear fluid (until fluid comes back out of the fill hole). Do not overfill! 10. Maximum operating fluid temperature: 225 degrees F. (107.2 degrees C.) PUMP DRIVE DISASSEMBLY 1. Drain fluid from pump drive gear box by removing Allen head pipe plug from bottom of main case. 2. Remove hydraulic pumps by removing capscrews, or nuts from studs. See Figure 2. Remove pumps straight away from pump drive.
  • Page 82 Last Updated - 08/31/2016 Operation and Maintenance Manual PUMP DRIVE MAINTENANCE CONTINUED... NOTE: Drive in direction of arrow. 8. To remove bearings from gear hubs, use gear puller or Arbor Press. REASSEMBLY OF PUMP DRIVE For reassembly, use the reverse procedure of 1 through 8. NOTE: Plastic cord used for gasket material under pump adaptor plates and input housing is not reusable.
  • Page 83 Last Updated - 08/31/2016 Operation and Maintenance Manual PUMP DRIVE MAINTENANCE CONTINUED... SINGLE PAD PUMP DRIVES This type of Pump Drive (See Figure 4), is mounted to the engine, and is virtually maintenance free. If a Disconnect Clutch (optional) is ordered on your machine, the following maintenance must be done. DISCONNECT CLUTCH (OPTIONAL) If clutch does not pull, heats, or operating lever jumps out, adjustment is required.

  • Page 84: Air Cleaner Maintenance

    Last Updated - 08/31/2016 Operation and Maintenance Manual AIR CLEANER MAINTENANCE Proper air cleaner servicing will result in maximum engine protection against the ravages of dust. Proper servicing can also save you time and money by increasing filter life and dust cleaning efficiency. Two of the most common servicing problems are: 1. Over-servicing: New filter elements increase in dust cleaning efficiency as dust builds up on the media. DON'T BE FOOLED by filter appearance, it should look dirty. By using proper filter restriction measurement tools you will use the full life of the filter at maximum efficiency. 2. Improper Servicing: Your engine is highly vulnerable to abrasive dust contaminants during the servicing process. THE MOST COMMON CAUSE OF ENGINE DAMAGE IS DUE TO CARELESS SERVICE PROCEDURES.
  • Page 85 Last Updated - 08/31/2016 Operation and Maintenance Manual AIR CLEANER MAINTENANCE CONTINUED... AIR CLEANERS WITH VACUATOR VALVE On vacuator valve equipped models, (see figure 3) dust DUST CUP cup service is cut to a minimum. A quick check to see that the vacuator valve is not inverted, damaged, or plugged is all that is necessary.
  • Page 86 Last Updated - 08/31/2016 Operation and Maintenance Manual AIR CLEANER MAINTENANCE CONTINUED... IMPORTANT STEPS TO FOLLOW EVERY TIME AN AIR CLEANER ELEMENT IS REPLACED: 1 REMOVE THE 5 PRESS YOUR OLD ELEMENT FRESH GASKET AS GENTLY TO SEE IF IT AS POSSIBLE SPRINGS BACK Loosen wing nut and remove old element.
  • Page 87 Last Updated - 08/31/2016 Operation and Maintenance Manual AIR CLEANER MAINTENANCE CONTINUED... THE IMPORTANT "DON'TS" TO ALWAYS REMEMBER: DON'T DON'T REMOVE ELEMENT FOR OVERLOOK A INPECTION WORN OR DAMAGED GASKET Such a check will always do more harm to your engine IN THE HOUSING than good.
  • Page 88 Last Updated - 08/31/2016 Operation and Maintenance Manual 495B ML TM (S)

  • Page 89: Turntable Bearing Maintenance

    Last Updated - 08/31/2016 Operation and Maintenance Manual TURNTABLE BEARING MAINTENANCE The turntable bearing area is a potential pinch point. Before doing any maintenance or inspection on turntable bearing, lower boom and attachment to the ground, shut machine down to a zero energy state and put ignition key in your pocket.
  • Page 90 Last Updated - 08/31/2016 Operation and Maintenance Manual TURNTABLE BEARING MAINTENANCE CONTINUED... Possible Indicator Position Bearing Mounting Bolts Upper Bearing Mounting Surface Dial Indicator (machine) Lower Bearing Upper Bearing Lower Bearing Mounting Surface (machine) Figure 1 1. Take measurements at 8 equally spaced locations on the bearing. See Figure 2. 2. Rotate machines upper works so that the centerline of the boom is aligned with the first measuring location and the centerline of the counterweight is aligned with another measuring location.
  • Page 91 Last Updated - 08/31/2016 Operation and Maintenance Manual TURNTABLE BEARING MAINTENANCE CONTINUED... TABLE 1 Maximum Allowable Clearances (inches) for 3000 Series Ball Bearings Ball Diameter Up To: 1-1/4 1-3/8 1-1/2 1-3/4 2-1/4 2-1/2 2-3/4 Ball Path Diameter .055 .055 .055 .059 .067 .075...
  • Page 92 Last Updated - 08/31/2016 Operation and Maintenance Manual LIVE HEEL PIN UPGRADE 495B ML TM (S)
  • Page 93 Last Updated - 08/31/2016 Operation and Maintenance Manual ITEM QTY PART NO. DESCRIPTION 113-01529 PL PIN LOCK 3.125" HEX 482-00256 BOLT 2-12UNX10.5 DGP 514-00096 WASHER - 2" DIA X 4" OD X 1/4" THICK 513-01016 NUT LOCK 2-12 GRADE C 495B ML TM (S)
  • Page 94 Last Updated - 08/31/2016 Operation and Maintenance Manual TURNTABLE BEARING MAINTENANCE CONTINUED... INSPECTING THE TURNTABLE BEARING The turntable bearing area is a potential pinch point. Before doing any maintenance or inspection on turntable bearing, lower boom and attachment to the ground, shut machine down to a zero energy state and put ignition key in your pocket.
  • Page 96 Last Updated - 08/31/2016 Operation and Maintenance Manual TROUBLE SHOOTING Use this section only as a general guide to finding solutions for machine problems. If the machine should malfunction, find the problem in the headings listed then refer to the possible causes and remedies listed with the problem. The list of problems, causes, and remedies will only give an indication of where a possible problem can be and what repairs are needed. More, or other, possible servicing may be needed beyond the recommendations in the list or a factory service man may be required.
  • Page 97 Last Updated - 08/31/2016 Operation and Maintenance Manual HYDRAULIC SYSTEM PROBLEM REMEDY CAUSE Pump or motor too noisy. Low hydraulic oil supply or wrong Fill hydraulic reservoir with proper viscosity. oil. Air in hydraulic oil. Check for foamy oil. Tighten connections, replace o-rings or lines.
  • Page 98 Last Updated - 08/31/2016 Operation and Maintenance Manual TROUBLE SHOOTING CONTINUED... HYDRAULIC SYSTEM CONTINUED... PROBLEM REMEDY CAUSE Fill hydraulic reservoir with proper No machine functions. Low hydraulic oil level. oil. Plugged suction line. Clean or replace strainer. ELECTRICAL SYSTEM REMEDY PROBLEM CAUSE Battery will not charge.
  • Page 99 Last Updated - 08/31/2016 Operation and Maintenance Manual TROUBLE SHOOTING CONTINUED... MACHINE OPERATIONS PROBLEM CAUSE REMEDY Boom will not remain raised. Main or Secondary boom valve Replace valve. needs service. No oil flow or pressure. Any or all of the following: - Replace dirty filters. No servo pressure. - Fill reservoir to proper level.
  • Page 100 Last Updated - 08/31/2016 Operation and Maintenance Manual NOTE This section of the manual is used for the decal kits appropriate for the 295 ML. Those kits are: Truck Mount Auxiliary Kit (539-00940) Base Kit (539-00775) Cab Kit 2006 (539-01063) Laminated Cab Sheet (539-01050) If the decal kit information is missing from this section of your hard copy of this manual, contact your Barko dealer to obtain copies of the kits and insert...
  • Page 101 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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