BARKO LOADERS Crawler 475A Service Manual

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BARKOBARKO

BARKO

BARKOBARKO LOADERSLOADERS

LOADERS

LOADERSLOADERS

SERVICE MANUALSERVICE MANUAL

SERVICE MANUAL

SERVICE MANUALSERVICE MANUAL

475A 475A

475A

475A 475A

Machine Serial Number

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.

CrawlerCrawler

Crawler

CrawlerCrawler

012501

BARKOBARKO

BARKO

BARKOBARKO HYDRAULICS,HYDRAULICS,

HYDRAULICS,

HYDRAULICS,HYDRAULICS,

mailing: PO Box 16227, Duluth, MN 55816 shipping: 1 Banks Avenue, Superior, WI 54880 phone: 715-392-5641 fax: 715-392-3931 website: www.barko.com email: barko@barko.com

OPERATORS: 800-00040 PARTS: 800-00101 SERVICE: 800-00167OPERATORS: 800-00040 PARTS: 800-00101 SERVICE: 800-00167

OPERATORS: 800-00040 PARTS: 800-00101 SERVICE: 800-00167

OPERATORS: 800-00040 PARTS: 800-00101 SERVICE: 800-00167OPERATORS: 800-00040 PARTS: 800-00101 SERVICE: 800-00167

LLCLLC

LLC

LLCLLC

TABLE OF CONTENTSTABLE OF CONTENTS

TABLE OF CONTENTS

TABLE OF CONTENTSTABLE OF CONTENTS

INTRODUCTIONINTRODUCTION

INTRODUCTION

INTRODUCTIONINTRODUCTION

Introduction ........................................................ 4

Abbreviations and Symbols .............................. 5

Hydraulic Pressure Warning Sheet ................... 6

Warranty ............................................................7

Know Your Machine ........................................... 8

Safety Summary ................................................ 9

Fire Prevention .................................................. 13

Model Description ............................................. 14

MAINTENANCEMAINTENANCE

MAINTENANCE

MAINTENANCEMAINTENANCE

A. Preventive MaintenanceA. Preventive Maintenance

A. Preventive Maintenance

A. Preventive MaintenanceA. Preventive Maintenance

Safety While Servicing ...................................... 16

Preventive Maintenance.................................... 17

Special New-Machine Instructions..................... 17

Service Schedule .............................................. 18

Lubrication Points .............................................. 20

Fluid Specifications ........................................... 22

Special Torque Specifications .......................... 24

General Torque Specifications .........................25

B. Hydraulic System MaintenanceB. Hydraulic System Maintenance

B. Hydraulic System Maintenance

B. Hydraulic System MaintenanceB. Hydraulic System Maintenance

Hydraulic Schematic ......................................... 27

Hydraulic Pressure Settings .............................. 28

Hydraulic Pressure Adjustment Procedure ....... 30

Hydraulic Reservoir Maintenance ..................... 35

Hydraulic Oil Filter Maintenance ........................ 38

Eliminating Air From the System ........................ 41

Hydraulic Fittings, Hoses and Tubing ............... 42

Hydraulic Cylinder Maintenance ....................... 43

Collector Maintenance ...................................... 45

Valve Maintenance (A20/A35 control valves) ....47

Pump Maintenance (swing) ............................... 57

Pump Maintenance (boom & travel) .................. 58

Pump Maintenance (servo) ............................... 65

Motor Maintenance (drive) ................................. 69

Swing Motor Gearbox Maintenance (S10A) .......70

Swing Brake Maintenance ................................. 78

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1515

1515 1515

1515

2626

C. Electrical System MaintenanceC. Electrical System Maintenance

C. Electrical System Maintenance

C. Electrical System MaintenanceC. Electrical System Maintenance

Electrical System Description ........................... 83

Electrical System Inspection ............................. 83

Using an Extra Battery to Start Machine ............. 83

Alternator Drive Belt Adjustment ........................ 85

Alternator Maintenance ..................................... 85

Electrical System Trouble Shooting ..................87

D. Power Unit MaintenanceD. Power Unit Maintenance

D. Power Unit Maintenance

D. Power Unit MaintenanceD. Power Unit Maintenance

Engine Maintenance ......................................... 89

Pump Drive Maintenance .................................. 90

A. Two, Three and Four Pad Pump Drives ........ 90

B. Single Pad Pump Drives ...............................93

C. Optional Disconnect Clutch ........................... 93

Air Cleaner Maintenance ................................... 94

E. Cat 330 Crawler Lower MaintenanceE. Cat 330 Crawler Lower Maintenance

E. Cat 330 Crawler Lower Maintenance

E. Cat 330 Crawler Lower MaintenanceE. Cat 330 Crawler Lower Maintenance

Track Adjustment Procedure ............................. 99

Crawler Lower Lubrication Points ....................... 100

Crawler Lower Torque Specifications ................ 100

Final Drives - checking the oil level ................... 100

Final Drives - changing the oil ........................... 100

F. Structural MaintenanceF. Structural Maintenance

F. Structural Maintenance

F. Structural MaintenanceF. Structural Maintenance

Turntable Bearing Maintenance ........................ 102

TROUBLE SHOOTINGTROUBLE SHOOTING

TROUBLE SHOOTING

TROUBLE SHOOTINGTROUBLE SHOOTING

Trouble Shooting............................................... 107

DECALSDECALS

DECALS

DECALSDECALS

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101101

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IntroductionIntroduction

Introduction

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INTRODUCTIONINTRODUCTION

INTRODUCTION

INTRODUCTIONINTRODUCTION

Your Barko Loader has been designed and manufactured with high quality materials and care in workmanship. This manual is intended as a permanent reference to aid professioinal operator's in their work, and should be available for use at any time. If the loader is not eqipped with this manual, ask your supervisor to obtain one for you.

Understand the correct servicing procedures before servicing the loader. It is important to know the correct operating and servicing procedures of the loader and all safety precautions to prevent the possibility of property damage and/or personal injury or death.

As a professional, trained operator, you are responsible for safety, both your own and that of your co-workers. Your knowledge and use of all safety practices and correct servicing procedures in this manual, and your good judgement, can be a major factor in preventing 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 American National Standards, SAE, OSHA, etc.

ADDITIONAL INFORMATION: Logging Safety Resource Guide (APA, 95-A-1) is available from the American Pulpwood Association. This guide lists sources of videotapes, slide programs, movies, and publications on various aspects of logging safety.

DON'T FORGET - SAFETY FIRST!DON'T FORGET - SAFETY FIRST!

DON'T FORGET - SAFETY FIRST!

DON'T FORGET - SAFETY FIRST!DON'T FORGET - SAFETY FIRST!

INFORMATIONINFORMATION

INFORMATION

INFORMATIONINFORMATION

All requests for information, service or spare parts should include loader serial number. For more information contact:

Barko Hydraulics,LLC P.O. Box 16227 One Banks Avenue Duluth, MN 55816

Phone: 715-392-5641 Fax: 715-392-3931

Website: www.barko.com Email: barko@barko.com

REFERENCEREFERENCE

REFERENCE

REFERENCEREFERENCE

The Loader serial number plate is located on the left side of the cab riser.

Loader

Model No.

Serial No.

Engine

Model No.

Serial No.

NOTE:NOTE:

NOTE: Information in this manual is current at the time of printing. Barko Hydraulics reserves the right to

NOTE:NOTE:

make changes and improvements to it's products and manuals at any time without notice or obligation.

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ABBREVIATIONS AND SYMBOLSABBREVIATIONS AND SYMBOLS

ABBREVIATIONS AND SYMBOLS

ABBREVIATIONS AND SYMBOLSABBREVIATIONS AND SYMBOLS

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. = bearing CAR = Carrier coll. = collector cond. = conditioner CRL = Crawler cyl. = cylinder dia. = diameter dwg. = drawing Ft. Lbs. = Foot Pounds gal. = gallon HRT = Hydrostatic Rough Terrain carrier ill. or illus. = illustration In. Lbs. = Inch Pounds incl. = includes or including j.s. = joystick Lbs. = pounds LH (lh) = left hand mtg. = mounting N/A = Not Applicable

no. = number NSS = Not Sold Separately opt. = optional pg. = page qt. = quart RH (rh) = right hand sec. = secondary see sep. ill. = see separate illustration (means:

located elsewhere in manual) SE = Stationary Electric SER or SR = Stationary Electric Remote s/n = serial number str. = straight swhd = saw head TM = Truck Mount w/ = with

EXPLANATIONS OF OTHER OCCURRENCES IN THIS MANUAL:EXPLANATIONS OF OTHER OCCURRENCES IN THIS MANUAL:

EXPLANATIONS OF OTHER OCCURRENCES IN THIS MANUAL:

EXPLANATIONS OF OTHER OCCURRENCES IN THIS MANUAL:EXPLANATIONS OF OTHER OCCURRENCES IN THIS MANUAL:

- In a parts list, when there are item numbers with empty spaces (no description or part number), these parts have been previously deleted from that parts list and are not recorded anywhere.

- In a parts list, when there are items with no part number and a dotted line (----) is in the part number space, this means that the part number is not sold separately or is not available at this time.

- When references to "right hand" or "left hand" are used in this manual, it is done from the operator's seat in the forward operating position.

SYMBOLS USED ON MACHINESYMBOLS USED ON MACHINE

SYMBOLS USED ON MACHINE

SYMBOLS USED ON MACHINESYMBOLS USED ON MACHINE

HornHorn

Horn

IgnitionIgnition

Ignition

IgnitionIgnition Key SwitchKey Switch

Key Switch

Key SwitchKey Switch

Power OnPower On

Power On

Power OnPower On (Accessory)(Accessory)

(Accessory)

(Accessory)(Accessory)

Power OffPower Off

Power Off

Power OffPower Off

HornHorn

StarterStarter

Starter

StarterStarter

EngineEngine

Engine

EngineEngine RPMRPM

RPM

RPMRPM

SlowerSlower

Slower

SlowerSlower

AirAir

Air

AirAir ConditionerConditioner

Conditioner

ConditionerConditioner

Power OnPower On

Power On

Power OnPower On

475 A CRL 800-00167

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FasterFaster

Faster

FasterFaster

HYDRAULIC PRESSURE WARNING SHEETHYDRAULIC PRESSURE WARNING SHEET

HYDRAULIC PRESSURE WARNING SHEET

HYDRAULIC PRESSURE WARNING SHEETHYDRAULIC PRESSURE WARNING SHEET

MODEL 475AMODEL 475A

MODEL 475A

MODEL 475AMODEL 475A

WARNINGWARNING

WARNING

WARNINGWARNING

MAXIMUM HYDRAULIC PRESSURE FORMAXIMUM HYDRAULIC PRESSURE FOR

MAXIMUM HYDRAULIC PRESSURE FOR

MAXIMUM HYDRAULIC PRESSURE FORMAXIMUM HYDRAULIC PRESSURE FOR THIS MACHINE IS 4,250 PSI. SETTINGSTHIS MACHINE IS 4,250 PSI. SETTINGS

THIS MACHINE IS 4,250 PSI. SETTINGS

THIS MACHINE IS 4,250 PSI. SETTINGSTHIS MACHINE IS 4,250 PSI. SETTINGS HIGHER THAN THIS MAY RESULT INHIGHER THAN THIS MAY RESULT IN

HIGHER THAN THIS MAY RESULT IN

HIGHER THAN THIS MAY RESULT INHIGHER THAN THIS MAY RESULT IN HARM TO PERSONS AND PROPERTY.HARM TO PERSONS AND PROPERTY.

HARM TO PERSONS AND PROPERTY.

HARM TO PERSONS AND PROPERTY.HARM TO PERSONS AND PROPERTY.

In many instances, we have learned that the hydraulic relief valves of this equipment have been reset, increasing the maximum system pressure, and with it, the load the unit will lift before the relief valve opens. In some instances, the consequences of increasing this setting have been serious. The function of the relief valve is to provide a fuse action to protect the machine and the operator from overloading. When overloaded, different portions of the machine can become stressed to a level where parts fracture and serious physical damage to the equipment and personnel can result.

Accordingly, you are advised that the setting of this valve is limited to a maximum of 4,250 psi.4,250 psi.

4,250 psi. Pressure settings in excess of this level render each and all Barko

4,250 psi.4,250 psi. warranties null and void and constitute an obvious misuse and abuse of our product.

This is an extremely dangerous practice. This is an extremely dangerous practice.

This is an extremely dangerous practice.

This is an extremely dangerous practice. This is an extremely dangerous practice.

NOTE:NOTE:

NOTE:

NOTE:NOTE:

4,250 PSI is the pump compensator pressure. Other pressure settings4,250 PSI is the pump compensator pressure. Other pressure settings

4,250 PSI is the pump compensator pressure. Other pressure settings

4,250 PSI is the pump compensator pressure. Other pressure settings4,250 PSI is the pump compensator pressure. Other pressure settings may be lower, and must be noted.may be lower, and must be noted.

may be lower, and must be noted.

may be lower, and must be noted.may be lower, and must be noted.

475 A CRL 800-00167

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BARKO HYDRAULICS, LLCBARKO HYDRAULICS, LLC

BARKO HYDRAULICS, LLC

BARKO HYDRAULICS, LLCBARKO HYDRAULICS, LLC

WARRANTYWARRANTY

WARRANTY

WARRANTYWARRANTY

BARKO HYDRAULICS, LLCBARKO HYDRAULICS, LLC

BARKO HYDRAULICS, LLC

BARKO HYDRAULICS, LLCBARKO HYDRAULICS, LLC

BARKO HYDRAULICS, L.L.C. ("Barko") warrants to the Distributor and/or original Buyer each new hydraulic knuckle boom loader, feller buncher or other product in BARKO HYDRAULICS Equipment Group including attach-

ments and accessories thereto, ("Product") sold by BARKO to be free from defects in material and workmanship under normal use, maintenance and service. BARKO will cause any major structural component of a BARKO product covered by this warranty which proves to be defective in material or workmanship under normal use, maintenance and service within three (3) years ) or 6,000 hours, whichever occurs first from first day in service, provided first day in service is not later than one (1) year from delivery to Distributor and/or original Buyer or other user, to be replaced without charge with a new or repaired part, at BARKO election. BARKO also will cause the labor to remove any such defective part and to install the new or repaired part to be provided without charge to the owner of said BARKO product. The parts and labor to meet this warranty will be furnished by designated BARKO distributor. BARKO will cause all other parts of product covered by this warranty which proves to be defective in material or workmanship under normal use, maintenance and service within one (1 ) year or 2,000 hours, whichever occurs first from first day in service, provided first day in service is not later than one (1) year from delivery to Distributor and/or original Buyer or other user, to be replaced, without charge, with a new or repaired part, at BARKO election. BARKO also will cause the labor to remove any such defective part and to install the new or repaired part to be provided without charge to the owner of said BARKO product. The parts and labor to meet this warranty will be furnished by BARKO designated distributor. BARKO warrants all service parts purchased from BARKO and used on a BARKO manufactured unit, to be free from defects in material and workmanship under normal use, maintenance and service for a period of six (6) months or 1,000 hours, whichever occurs first. BARKO will cause any such part which proves to be defective to be replaced with a new or repaired part at BARKO election on a parts only basis. Proof of any defect must be submitted to BARKO within ten (10) days from the date on which the defect was discovered and any claim submitted within thirty (30) days after repair work is completed.

BARKO warranty does not cover: 1 Defects, damage or deterioration due to normal use, wear, tear, exposure, storage or corrosion.

2. Normal maintenance service, including replacement of filters, oil, seals and the like.

3. Damage due to failure to maintain or use the BARKO product or part according to manuals, schedules or good practice.

4. Damage caused by abuse of equipment or parts by overloading, misapplication, improper operation or use, installation of unapproved accessories or unauthorized alterations.

5. Damage resulting from repairs made in an unauthorized manner or installation of components not authorized by BARKO.

6. The labor to remove and reinstall a defective replacement part after the expiration of the warranty period applicable to the product in which part is located.

7. Overtime labor premiums.

8. Transportation of the BARKO product to the distributor's service facility or transportation of the distributor's serviceman to the product's location.

9. Vendor components not manufactured by BARKO, such as engines, transmissions and components, Tires, batteries or other parts normally warrantied and serviced by the manufacturer. The warranty of the respective manufacturers of these components shall apply.

The Buyer accepts this warranty and the limitations and disclaimers set forth herein as part of the purchase of the BARKO product or part to which this warranty applies. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED, STATUTORY, WRITTEN OR ORAL, AND THERE IS NO IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Remedies available to any person claiming under this warranty are exclusive and expressly limited to obtaining the parts and the labor, where applicable, in accordance with terms of this warranty. BARKO liability for losses, damages or expenses of any kind arising from the design, manufacture or sale of the product covered by this warranty, whether based on warranty, negligence, contract, tort or otherwise, is limited to an amount not exceeding the cost of correcting the defects as herein provided, and, at the expiration of the applicable warranty period, all such liability shall terminate. BARKO shall in no event be liable for incidental, consequential or special damages to losses of use of the BARKO product, a loss or damage to property other than the BARKO product, a loss of profits or other commercial loss, or any special or consequential damages (except liability for consequential damages which by law may not be disclaimed).

Revised 2/98

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KNOW YOUR MACHINEKNOW YOUR MACHINE

KNOW YOUR MACHINE

KNOW YOUR MACHINEKNOW 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.

1.1.

Don't assume that because you know the control functions of other similar machinery, that you can run and/

1.1.

Don't assume that because you know the control functions of other similar machinery, that you can run and/Don't assume that because you know the control functions of other similar machinery, that you can run and/ or service the Barko Loader. All machines differ in some ways, and these differences must be noted andor service the Barko Loader. All machines differ in some ways, and these differences must be noted and

or service the Barko Loader. All machines differ in some ways, and these differences must be noted and

or service the Barko Loader. All machines differ in some ways, and these differences must be noted andor service the Barko Loader. All machines differ in some ways, and these differences must be noted and

acknowledged. Read this manual thoroughly and understand all safety, operating, and servicingacknowledged. Read this manual thoroughly and understand all safety, operating, and servicing

acknowledged. Read this manual thoroughly and understand all safety, operating, and servicing

acknowledged. Read this manual thoroughly and understand all safety, operating, and servicingacknowledged. Read this manual thoroughly and understand all safety, operating, and servicing procedures before using the loader.procedures before using the loader.

procedures before using the loader.

procedures before using the loader.procedures before using the loader.

2.2.

Know how to put your machine in a zero energy state for purposes of inspection, maintenance, or repair.Know how to put your machine in a zero energy state for purposes of inspection, maintenance, or repair.

Know how to put your machine in a zero energy state for purposes of inspection, maintenance, or repair.

2.2.

3.3.

Clear operating area of all obstacles and personnel before operating loader.Clear operating area of all obstacles and personnel before operating loader.

Clear operating area of all obstacles and personnel before operating loader.

3.3.

Clear operating area of all obstacles and personnel before operating loader.Clear operating area of all obstacles and personnel before operating loader.

4.4.

Never approach power lines with any part of the machine or load! Current in a high voltage power line mayNever approach power lines with any part of the machine or load! Current in a high voltage power line may

Never approach power lines with any part of the machine or load! Current in a high voltage power line may

4.4.

arc some distance to jump from the wire to a nearby "ground". KEEP WELL CLEAR!arc some distance to jump from the wire to a nearby "ground". KEEP WELL CLEAR!

arc some distance to jump from the wire to a nearby "ground". KEEP WELL CLEAR!

arc some distance to jump from the wire to a nearby "ground". KEEP WELL CLEAR!arc some distance to jump from the wire to a nearby "ground". KEEP WELL CLEAR!

5.5.

Allow only the operator on the machine. Keep riders off. Riders on machine are subject to injury such asAllow only the operator on the machine. Keep riders off. Riders on machine are subject to injury such as

Allow only the operator on the machine. Keep riders off. Riders on machine are subject to injury such as

5.5.

being struck by foreign objects and being thrown off the machine. Riders also obstruct the operator's view,

being struck by foreign objects and being thrown off the machine. Riders also obstruct the operator's view,being struck by foreign objects and being thrown off the machine. Riders also obstruct the operator's view, resulting in the machine being operated in an unsafe manner.resulting in the machine being operated in an unsafe manner.

resulting in the machine being operated in an unsafe manner.

resulting in the machine being operated in an unsafe manner.resulting in the machine being operated in an unsafe manner.

6.6.

Never use a boom or attachment for a work platform or personnel carrier. Serious injury or death mayNever use a boom or attachment for a work platform or personnel carrier. Serious injury or death may

Never use a boom or attachment for a work platform or personnel carrier. Serious injury or death may

6.6.

result.result.

result.

result.result.

7.7.

When machine is not operating or when leaving cab, boom and attachment must be lowered to the ground.When machine is not operating or when leaving cab, boom and attachment must be lowered to the ground.

When machine is not operating or when leaving cab, boom and attachment must be lowered to the ground.

7.7.

Failure to do so may allow boom or attachment to move, causing property damage, injury, or death.Failure to do so may allow boom or attachment to move, causing property damage, injury, or death.

Failure to do so may allow boom or attachment to move, causing property damage, injury, or death.

Failure to do so may allow boom or attachment to move, causing property damage, injury, or death.Failure to do so may allow boom or attachment to move, causing property damage, injury, or death.

8.8.

Do not tamper with any hydraulic line when it is pressurized. Escaping fluid under pressure can penetrateDo not tamper with any hydraulic line when it is pressurized. Escaping fluid under pressure can penetrate

Do not tamper with any hydraulic line when it is pressurized. Escaping fluid under pressure can penetrate

8.8.

the skin, causing serious injury. Relieve pressure before unhooking hydraulic or other lines. Tighten all

the skin, causing serious injury. Relieve pressure before unhooking hydraulic or other lines. Tighten allthe skin, causing serious injury. Relieve pressure before unhooking hydraulic or other lines. Tighten all connections before applying pressure. Keep hands and body away from pinholes and nozzles which ejectconnections before applying pressure. Keep hands and body away from pinholes and nozzles which eject

connections before applying pressure. Keep hands and body away from pinholes and nozzles which eject

connections before applying pressure. Keep hands and body away from pinholes and nozzles which ejectconnections before applying pressure. Keep hands and body away from pinholes and nozzles which eject fluids under high pressure. Use a piece of cardboard to search for leaks.fluids under high pressure. Use a piece of cardboard to search for leaks.

fluids under high pressure. Use a piece of cardboard to search for leaks.

fluids under high pressure. Use a piece of cardboard to search for leaks.fluids under high pressure. Use a piece of cardboard to search for leaks.

If any fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiarIf any fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar

If any fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar

with this type of injury or gangrene may result.with this type of injury or gangrene may result.

with this type of injury or gangrene may result.

with this type of injury or gangrene may result.with this type of injury or gangrene may result.

9.9.

Under no circumstances should any modifications be made to Barko machinery without factoryUnder no circumstances should any modifications be made to Barko machinery without factory

Under no circumstances should any modifications be made to Barko machinery without factory

9.9.

Under no circumstances should any modifications be made to Barko machinery without factoryUnder no circumstances should any modifications be made to Barko machinery without factory

authorization. Any modifications may void the warranty. This machine was designed to do a specific job

authorization. Any modifications may void the warranty. This machine was designed to do a specific jobauthorization. Any modifications may void the warranty. This machine was designed to do a specific job and alterations could result in property damage, injury or death.and alterations could result in property damage, injury or death.

and alterations could result in property damage, injury or death.

and alterations could result in property damage, injury or death.and alterations could result in property damage, injury or death.

10.10.

Replace any safety decals that are faded, torn, missing, illegible, or otherwise damaged. See yourReplace any safety decals that are faded, torn, missing, illegible, or otherwise damaged. See your

10.

Replace any safety decals that are faded, torn, missing, illegible, or otherwise damaged. See your

10.10.

Replace any safety decals that are faded, torn, missing, illegible, or otherwise damaged. See yourReplace any safety decals that are faded, torn, missing, illegible, or otherwise damaged. See your

machine's Decals section for decal kits applicable to your machine and for locations of all decals.machine's Decals section for decal kits applicable to your machine and for locations of all decals.

machine's Decals section for decal kits applicable to your machine and for locations of all decals.

machine's Decals section for decal kits applicable to your machine and for locations of all decals.machine's Decals section for decal kits applicable to your machine and for locations of all decals.

Don't stop here - read on.Don't stop here - read on.

Don't stop here - read on.

Don't stop here - read on.Don't stop here - read on.

475 A CRL 800-00167

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SAFETY SUMMARYSAFETY SUMMARY

SAFETY SUMMARY

SAFETY SUMMARYSAFETY SUMMARY

Failure to follow 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.

DANGERDANGER

DANGER - Indicates an immediate hazard which WILL result in severe personal injury or death.

DANGERDANGER

WARNING WARNING

WARNING - Indicates a hazard or unsafe practice which COULD result in severe personal injury or death.

WARNING WARNING

CAUTION CAUTION

CAUTION - Indicates a hazard or unsafe practice which could result in minor personal injury or property

CAUTION CAUTION

Never approach power lines with any part of theNever approach power lines with any part of the

Never approach power lines with any part of the

Never approach power lines with any part of theNever approach power lines with any part of the machine. Current in a high voltage line may arcmachine. Current in a high voltage line may arc

machine. Current in a high voltage line may arc

machine. Current in a high voltage line may arcmachine. Current in a high voltage line may arc some distance to jump from the wire to a nearbysome distance to jump from the wire to a nearby

some distance to jump from the wire to a nearby

some distance to jump from the wire to a nearbysome distance to jump from the wire to a nearby "ground". KEEP WELL CLEAR!"ground". KEEP WELL CLEAR!

"ground". KEEP WELL CLEAR!

"ground". KEEP WELL CLEAR!"ground". KEEP WELL CLEAR!

damage.

DANGER DANGER

DANGER

DANGER DANGER

WARNING WARNING

WARNING

WARNING WARNING

Combustible and flammable fluids can causeCombustible and flammable fluids can cause

Combustible and flammable fluids can cause

Combustible and flammable fluids can causeCombustible and flammable fluids can cause death or severe injury. Do not smoke or permitdeath or severe injury. Do not smoke or permit

death or severe injury. Do not smoke or permit

death or severe injury. Do not smoke or permitdeath or severe injury. Do not smoke or permit open flames near fuels or hydraulic fluids. Do notopen flames near fuels or hydraulic fluids. Do not

open flames near fuels or hydraulic fluids. Do not

open flames near fuels or hydraulic fluids. Do notopen flames near fuels or hydraulic fluids. Do not fill the tanks to capacity - allow room for fluidfill the tanks to capacity - allow room for fluid

fill the tanks to capacity - allow room for fluid

fill the tanks to capacity - allow room for fluidfill the tanks to capacity - allow room for fluid expansion. Do not remove the fuel cap or refuelexpansion. Do not remove the fuel cap or refuel

expansion. Do not remove the fuel cap or refuel

expansion. Do not remove the fuel cap or refuelexpansion. Do not remove the fuel cap or refuel while engine is hot, running or without properwhile engine is hot, running or without proper

while engine is hot, running or without proper

while engine is hot, running or without properwhile engine is hot, running or without proper ventilation. Never use fuel for cleaning purposes.ventilation. Never use fuel for cleaning purposes.

ventilation. Never use fuel for cleaning purposes.

ventilation. Never use fuel for cleaning purposes.ventilation. Never use fuel for cleaning purposes. Clean up any fluid spills immediately.Clean up any fluid spills immediately.

Clean up any fluid spills immediately.

Clean up any fluid spills immediately.Clean up any fluid spills immediately.

DANGER DANGER

DANGER

DANGER DANGER

Do not operate machine during electrical storms.Do not operate machine during electrical storms.

Do not operate machine during electrical storms.

Do not operate machine during electrical storms.Do not operate machine during electrical storms.

WARNING WARNING

WARNING

WARNING WARNING

Always lower boom to ground and shut downAlways lower boom to ground and shut down

Always lower boom to ground and shut down

Always lower boom to ground and shut downAlways lower boom to ground and shut down engine before leaving cab. If necessary to workengine before leaving cab. If necessary to work

engine before leaving cab. If necessary to work

engine before leaving cab. If necessary to workengine before leaving cab. If necessary to work on machine with lifted boom, securely supporton machine with lifted boom, securely support

on machine with lifted boom, securely support

on machine with lifted boom, securely supporton machine with lifted boom, securely support machine and attachment.machine and attachment.

machine and attachment.

machine and attachment.machine and attachment.

WARNING WARNING

WARNING

WARNING WARNING

Be extra careful when traveling on a slope, nearBe extra careful when traveling on a slope, near

Be extra careful when traveling on a slope, near

Be extra careful when traveling on a slope, nearBe extra careful when traveling on a slope, near ditches, congested areas or over rough ground.ditches, congested areas or over rough ground.

ditches, congested areas or over rough ground.

ditches, congested areas or over rough ground.ditches, congested areas or over rough ground. The danger of tipping is always present. KnowThe danger of tipping is always present. Know

The danger of tipping is always present. Know

The danger of tipping is always present. KnowThe danger of tipping is always present. Know your machine's capabilities.your machine's capabilities.

your machine's capabilities.

your machine's capabilities.your machine's capabilities.

WARNING WARNING

WARNING

WARNING WARNING

If machine malfunctions during operation, stopIf machine malfunctions during operation, stop

If machine malfunctions during operation, stop

If machine malfunctions during operation, stopIf machine malfunctions during operation, stop machine motion as quickly as possible, lowermachine motion as quickly as possible, lower

machine motion as quickly as possible, lower

machine motion as quickly as possible, lowermachine motion as quickly as possible, lower boom to the ground and shut down the machine.boom to the ground and shut down the machine.

boom to the ground and shut down the machine.

boom to the ground and shut down the machine.boom to the ground and shut down the machine. Service or repair the machine as needed beforeService or repair the machine as needed before

Service or repair the machine as needed before

Service or repair the machine as needed beforeService or repair the machine as needed before running or operating again.running or operating again.

running or operating again.

running or operating again.running or operating again.

DANGER DANGER

DANGER

DANGER DANGER

Falling boom or load will cause death or severeFalling boom or load will cause death or severe

Falling boom or load will cause death or severe

Falling boom or load will cause death or severeFalling boom or load will cause death or severe injury. Stay clear if boom or load are notinjury. Stay clear if boom or load are not

injury. Stay clear if boom or load are not

injury. Stay clear if boom or load are notinjury. Stay clear if boom or load are not grounded.grounded.

grounded.

grounded.grounded. Clear all persons from area of operation andClear all persons from area of operation and

Clear all persons from area of operation and

Clear all persons from area of operation andClear all persons from area of operation and machine movement. Never move boom or loadsmachine movement. Never move boom or loads

machine movement. Never move boom or loads

machine movement. Never move boom or loadsmachine movement. Never move boom or loads over the heads of other persons.over the heads of other persons.

over the heads of other persons.

over the heads of other persons.over the heads of other persons.

475 A CRL 800-00167

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page 9

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SAFETY SUMMARY CONTINUED...

WARNING WARNING

WARNING

WARNING WARNING

Do not operate or work on machine until you:Do not operate or work on machine until you:

Do not operate or work on machine until you:

Do not operate or work on machine until you:Do not operate or work on machine until you:

Read and understand machine manuals, safetyRead and understand machine manuals, safety

Read and understand machine manuals, safety

Read and understand machine manuals, safetyRead and understand machine manuals, safety decals, employer work rules, and applicabledecals, employer work rules, and applicable

decals, employer work rules, and applicable

decals, employer work rules, and applicabledecals, employer work rules, and applicable government regulations.government regulations.

government regulations.

government regulations.government regulations.

Are trained and qualified in safe machineAre trained and qualified in safe machine

Are trained and qualified in safe machine

Are trained and qualified in safe machineAre trained and qualified in safe machine operation and maintenance.operation and maintenance.

operation and maintenance.

operation and maintenance.operation and maintenance.

Consult supervisor to explain any unclearConsult supervisor to explain any unclear

Consult supervisor to explain any unclear

Consult supervisor to explain any unclearConsult supervisor to explain any unclear instructions and warnings.instructions and warnings.

instructions and warnings.

instructions and warnings.instructions and warnings.

Contact Barko to replace lost manuals.

WARNING WARNING

WARNING

WARNING WARNING

Use caution when checking items beyond yourUse caution when checking items beyond your

Use caution when checking items beyond your

Use caution when checking items beyond yourUse caution when checking items beyond your reach. Use an approved safety ladder.reach. Use an approved safety ladder.

reach. Use an approved safety ladder.

reach. Use an approved safety ladder.reach. Use an approved safety ladder.

WARNING WARNING

WARNING

WARNING WARNING

Older air conditioning equipment may contain R-12,Older air conditioning equipment may contain R-12,

Older air conditioning equipment may contain R-12,

Older air conditioning equipment may contain R-12,Older air conditioning equipment may contain R-12, a substance which harms public health anda substance which harms public health and

a substance which harms public health and

a substance which harms public health anda substance which harms public health and environment by destroying ozone in the upperenvironment by destroying ozone in the upper

environment by destroying ozone in the upper

environment by destroying ozone in the upperenvironment by destroying ozone in the upper atmosphere. To remove R-12 from the airatmosphere. To remove R-12 from the air

atmosphere. To remove R-12 from the air

atmosphere. To remove R-12 from the airatmosphere. To remove R-12 from the air conditioning system, use service equipmentconditioning system, use service equipment

conditioning system, use service equipment

conditioning system, use service equipmentconditioning system, use service equipment certified to meet the requirements of S.A.E. J2209 orcertified to meet the requirements of S.A.E. J2209 or

certified to meet the requirements of S.A.E. J2209 or

certified to meet the requirements of S.A.E. J2209 orcertified to meet the requirements of S.A.E. J2209 or J1990.J1990.

J1990.

J1990.J1990.

WARNING WARNING

WARNING

WARNING WARNING

Allow only the operator on the machine. KeepAllow only the operator on the machine. Keep

Allow only the operator on the machine. Keep

Allow only the operator on the machine. KeepAllow only the operator on the machine. Keep riders off. Riders on machine are subject to deathriders off. Riders on machine are subject to death

riders off. Riders on machine are subject to death

riders off. Riders on machine are subject to deathriders off. Riders on machine are subject to death or injury from being struck by foreign objects andor injury from being struck by foreign objects and

or injury from being struck by foreign objects and

or injury from being struck by foreign objects andor injury from being struck by foreign objects and being thrown from machine. Riders also obstructbeing thrown from machine. Riders also obstruct

being thrown from machine. Riders also obstruct

being thrown from machine. Riders also obstructbeing thrown from machine. Riders also obstruct the operator's view, resulting in machine beingthe operator's view, resulting in machine being

the operator's view, resulting in machine being

the operator's view, resulting in machine beingthe operator's view, resulting in machine being operated in an unsafe manner.operated in an unsafe manner.

operated in an unsafe manner.

operated in an unsafe manner.operated in an unsafe manner.

Never use a boom attachment for a work platformNever use a boom attachment for a work platform

Never use a boom attachment for a work platform

Never use a boom attachment for a work platformNever use a boom attachment for a work platform or personnel carrier.or personnel carrier.

or personnel carrier.

or personnel carrier.or personnel carrier.

WARNING WARNING

WARNING

WARNING WARNING

Wear required personal protective equipment atWear required personal protective equipment at

Wear required personal protective equipment at

Wear required personal protective equipment atWear required personal protective equipment at all times to help prevent personal injury. Do notall times to help prevent personal injury. Do not

all times to help prevent personal injury. Do not

all times to help prevent personal injury. Do notall times to help prevent personal injury. Do not wear loose fitting clothing or personal articles,wear loose fitting clothing or personal articles,

wear loose fitting clothing or personal articles,

wear loose fitting clothing or personal articles,wear loose fitting clothing or personal articles, loose or uncovered long hair, or jewelry.loose or uncovered long hair, or jewelry.

loose or uncovered long hair, or jewelry.

loose or uncovered long hair, or jewelry.loose or uncovered long hair, or jewelry.

WARNING WARNING

WARNING

WARNING WARNING

Do not exceed 15 PSI nozzle pressure whenDo not exceed 15 PSI nozzle pressure when

Do not exceed 15 PSI nozzle pressure when

Do not exceed 15 PSI nozzle pressure whenDo not exceed 15 PSI nozzle pressure when drying parts with compressed air. Do not directdrying parts with compressed air. Do not direct

drying parts with compressed air. Do not direct

drying parts with compressed air. Do not directdrying parts with compressed air. Do not direct compressed air against human skin. Seriouscompressed air against human skin. Serious

compressed air against human skin. Serious

compressed air against human skin. Seriouscompressed air against human skin. Serious injury could result.injury could result.

injury could result.

injury could result.injury could result.

WARNING WARNING

WARNING

WARNING WARNING

Improper machine transport can cause death,Improper machine transport can cause death,

Improper machine transport can cause death,

Improper machine transport can cause death,Improper machine transport can cause death, severe injury or property damage.severe injury or property damage.

severe injury or property damage.

severe injury or property damage.severe injury or property damage. Before transporting:Before transporting:

Before transporting:

Before transporting:Before transporting:

Lower and secure boom/attachment.Lower and secure boom/attachment.

Lower and secure boom/attachment.

Lower and secure boom/attachment.Lower and secure boom/attachment.

Raise stabilizers.Raise stabilizers.

Raise stabilizers.

Raise stabilizers.Raise stabilizers.

Shut down machine to a zero energy state.Shut down machine to a zero energy state.

Shut down machine to a zero energy state.

Shut down machine to a zero energy state.Shut down machine to a zero energy state.

CAUTION CAUTION

CAUTION

CAUTION CAUTION

Use only hydraulic fluid in hydraulic oil reservoir.Use only hydraulic fluid in hydraulic oil reservoir.

Use only hydraulic fluid in hydraulic oil reservoir.

Use only hydraulic fluid in hydraulic oil reservoir.Use only hydraulic fluid in hydraulic oil reservoir. Use only diesel fuel in fuel reservoir.Use only diesel fuel in fuel reservoir.

Use only diesel fuel in fuel reservoir.

Use only diesel fuel in fuel reservoir.Use only diesel fuel in fuel reservoir.

Other fluids will cause machine damage.Other fluids will cause machine damage.

Other fluids will cause machine damage.

Other fluids will cause machine damage.Other fluids will cause machine damage.

475 A CRL 800-00167

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WARNING WARNING

WARNING

WARNING WARNING

On machines equipped with an accumulator,On machines equipped with an accumulator,

On machines equipped with an accumulator,

On machines equipped with an accumulator,On machines equipped with an accumulator, release all pressure before working on therelease all pressure before working on the

release all pressure before working on the

release all pressure before working on therelease all pressure before working on the system. After service work is done, repressurizesystem. After service work is done, repressurize

system. After service work is done, repressurize

system. After service work is done, repressurizesystem. After service work is done, repressurize the accumulator(s) to the proper specification.the accumulator(s) to the proper specification.

the accumulator(s) to the proper specification.

the accumulator(s) to the proper specification.the accumulator(s) to the proper specification.

WARNING WARNING

WARNING

WARNING WARNING

Any unauthorized welding, alterations, additionsAny unauthorized welding, alterations, additions

Any unauthorized welding, alterations, additions

Any unauthorized welding, alterations, additionsAny unauthorized welding, alterations, additions or modifications made to Barko machinery willor modifications made to Barko machinery will

or modifications made to Barko machinery will

or modifications made to Barko machinery willor modifications made to Barko machinery will void warranty. This machine was designed to dovoid warranty. This machine was designed to do

void warranty. This machine was designed to do

void warranty. This machine was designed to dovoid warranty. This machine was designed to do a specific job and alterations could result ina specific job and alterations could result in

a specific job and alterations could result in

a specific job and alterations could result ina specific job and alterations could result in death, severe injury or property damage.death, severe injury or property damage.

death, severe injury or property damage.

death, severe injury or property damage.death, severe injury or property damage.

If Barko-authorized welding must be done, firstIf Barko-authorized welding must be done, first

If Barko-authorized welding must be done, first

If Barko-authorized welding must be done, firstIf Barko-authorized welding must be done, first disconnect battery, electronic throttle, and radio,disconnect battery, electronic throttle, and radio,

disconnect battery, electronic throttle, and radio,

disconnect battery, electronic throttle, and radio,disconnect battery, electronic throttle, and radio, or electrical and structural damage may occur.or electrical and structural damage may occur.

or electrical and structural damage may occur.

or electrical and structural damage may occur.or electrical and structural damage may occur.

SAFETY SUMMARY CONTINUED...

WARNING WARNING

WARNING

WARNING WARNING

High pressure hydraulic fluid can penetrate skinHigh pressure hydraulic fluid can penetrate skin

High pressure hydraulic fluid can penetrate skin

High pressure hydraulic fluid can penetrate skinHigh pressure hydraulic fluid can penetrate skin causing death, gangrene or other severe injury.causing death, gangrene or other severe injury.

causing death, gangrene or other severe injury.

causing death, gangrene or other severe injury.causing death, gangrene or other severe injury. Seek immediate medical help to remove fluid.Seek immediate medical help to remove fluid.

Seek immediate medical help to remove fluid.

Seek immediate medical help to remove fluid.Seek immediate medical help to remove fluid.

Keep hands and body away from areasKeep hands and body away from areas

Keep hands and body away from areas

Keep hands and body away from areasKeep hands and body away from areas

ejecting fluid. Use piece of cardboard toejecting fluid. Use piece of cardboard to

ejecting fluid. Use piece of cardboard to

ejecting fluid. Use piece of cardboard toejecting fluid. Use piece of cardboard to check for leaks. Wear proper hand and eyecheck for leaks. Wear proper hand and eye

check for leaks. Wear proper hand and eye

check for leaks. Wear proper hand and eyecheck for leaks. Wear proper hand and eye protection.protection.

protection.

protection.protection.

Relieve hydraulic pressure before looseningRelieve hydraulic pressure before loosening

Relieve hydraulic pressure before loosening

Relieve hydraulic pressure before looseningRelieve hydraulic pressure before loosening

any hydraulic connections.any hydraulic connections.

any hydraulic connections.

any hydraulic connections.any hydraulic connections.

Tighten all hydraulic connections beforeTighten all hydraulic connections before

Tighten all hydraulic connections before

Tighten all hydraulic connections beforeTighten all hydraulic connections before

applying hydraulic pressure.applying hydraulic pressure.

applying hydraulic pressure.

applying hydraulic pressure.applying hydraulic pressure.

WARNING WARNING

WARNING

WARNING WARNING

Always maintain 3-point contact with handles andAlways maintain 3-point contact with handles and

Always maintain 3-point contact with handles and

Always maintain 3-point contact with handles andAlways maintain 3-point contact with handles and steps when mounting or dismounting. Neversteps when mounting or dismounting. Never

steps when mounting or dismounting. Never

steps when mounting or dismounting. Neversteps when mounting or dismounting. Never jump on or off machine. Do not rush. Walk, dojump on or off machine. Do not rush. Walk, do

jump on or off machine. Do not rush. Walk, do

jump on or off machine. Do not rush. Walk, dojump on or off machine. Do not rush. Walk, do not run.not run.

not run.

not run.not run.

WARNING WARNING

WARNING

WARNING WARNING

Improper load handling and/or hydraulic pressureImproper load handling and/or hydraulic pressure

Improper load handling and/or hydraulic pressure

Improper load handling and/or hydraulic pressureImproper load handling and/or hydraulic pressure loss can cause load to impact cab guard,loss can cause load to impact cab guard,

loss can cause load to impact cab guard,

loss can cause load to impact cab guard,loss can cause load to impact cab guard, resulting in death or severe injury.resulting in death or severe injury.

resulting in death or severe injury.

resulting in death or severe injury.resulting in death or severe injury.

Do not rely on guard alone for personalDo not rely on guard alone for personal

Do not rely on guard alone for personal

Do not rely on guard alone for personalDo not rely on guard alone for personal protection. Use safe and proper loadprotection. Use safe and proper load

protection. Use safe and proper load

protection. Use safe and proper loadprotection. Use safe and proper load handling techniques.handling techniques.

handling techniques.

handling techniques.handling techniques.

Do not operate machine with damaged orDo not operate machine with damaged or

Do not operate machine with damaged or

Do not operate machine with damaged orDo not operate machine with damaged or unsecured guard or cab.unsecured guard or cab.

unsecured guard or cab.

unsecured guard or cab.unsecured guard or cab.

Do not repair damaged guard. Replace withDo not repair damaged guard. Replace with

Do not repair damaged guard. Replace with

Do not repair damaged guard. Replace withDo not repair damaged guard. Replace with factory-authorized guard.factory-authorized guard.

factory-authorized guard.

factory-authorized guard.factory-authorized guard.

Do not modify guard without factoryDo not modify guard without factory

Do not modify guard without factory

Do not modify guard without factoryDo not modify guard without factory authorization.authorization.

authorization.

authorization.authorization.

Do not operate before conducting Pre-StartDo not operate before conducting Pre-Start

Do not operate before conducting Pre-Start

Do not operate before conducting Pre-StartDo not operate before conducting Pre-Start Maintenance Inspection. Check hydraulicMaintenance Inspection. Check hydraulic

Maintenance Inspection. Check hydraulic

Maintenance Inspection. Check hydraulicMaintenance Inspection. Check hydraulic components for leaks, loose fittings orcomponents for leaks, loose fittings or

components for leaks, loose fittings or

components for leaks, loose fittings orcomponents for leaks, loose fittings or damage.damage.

damage.

damage.damage.

WARNING WARNING

WARNING

WARNING WARNING

Remove or secure all personal or maintenanceRemove or secure all personal or maintenance

Remove or secure all personal or maintenance

Remove or secure all personal or maintenanceRemove or secure all personal or maintenance items such as lunch buckets, chains, shovels,items such as lunch buckets, chains, shovels,

items such as lunch buckets, chains, shovels,

items such as lunch buckets, chains, shovels,items such as lunch buckets, chains, shovels, tools, etc., before moving or operating machine.tools, etc., before moving or operating machine.

tools, etc., before moving or operating machine.

tools, etc., before moving or operating machine.tools, etc., before moving or operating machine.

WARNING WARNING

WARNING

WARNING WARNING

Make sure that all walking and climbing surfacesMake sure that all walking and climbing surfaces

Make sure that all walking and climbing surfaces

Make sure that all walking and climbing surfacesMake sure that all walking and climbing surfaces of machine are free of dirt, debris, water, grease,of machine are free of dirt, debris, water, grease,

of machine are free of dirt, debris, water, grease,

of machine are free of dirt, debris, water, grease,of machine are free of dirt, debris, water, grease, oil, and snow. Do not leave loose tools or ragsoil, and snow. Do not leave loose tools or rags

oil, and snow. Do not leave loose tools or rags

oil, and snow. Do not leave loose tools or ragsoil, and snow. Do not leave loose tools or rags on machine. Replace all non-skid material that ison machine. Replace all non-skid material that is

on machine. Replace all non-skid material that is

on machine. Replace all non-skid material that ison machine. Replace all non-skid material that is torn, missing or damaged.torn, missing or damaged.

torn, missing or damaged.

torn, missing or damaged.torn, missing or damaged.

WARNING WARNING

WARNING

WARNING WARNING

Replace any safety decals that are faded, torn,Replace any safety decals that are faded, torn,

Replace any safety decals that are faded, torn,

Replace any safety decals that are faded, torn,Replace any safety decals that are faded, torn, missing, illegible, or otherwise damaged.missing, illegible, or otherwise damaged.

missing, illegible, or otherwise damaged.

missing, illegible, or otherwise damaged.missing, illegible, or otherwise damaged.

WARNING WARNING

WARNING

WARNING WARNING

Mechanically connected controls will causeMechanically connected controls will cause

Mechanically connected controls will cause

Mechanically connected controls will causeMechanically connected controls will cause

movement of components at all times - even ifmovement of components at all times - even if

movement of components at all times - even if

movement of components at all times - even ifmovement of components at all times - even if pump or engine is not operating. Always bepump or engine is not operating. Always be

pump or engine is not operating. Always be

pump or engine is not operating. Always bepump or engine is not operating. Always be certain that boom and attachment are properlycertain that boom and attachment are properly

certain that boom and attachment are properly

certain that boom and attachment are properlycertain that boom and attachment are properly supported or resting on firm ground beforesupported or resting on firm ground before

supported or resting on firm ground before

supported or resting on firm ground beforesupported or resting on firm ground before stopping engine to minimize chance ofstopping engine to minimize chance of

stopping engine to minimize chance of

stopping engine to minimize chance ofstopping engine to minimize chance of accidental movements of components causingaccidental movements of components causing

accidental movements of components causing

accidental movements of components causingaccidental movements of components causing death, severe injury or property damage.death, severe injury or property damage.

death, severe injury or property damage.

death, severe injury or property damage.death, severe injury or property damage.

WARNING WARNING

WARNING

WARNING WARNING

Loose or overtorqued bolts can cause death,Loose or overtorqued bolts can cause death,

Loose or overtorqued bolts can cause death,

Loose or overtorqued bolts can cause death,Loose or overtorqued bolts can cause death, severe injury, or property damage. Maintainsevere injury, or property damage. Maintain

severe injury, or property damage. Maintain

severe injury, or property damage. Maintainsevere injury, or property damage. Maintain proper bolt torque. Visually check bolts daily.proper bolt torque. Visually check bolts daily.

proper bolt torque. Visually check bolts daily.

proper bolt torque. Visually check bolts daily.proper bolt torque. Visually check bolts daily. Check torque every 50 hours.Check torque every 50 hours.

Check torque every 50 hours.

Check torque every 50 hours.Check torque every 50 hours.

WARNING WARNING

WARNING

WARNING WARNING

Grease all boom, cylinder, and turntable bearing/Grease all boom, cylinder, and turntable bearing/

Grease all boom, cylinder, and turntable bearing/

Grease all boom, cylinder, and turntable bearing/Grease all boom, cylinder, and turntable bearing/ pinion points daily.pinion points daily.

pinion points daily.

pinion points daily.pinion points daily.

WARNING WARNING

WARNING

WARNING WARNING

Transparent material such as safety glass must beTransparent material such as safety glass must be

Transparent material such as safety glass must be

Transparent material such as safety glass must beTransparent material such as safety glass must be replaced when it is cracked or broken, or whenreplaced when it is cracked or broken, or when

replaced when it is cracked or broken, or when

replaced when it is cracked or broken, or whenreplaced when it is cracked or broken, or when vision is obscured due to scratches.vision is obscured due to scratches.

vision is obscured due to scratches.

vision is obscured due to scratches.vision is obscured due to scratches.

475 A CRL 800-00167

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SAFETY SUMMARY CONTINUED...

WARNING WARNING

WARNING

WARNING WARNING

Always wear seat belt when operating or runningAlways wear seat belt when operating or running

Always wear seat belt when operating or running

Always wear seat belt when operating or runningAlways wear seat belt when operating or running machine.machine.

machine.

machine.machine.

DANGER DANGER

DANGER

DANGER DANGER

Improper electrical connections will cause batteryImproper electrical connections will cause battery

Improper electrical connections will cause battery

Improper electrical connections will cause batteryImproper electrical connections will cause battery explosion, combustion or electrical componentexplosion, combustion or electrical component

explosion, combustion or electrical component

explosion, combustion or electrical componentexplosion, combustion or electrical component damage, and may result in death or severe injury.damage, and may result in death or severe injury.

damage, and may result in death or severe injury.

damage, and may result in death or severe injury.damage, and may result in death or severe injury.

This is a 12 volt negative ground electricalThis is a 12 volt negative ground electrical

This is a 12 volt negative ground electrical

This is a 12 volt negative ground electricalThis is a 12 volt negative ground electrical system.system.

system.

system.system.

WARNING WARNING

WARNING

WARNING WARNING

Hot and pressurized fluid can cause severe burns.Hot and pressurized fluid can cause severe burns.

Hot and pressurized fluid can cause severe burns.

Hot and pressurized fluid can cause severe burns.Hot and pressurized fluid can cause severe burns. Let system cool before removing any caps. ThenLet system cool before removing any caps. Then

Let system cool before removing any caps. Then

Let system cool before removing any caps. ThenLet system cool before removing any caps. Then remove caps slowly.remove caps slowly.

remove caps slowly.

remove caps slowly.remove caps slowly.

WARNING WARNING

WARNING

WARNING WARNING

If this machine is equipped with electric motorIf this machine is equipped with electric motor

If this machine is equipped with electric motor

If this machine is equipped with electric motorIf this machine is equipped with electric motor driven Auxiliary Oil Cooler, be sure battery isdriven Auxiliary Oil Cooler, be sure battery is

driven Auxiliary Oil Cooler, be sure battery is

driven Auxiliary Oil Cooler, be sure battery isdriven Auxiliary Oil Cooler, be sure battery is disconnected before going near cooler fan. Ifdisconnected before going near cooler fan. If

disconnected before going near cooler fan. If

disconnected before going near cooler fan. Ifdisconnected before going near cooler fan. If battery is not disconnected, fan may come on atbattery is not disconnected, fan may come on at

battery is not disconnected, fan may come on at

battery is not disconnected, fan may come on atbattery is not disconnected, fan may come on at any time causing severe injury.any time causing severe injury.

any time causing severe injury.

any time causing severe injury.any time causing severe injury.

WARNING WARNING

WARNING

WARNING WARNING

Hot exhaust pipe can cause severe burns. Do notHot exhaust pipe can cause severe burns. Do not

Hot exhaust pipe can cause severe burns. Do not

Hot exhaust pipe can cause severe burns. Do notHot exhaust pipe can cause severe burns. Do not touch exhaust pipe when hot, or when engine istouch exhaust pipe when hot, or when engine is

touch exhaust pipe when hot, or when engine is

touch exhaust pipe when hot, or when engine istouch exhaust pipe when hot, or when engine is running.running.

running.

running.running.

CAUTION CAUTION

CAUTION

CAUTION CAUTION

Check the Air Cleaner Assembly daily for cracks,Check the Air Cleaner Assembly daily for cracks,

Check the Air Cleaner Assembly daily for cracks,

Check the Air Cleaner Assembly daily for cracks,Check the Air Cleaner Assembly daily for cracks, loose clamps, or any other damage. If debris isloose clamps, or any other damage. If debris is

loose clamps, or any other damage. If debris is

loose clamps, or any other damage. If debris isloose clamps, or any other damage. If debris is able to bypass the Air Cleaner for any reason, itable to bypass the Air Cleaner for any reason, it

able to bypass the Air Cleaner for any reason, it

able to bypass the Air Cleaner for any reason, itable to bypass the Air Cleaner for any reason, it can damage the engine.can damage the engine.

can damage the engine.

can damage the engine.can damage the engine.

CALIFORNIACALIFORNIA

CALIFORNIA

CALIFORNIACALIFORNIA

Proposition 65 WarningProposition 65 Warning

Proposition 65 Warning

Proposition 65 WarningProposition 65 Warning

Diesel engine exhaust and some of its constituents are knownDiesel engine exhaust and some of its constituents are known

Diesel engine exhaust and some of its constituents are known

Diesel engine exhaust and some of its constituents are knownDiesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, andto the State of California to cause cancer, birth defects, and

to the State of California to cause cancer, birth defects, and

to the State of California to cause cancer, birth defects, andto the State of California to cause cancer, birth defects, and other reproductive harm.other reproductive harm.

other reproductive harm.

other reproductive harm.other reproductive harm.

475 A CRL 800-00167

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WARNING WARNING

WARNING

WARNING WARNING

Maintain all components of Muffler Assembly toMaintain all components of Muffler Assembly to

Maintain all components of Muffler Assembly to

Maintain all components of Muffler Assembly toMaintain all components of Muffler Assembly to meet noise and exhaust standards.meet noise and exhaust standards.

meet noise and exhaust standards.

meet noise and exhaust standards.meet noise and exhaust standards.

FIRE PREVENTIONFIRE PREVENTION

FIRE PREVENTION

FIRE PREVENTIONFIRE 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.

The following list of hazards provides information which will help to prevent fires:

WARNING WARNING

WARNING

WARNING WARNING

Always keep a fire extinguisherAlways keep a fire extinguisher

Always keep a fire extinguisher

Always keep a fire extinguisherAlways keep a fire extinguisher and first aid kit where they can beand first aid kit where they can be

and first aid kit where they can be

and first aid kit where they can beand first aid kit where they can be easily reached in case of fire andeasily reached in case of fire and

easily reached in case of fire and

easily reached in case of fire andeasily reached in case of fire and keep these items properlykeep these items properly

keep these items properly

keep these items properlykeep these items properly maintained.maintained.

maintained.

maintained.maintained.

Operating personnel should beOperating personnel should be

Operating personnel should be

Operating personnel should beOperating personnel should be instructed on what to do in caseinstructed on what to do in case

instructed on what to do in case

instructed on what to do in caseinstructed on what to do in case of fire and be required toof fire and be required to

of fire and be required to

of fire and be required toof fire and be required to demonstrate how to use firedemonstrate how to use fire

demonstrate how to use fire

demonstrate how to use firedemonstrate how to use fire extinguisher and fire suppressionextinguisher and fire suppression

extinguisher and fire suppression

extinguisher and fire suppressionextinguisher and fire suppression equipment.equipment.

equipment.

equipment.equipment.

Any portable fire extinguisher orAny portable fire extinguisher or

Any portable fire extinguisher or

Any portable fire extinguisher orAny portable fire extinguisher or fire suppression system carriedfire suppression system carried

fire suppression system carried

fire suppression system carriedfire suppression system carried on the machine that has beenon the machine that has been

on the machine that has been

on the machine that has beenon the machine that has been used, should be recharged orused, should be recharged or

used, should be recharged or

used, should be recharged orused, should be recharged or replaced before the machinereplaced before the machine

replaced before the machine

replaced before the machinereplaced before the machine resumes operating. Fireresumes operating. Fire

resumes operating. Fire

resumes operating. Fireresumes operating. Fire extinguisher manufacturersextinguisher manufacturers

extinguisher manufacturers

extinguisher manufacturersextinguisher manufacturers recommended service intervalsrecommended service intervals

recommended service intervals

recommended service intervalsrecommended service intervals should be followed.should be followed.

should be followed.

should be followed.should be followed.

WARNING WARNING

WARNING

WARNING WARNING

Allow machine to cool down byAllow machine to cool down by

Allow machine to cool down by

Allow machine to cool down byAllow machine to cool down by idling the engine for a whileidling the engine for a while

idling the engine for a while

idling the engine for a whileidling the engine for a while before shut-down. Many enginebefore shut-down. Many engine

before shut-down. Many engine

before shut-down. Many enginebefore shut-down. Many engine and transmission fires start and transmission fires start

and transmission fires start

and transmission fires start and transmission fires start shut-down.shut-down.

shut-down.

shut-down.shut-down.

WARNING WARNING

WARNING

WARNING WARNING

Before adding fuel, shut down theBefore adding fuel, shut down the

Before adding fuel, shut down the

Before adding fuel, shut down theBefore adding fuel, shut down the engine and allow it to cool. Neverengine and allow it to cool. Never

engine and allow it to cool. Never

engine and allow it to cool. Neverengine and allow it to cool. Never smoke while handling fuel orsmoke while handling fuel or

smoke while handling fuel or

smoke while handling fuel orsmoke while handling fuel or working on either the fuel or theworking on either the fuel or the

working on either the fuel or the

working on either the fuel or theworking on either the fuel or the hydraulic system.hydraulic system.

hydraulic system.

hydraulic system.hydraulic system.

WARNING WARNING

WARNING

WARNING WARNING

Do not use the machine in areasDo not use the machine in areas

Do not use the machine in areas

Do not use the machine in areasDo not use the machine in areas with explosive dust or gases thatwith explosive dust or gases that

with explosive dust or gases that

with explosive dust or gases thatwith explosive dust or gases that can be ignited by arcs, sparks,can be ignited by arcs, sparks,

can be ignited by arcs, sparks,

can be ignited by arcs, sparks,can be ignited by arcs, sparks, hot components, or exhausthot components, or exhaust

hot components, or exhaust

hot components, or exhausthot components, or exhaust fumes.fumes.

fumes.

fumes.fumes.

afterafter

after

afterafter

WARNING WARNING

WARNING

WARNING WARNING

Daily inspect the machine forDaily inspect the machine for

Daily inspect the machine for

Daily inspect the machine forDaily inspect the machine for flammable debris, removing anyflammable debris, removing any

flammable debris, removing any

flammable debris, removing anyflammable debris, removing any twigs, leaves, straw, rags, fluidtwigs, leaves, straw, rags, fluid

twigs, leaves, straw, rags, fluid

twigs, leaves, straw, rags, fluidtwigs, leaves, straw, rags, fluid spills or leaks, dirt or grime. Payspills or leaks, dirt or grime. Pay

spills or leaks, dirt or grime. Pay

spills or leaks, dirt or grime. Payspills or leaks, dirt or grime. Pay special attention to areas such asspecial attention to areas such as

special attention to areas such as

special attention to areas such asspecial attention to areas such as the engine, engine coolingthe engine, engine cooling

the engine, engine cooling

the engine, engine coolingthe engine, engine cooling system, exhaust system, battery,system, exhaust system, battery,

system, exhaust system, battery,

system, exhaust system, battery,system, exhaust system, battery, electrical connections, brakeelectrical connections, brake

electrical connections, brake

electrical connections, brakeelectrical connections, brake systems, transmission/drivetrain,systems, transmission/drivetrain,

systems, transmission/drivetrain,

systems, transmission/drivetrain,systems, transmission/drivetrain, fuel system and hydraulic system.fuel system and hydraulic system.

fuel system and hydraulic system.

fuel system and hydraulic system.fuel system and hydraulic system. Clean as often as necessary toClean as often as necessary to

Clean as often as necessary to

Clean as often as necessary toClean as often as necessary to help prevent overheating andhelp prevent overheating and

help prevent overheating and

help prevent overheating andhelp prevent overheating and combustion.combustion.

combustion.

combustion.combustion.

WARNING WARNING

WARNING

WARNING WARNING

The electrical system (battery,The electrical system (battery,

The electrical system (battery,

The electrical system (battery,The electrical system (battery, electrical connections, etc.) can beelectrical connections, etc.) can be

electrical connections, etc.) can be

electrical connections, etc.) can beelectrical connections, etc.) can be a source of arcs or sparks ifa source of arcs or sparks if

a source of arcs or sparks if

a source of arcs or sparks ifa source of arcs or sparks if damaged or incorrectlydamaged or incorrectly

damaged or incorrectly

damaged or incorrectlydamaged or incorrectly maintained. Daily inspect allmaintained. Daily inspect all

maintained. Daily inspect all

maintained. Daily inspect allmaintained. Daily inspect all electrical wiring and connectionselectrical wiring and connections

electrical wiring and connections

electrical wiring and connectionselectrical wiring and connections for damage. Keep the batteryfor damage. Keep the battery

for damage. Keep the battery

for damage. Keep the batteryfor damage. Keep the battery terminals clean and tight. Replaceterminals clean and tight. Replace

terminals clean and tight. Replace

terminals clean and tight. Replaceterminals clean and tight. Replace or repair any damaged part. Useor repair any damaged part. Use

or repair any damaged part. Use

or repair any damaged part. Useor repair any damaged part. Use proper battery connection andproper battery connection and

proper battery connection and

proper battery connection andproper battery connection and disconnection procedures.disconnection procedures.

disconnection procedures.

disconnection procedures.disconnection procedures.

WARNING WARNING

WARNING

WARNING WARNING

Daily inspect all fuel and hydraulicDaily inspect all fuel and hydraulic

Daily inspect all fuel and hydraulic

Daily inspect all fuel and hydraulicDaily inspect all fuel and hydraulic oil tubes, hoses, and fittings foroil tubes, hoses, and fittings for

oil tubes, hoses, and fittings for

oil tubes, hoses, and fittings foroil tubes, hoses, and fittings for damage and leakage. Tighten ordamage and leakage. Tighten or

damage and leakage. Tighten or

damage and leakage. Tighten ordamage and leakage. Tighten or replace as necessary. Alwaysreplace as necessary. Always

replace as necessary. Always

replace as necessary. Alwaysreplace as necessary. Always clean fluid spills.clean fluid spills.

clean fluid spills.

clean fluid spills.clean fluid spills.

WARNING WARNING

WARNING

WARNING WARNING

Do not use ether or starting fluidsDo not use ether or starting fluids

Do not use ether or starting fluids

Do not use ether or starting fluidsDo not use ether or starting fluids on diesel engines with glowon diesel engines with glow

on diesel engines with glow

on diesel engines with glowon diesel engines with glow plugs. These starting aids canplugs. These starting aids can

plugs. These starting aids can

plugs. These starting aids canplugs. These starting aids can explode and injure bystanders.explode and injure bystanders.

explode and injure bystanders.

explode and injure bystanders.explode and injure bystanders.

475 A CRL

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800-00167

WARNING WARNING

WARNING

WARNING WARNING

Before doing welding of any kind,Before doing welding of any kind,

Before doing welding of any kind,

Before doing welding of any kind,Before doing welding of any kind, clean machine and disconnectclean machine and disconnect

clean machine and disconnect

clean machine and disconnectclean machine and disconnect battery cables. Cover rubberbattery cables. Cover rubber

battery cables. Cover rubber

battery cables. Cover rubberbattery cables. Cover rubber hoses, battery, and otherhoses, battery, and other

hoses, battery, and other

hoses, battery, and otherhoses, battery, and other flammable parts. Never ground anflammable parts. Never ground an

flammable parts. Never ground an

flammable parts. Never ground anflammable parts. Never ground an arc welder or electricalarc welder or electrical

arc welder or electrical

arc welder or electricalarc welder or electrical accessories through turntable oraccessories through turntable or

accessories through turntable or

accessories through turntable oraccessories through turntable or boom bearings as arcing mayboom bearings as arcing may

boom bearings as arcing may

boom bearings as arcing mayboom bearings as arcing may occur causing bearing damage.occur causing bearing damage.

occur causing bearing damage.

occur causing bearing damage.occur causing bearing damage.

Do not weld on any structuralDo not weld on any structural

Do not weld on any structural

Do not weld on any structuralDo not weld on any structural member unless specificallymember unless specifically

member unless specifically

member unless specificallymember unless specifically authorized by Barkoauthorized by Barko

authorized by Barko

authorized by Barkoauthorized by Barko Hydraulics. Any unauthorizedHydraulics. Any unauthorized

Hydraulics. Any unauthorized

Hydraulics. Any unauthorizedHydraulics. Any unauthorized welding or welding procedureswelding or welding procedures

welding or welding procedures

welding or welding procedureswelding or welding procedures will void the warranty, and maywill void the warranty, and may

will void the warranty, and may

will void the warranty, and maywill void the warranty, and may cause structural damage.cause structural damage.

cause structural damage.

cause structural damage.cause structural damage.

WARNING WARNING

WARNING

WARNING WARNING

Read the Engine Manual thatRead the Engine Manual that

Read the Engine Manual that

Read the Engine Manual thatRead the Engine Manual that comes with every machine forcomes with every machine for

comes with every machine for

comes with every machine forcomes with every machine for complete engine operating andcomplete engine operating and

complete engine operating and

complete engine operating andcomplete engine operating and engine safety instructions.engine safety instructions.

engine safety instructions.

engine safety instructions.engine safety instructions.

HYDRAULIC OILHYDRAULIC OIL

HYDRAULIC OIL

HYDRAULIC OILHYDRAULIC OIL RESERVOIRRESERVOIR

RESERVOIR

RESERVOIRRESERVOIR

SHROUDINGSHROUDING

SHROUDING

SHROUDINGSHROUDING (Engine,(Engine,

(Engine,

(Engine,(Engine, Pumps, etc.)Pumps, etc.)

Pumps, etc.)

Pumps, etc.)Pumps, etc.)

MAIN BOOMMAIN BOOM

MAIN BOOM

MAIN BOOMMAIN BOOM CYLINDERCYLINDER

CYLINDER

CYLINDERCYLINDER

CABCAB

CAB

CABCAB

MODEL DESCRIPTIONMODEL DESCRIPTION

MODEL DESCRIPTION

MODEL DESCRIPTIONMODEL DESCRIPTION

STICK BOOMSTICK BOOM

STICK BOOM

STICK BOOMSTICK BOOM CYLINDERCYLINDER

CYLINDER

MAIN BOOMMAIN BOOM

MAIN BOOM

MAIN BOOMMAIN BOOM

CYLINDERCYLINDER

STICK BOOMSTICK BOOM

STICK BOOM

STICK BOOMSTICK BOOM

LIVE HEELLIVE HEEL

LIVE HEEL

LIVE HEELLIVE HEEL BOOMBOOM

BOOM

BOOMBOOM CYLINDERCYLINDER

CYLINDER

CYLINDERCYLINDER

LIVE HEELLIVE HEEL

LIVE HEEL

LIVE HEELLIVE HEEL BOOMBOOM

BOOM

BOOMBOOM

COUNTERWEIGHTCOUNTERWEIGHT

COUNTERWEIGHT

COUNTERWEIGHTCOUNTERWEIGHT

CRAWLERCRAWLER

CRAWLER

CRAWLERCRAWLER LOWERLOWER

LOWER

LOWERLOWER

FUELFUEL

FUEL

FUELFUEL RESERVOIRRESERVOIR

RESERVOIR

RESERVOIRRESERVOIR

TURNTABLETURNTABLE

TURNTABLE

TURNTABLETURNTABLE BEARINGBEARING

BEARING

BEARINGBEARING

GRAPPLEGRAPPLE

GRAPPLE

GRAPPLEGRAPPLE CYLINDERCYLINDER

CYLINDER

CYLINDERCYLINDER

GRAPPLEGRAPPLE

GRAPPLE

GRAPPLEGRAPPLE ROTATORROTATOR

ROTATOR

ROTATORROTATOR

GRAPPLEGRAPPLE

GRAPPLE

GRAPPLEGRAPPLE ARMSARMS

ARMS

ARMSARMS

475 A CRL 800-00167

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A. PREVENTIVE MAINTENANCEA. PREVENTIVE MAINTENANCE

A. PREVENTIVE MAINTENANCE

A. PREVENTIVE MAINTENANCEA. PREVENTIVE MAINTENANCE

MaintenanceMaintenance

Maintenance

475 A CRL

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800-00167

MaintenanceMaintenance

Maintenance

SAFETY WHILE SERVICINGSAFETY WHILE SERVICING

SAFETY WHILE SERVICING

SAFETY WHILE SERVICINGSAFETY WHILE SERVICING

The following maintenance section gives suggested guidelines for operational maintenance on your machine. It is not intended for use as a service manual.

In severe conditions (extreme dust, heat, cold, humidity, etc.) you will need to service your machine more often. Your experience will dictate a more severe servicing program.

Safety while servicing your machine is your responsibility. Only qualified and authorized personnel should be permitted to maintain, repair, adjust and inspect machine.

Read and understand warnings and safety precautions in Safety Summary and elsewhere in this manual before doing any service on machine. The following precautions should be used as a reminder to safe servicing.

BEFORE INSPECTION OR MAINTENANCE:BEFORE INSPECTION OR MAINTENANCE:

BEFORE INSPECTION OR MAINTENANCE:

BEFORE INSPECTION OR MAINTENANCE:BEFORE INSPECTION OR MAINTENANCE:

- Lower boom to ground.

- Shut down machine to a zero energy state.

- Remove key from ignition.

- On joystick machines, disengage servo lever.

- Allow machine to cool.

- Relieve all hydraulic pressure.

- Disconnect battery.

WARNING WARNING

WARNING

WARNING WARNING

Always shut down the machine and lower the boomAlways shut down the machine and lower the boom

Always shut down the machine and lower the boom

Always shut down the machine and lower the boomAlways shut down the machine and lower the boom and attachment to the ground before working on theand attachment to the ground before working on the

and attachment to the ground before working on the

and attachment to the ground before working on theand attachment to the ground before working on the machine. If necessary to work on a lifted boom ormachine. If necessary to work on a lifted boom or

machine. If necessary to work on a lifted boom or

machine. If necessary to work on a lifted boom ormachine. If necessary to work on a lifted boom or attachment, securely support the boom andattachment, securely support the boom and

attachment, securely support the boom and

attachment, securely support the boom andattachment, securely support the boom and attachment so they cannot move or fall in any way.attachment so they cannot move or fall in any way.

attachment so they cannot move or fall in any way.

attachment so they cannot move or fall in any way.attachment so they cannot move or fall in any way.

WARNING WARNING

WARNING

WARNING WARNING

Don't leave loose tools and rags on the machine.Don't leave loose tools and rags on the machine.

Don't leave loose tools and rags on the machine.

Don't leave loose tools and rags on the machine.Don't leave loose tools and rags on the machine. Ensure that all walking and climbing surfaces areEnsure that all walking and climbing surfaces are

Ensure that all walking and climbing surfaces are

Ensure that all walking and climbing surfaces areEnsure that all walking and climbing surfaces are clean.clean.

clean.

clean.clean.

- Remove, block or guard against body contact with all other sources of hazardous pressure, temperature, electricity, or machine motion.

- Ensure machine, boom or attachment are not supported on props that may collapse. Ensure boom and attachment are grounded.

WARNING WARNING

WARNING

WARNING WARNING

Do not support the machine on cinder blocks,Do not support the machine on cinder blocks,

Do not support the machine on cinder blocks,

Do not support the machine on cinder blocks,Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under ahollow tiles, or props that may crumble under a

hollow tiles, or props that may crumble under a

hollow tiles, or props that may crumble under ahollow tiles, or props that may crumble under a load. Do not work under a machine that isload. Do not work under a machine that is

load. Do not work under a machine that is

load. Do not work under a machine that isload. Do not work under a machine that is supported solely by a jack.supported solely by a jack.

supported solely by a jack.

supported solely by a jack.supported solely by a jack.

CAUTION CAUTION

CAUTION

CAUTION CAUTION

Check the Hour Meter regularly to determine whenCheck the Hour Meter regularly to determine when

Check the Hour Meter regularly to determine when

Check the Hour Meter regularly to determine whenCheck the Hour Meter regularly to determine when the machine needs periodic maintenance. Use thethe machine needs periodic maintenance. Use the

the machine needs periodic maintenance. Use the

the machine needs periodic maintenance. Use thethe machine needs periodic maintenance. Use the intervals on the Service Schedule except whenintervals on the Service Schedule except when

intervals on the Service Schedule except when

intervals on the Service Schedule except whenintervals on the Service Schedule except when operating in extreme conditions; then shorteroperating in extreme conditions; then shorter

operating in extreme conditions; then shorter

operating in extreme conditions; then shorteroperating in extreme conditions; then shorter intervals must be used.intervals must be used.

intervals must be used.

intervals must be used.intervals must be used.

WARNING WARNING

WARNING

WARNING WARNING

Handle fuel carefully. Do not smoke while fillingHandle fuel carefully. Do not smoke while filling

Handle fuel carefully. Do not smoke while filling

Handle fuel carefully. Do not smoke while fillingHandle fuel carefully. Do not smoke while filling fuel tank or working near fuel.fuel tank or working near fuel.

fuel tank or working near fuel.

fuel tank or working near fuel.fuel tank or working near fuel.

Refer to Fluid Specifications wheneverRefer to Fluid Specifications whenever

Refer to Fluid Specifications whenever

Refer to Fluid Specifications wheneverRefer to Fluid Specifications whenever replacing oils, fluids, or filling fuel tank.replacing oils, fluids, or filling fuel tank.

replacing oils, fluids, or filling fuel tank.

replacing oils, fluids, or filling fuel tank.replacing oils, fluids, or filling fuel tank.

WARNING WARNING

WARNING

WARNING WARNING

Do not weld on any structural member unlessDo not weld on any structural member unless

Do not weld on any structural member unless

Do not weld on any structural member unlessDo not weld on any structural member unless specifically authorized by Barko Hydraulics. Anyspecifically authorized by Barko Hydraulics. Any

specifically authorized by Barko Hydraulics. Any

specifically authorized by Barko Hydraulics. Anyspecifically authorized by Barko Hydraulics. Any unauthorized welding or welding procedures willunauthorized welding or welding procedures will

unauthorized welding or welding procedures will

unauthorized welding or welding procedures willunauthorized welding or welding procedures will void the warranty, and may cause death, severevoid the warranty, and may cause death, severe

void the warranty, and may cause death, severe

void the warranty, and may cause death, severevoid the warranty, and may cause death, severe injury, property damage or structural damage to theinjury, property damage or structural damage to the

injury, property damage or structural damage to the

injury, property damage or structural damage to theinjury, property damage or structural damage to the machine.machine.

machine.

machine.machine.

REMEMBER: SAFETY FIRST!REMEMBER: SAFETY FIRST!

REMEMBER: SAFETY FIRST!

REMEMBER: SAFETY FIRST!REMEMBER: SAFETY FIRST!

475 A CRL

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800-00167

WARNING WARNING

WARNING

WARNING WARNING

Under no circumstances should any modificationsUnder no circumstances should any modifications

Under no circumstances should any modifications

Under no circumstances should any modificationsUnder no circumstances should any modifications be made to Barko machinery without factorybe made to Barko machinery without factory

be made to Barko machinery without factory

be made to Barko machinery without factorybe made to Barko machinery without factory authorization. Any modifications may void theauthorization. Any modifications may void the

authorization. Any modifications may void the

authorization. Any modifications may void theauthorization. Any modifications may void the warranty. This machine was designed to do awarranty. This machine was designed to do a

warranty. This machine was designed to do a

warranty. This machine was designed to do awarranty. This machine was designed to do a specific job and alterations could result in death,specific job and alterations could result in death,

specific job and alterations could result in death,

specific job and alterations could result in death,specific job and alterations could result in death, severe injury or property damage.severe injury or property damage.

severe injury or property damage.

severe injury or property damage.severe injury or property damage.

WARNING WARNING

WARNING

WARNING WARNING

Relieve all hydraulic pressure before breaking anyRelieve all hydraulic pressure before breaking any

Relieve all hydraulic pressure before breaking any

Relieve all hydraulic pressure before breaking anyRelieve all hydraulic pressure before breaking any hydraulic connection, opening the reservoir accesshydraulic connection, opening the reservoir access

hydraulic connection, opening the reservoir access

hydraulic connection, opening the reservoir accesshydraulic connection, opening the reservoir access cover, or performing any maintenance on thecover, or performing any maintenance on the

cover, or performing any maintenance on the

cover, or performing any maintenance on thecover, or performing any maintenance on the machine.machine.

machine.

machine.machine.

PREVENTIVE MAINTENANCEPREVENTIVE MAINTENANCE

PREVENTIVE MAINTENANCE

PREVENTIVE MAINTENANCEPREVENTIVE 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. The only other requisite to such a program is the regular scheduling of such maintenance.

Obviously, when you are operating under severe job conditions, such as a dusty job site, in extreme heat or cold, a long operating day, or extremely heavy loads, the recommended intervals in the schedule should be shortened.

The suggested schedule on the following page is designed to be just a reminder of what should be done. For detailed instructions on each item, consult the Table of Contents for where each is located in this manual.

WARNING WARNING

WARNING

WARNING WARNING

Instructions are necessary before doing service on loader. SeeInstructions are necessary before doing service on loader. See

Instructions are necessary before doing service on loader. See

Instructions are necessary before doing service on loader. SeeInstructions are necessary before doing service on loader. See warnings and instructions both at the beginning andwarnings and instructions both at the beginning and

warnings and instructions both at the beginning and

warnings and instructions both at the beginning andwarnings and instructions both at the beginning and throughout this manual. After doing service or making repairsthroughout this manual. After doing service or making repairs

throughout this manual. After doing service or making repairs

throughout this manual. After doing service or making repairsthroughout this manual. After doing service or making repairs or adjustments always check function of loader.or adjustments always check function of loader.

or adjustments always check function of loader.

or adjustments always check function of loader.or adjustments always check function of loader.

Safety glasses or goggles are always needed for eye protectionSafety glasses or goggles are always needed for eye protection

Safety glasses or goggles are always needed for eye protection

Safety glasses or goggles are always needed for eye protectionSafety glasses or goggles are always needed for eye protection from electric arcs, from shorts or welding, battery acid,from electric arcs, from shorts or welding, battery acid,

from electric arcs, from shorts or welding, battery acid,

from electric arcs, from shorts or welding, battery acid,from electric arcs, from shorts or welding, battery acid, compressed springs, fluids under pressure, and flying debriscompressed springs, fluids under pressure, and flying debris

compressed springs, fluids under pressure, and flying debris

compressed springs, fluids under pressure, and flying debriscompressed springs, fluids under pressure, and flying debris or loose material when engines are running or tools are used.or loose material when engines are running or tools are used.

or loose material when engines are running or tools are used.

or loose material when engines are running or tools are used.or loose material when engines are running or tools are used. Use eye protection approved for type of welding. Failure toUse eye protection approved for type of welding. Failure to

Use eye protection approved for type of welding. Failure to

Use eye protection approved for type of welding. Failure toUse eye protection approved for type of welding. Failure to obey warnings can cause death, severe injury or propertyobey warnings can cause death, severe injury or property

obey warnings can cause death, severe injury or property

obey warnings can cause death, severe injury or propertyobey warnings can cause death, severe injury or property damage.damage.

damage.

damage.damage.

SPECIAL NEW-MACHINE INSTRUCTIONSSPECIAL NEW-MACHINE INSTRUCTIONS

SPECIAL NEW-MACHINE INSTRUCTIONS

SPECIAL NEW-MACHINE INSTRUCTIONSSPECIAL NEW-MACHINE INSTRUCTIONS

AFTER THE FIRST 50 HOURS OF OPERATION OF A NEW MACHINEAFTER THE FIRST 50 HOURS OF OPERATION OF A NEW MACHINE

AFTER THE FIRST 50 HOURS OF OPERATION OF A NEW MACHINE

AFTER THE FIRST 50 HOURS OF OPERATION OF A NEW MACHINEAFTER THE FIRST 50 HOURS OF OPERATION OF A NEW MACHINE

A new machine needs a special maintenance procedure after the first 50 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

- Mounting Bolts/Nuts on major machine components (gearboxes, motors, pumps, booms, attachment, turntable bearing, lower assembly, tires, etc.)

3. Check torque of loader mounting bolts. Retorque if necessary.

4. Change all filter elements.

5. Change hydraulic oil in hydraulic oil reservoir.

6. Change gear fluid in swing motor gearbox.

Resume the normal maintenance intervals after this. See the Service Schedule for more information.

475 A CRL

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800-00167

SERVICE SCHEDULESERVICE SCHEDULE

SERVICE SCHEDULE

SERVICE SCHEDULESERVICE SCHEDULE

SERVICE REQUIREDSERVICE REQUIRED

SERVICE REQUIRED

SERVICE REQUIREDSERVICE REQUIRED

Hydraulic ReservoirHydraulic Reservoir

Hydraulic Reservoir - check level/quality of oil.

Hydraulic ReservoirHydraulic Reservoir

Fuel Tank Fuel Tank

Fuel Tank - Check level and fill if necessary.

Fuel Tank Fuel Tank

Engine Crankcase Oil Engine Crankcase Oil

Engine Crankcase Oil - Check level.

Engine Crankcase Oil Engine Crankcase Oil

Engine RadiatorEngine Radiator

Engine Radiator - Check coolant level and fill if

Engine RadiatorEngine Radiator needed. Inspect for dirt/debris and clean if needed.

Engine Air CleanerEngine Air Cleaner

Engine Air Cleaner - Check/replace element, if

Engine Air CleanerEngine Air Cleaner needed.

Engine ShroudingEngine Shrouding

Engine Shrouding - Clean and inspect.

Engine ShroudingEngine Shrouding

Fan and DrivebeltsFan and Drivebelts

Fan and Drivebelts - Check for looseness/wear.

Fan and DrivebeltsFan and Drivebelts

Tighten or replace as needed.

Pump DrivePump Drive

Pump Drive - Check fluid level.

Pump DrivePump Drive

Swing Motor GearboxSwing Motor Gearbox

Swing Motor Gearbox - Check fluid level.

Swing Motor GearboxSwing Motor Gearbox

Hoses, Connections, Cylinders Hoses, Connections, Cylinders

Hoses, Connections, Cylinders - Check for leaks/

Hoses, Connections, Cylinders Hoses, Connections, Cylinders damage. Tighten, repair, or replace parts if needed.

FittingsFittings

Fittings - Lubricate as shown on Lubrication

FittingsFittings

Points. Use a multi-purpose grease. Bolts/Nuts Bolts/Nuts

Bolts/Nuts - Visually inspect for wear or

Bolts/Nuts Bolts/Nuts damage.

Operator's PlatformOperator's Platform

Operator's Platform - Clean area of debris,

Operator's PlatformOperator's Platform tools, rags, water, ice, and snow. Hydraulic Oil FilterHydraulic Oil Filter

Hydraulic Oil Filter - On new machines filter

Hydraulic Oil FilterHydraulic Oil Filter element should be replaced first at 50 hrs. - at 400 hrs. thereafter.

Hydraulic Oil Reservoir Hydraulic Oil Reservoir

Hydraulic Oil Reservoir - On new machines oil must

Hydraulic Oil Reservoir Hydraulic Oil Reservoir be changed after first 50 hours, - every 1000 hours after that.

Bolts/NutsBolts/Nuts

Bolts/Nuts - Inspect for tightness and\or damage on

Bolts/NutsBolts/Nuts boom and grapple.

Control Lever Linkage (if applicable)Control Lever Linkage (if applicable)

Control Lever Linkage (if applicable) - Lubricate.

Control Lever Linkage (if applicable)Control Lever Linkage (if applicable)

8 HRS.8 HRS.

8 HRS.

8 HRS.8 HRS.

DAILYDAILY

DAILY

DAILYDAILY

50 HRS.50 HRS.

50 HRS.

50 HRS.50 HRS.

WEEKLYWEEKLY

WEEKLY

WEEKLYWEEKLY

100 HRS.100 HRS.

100 HRS.

100 HRS.100 HRS.

MONTHLYMONTHLY

MONTHLY

MONTHLYMONTHLY

400 HRS.400 HRS.

400 HRS.

400 HRS.400 HRS.

2 MONTHS2 MONTHS

2 MONTHS

2 MONTHS2 MONTHS

1000 HRS.1000 HRS.

1000 HRS.

1000 HRS.1000 HRS.

6 MONTHS6 MONTHS

6 MONTHS

6 MONTHS6 MONTHS

Battery Battery

Battery - Clean and coat posts with grease.

Battery Battery

Check electrolyte level and fill if necessary.

Engine Oil Filter Engine Oil Filter

Engine Oil Filter - Replace.

Engine Oil Filter Engine Oil Filter

Hydraulic Oil Cooler and RadiatorHydraulic Oil Cooler and Radiator

Hydraulic Oil Cooler and Radiator - Clean.

Hydraulic Oil Cooler and RadiatorHydraulic Oil Cooler and Radiator

AccumulatorsAccumulators

Accumulators - Check pressure and maintain

AccumulatorsAccumulators

at 900 PSI.

Hydraulic Oil Reservoir Breather Hydraulic Oil Reservoir Breather

Hydraulic Oil Reservoir Breather - Replace.

Hydraulic Oil Reservoir Breather Hydraulic Oil Reservoir Breather

Hydraulic CollectorHydraulic Collector

Hydraulic Collector - Check mounting bolts.

Hydraulic CollectorHydraulic Collector

Hydraulic Oil FilterHydraulic Oil Filter

Hydraulic Oil Filter - Replace elements every

Hydraulic Oil FilterHydraulic Oil Filter 400 hours, after initial change at 50 hours on a new machine.

Pump Drive Pump Drive

Pump Drive - Replace fluid.

Pump Drive Pump Drive

Swing Motor GearboxSwing Motor Gearbox

Swing Motor Gearbox - Replace fluid.

Swing Motor GearboxSwing Motor Gearbox

Hydraulic ReservoirHydraulic Reservoir

Hydraulic Reservoir

Hydraulic ReservoirHydraulic Reservoir

- -

- Replace oil and clean

- -

suction screens. Entire Loader - Entire Loader -

Entire Loader - Steam clean, inspect for

Entire Loader - Entire Loader stress, wear, cracks, damage, and loose parts.

475 A CRL 800-00167

page 18page 18

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SERVICE SCHEDULE CONTINUED...

CRAWLER LOWER SERVICE SCHEDULECRAWLER LOWER SERVICE SCHEDULE

CRAWLER LOWER SERVICE SCHEDULE

CRAWLER LOWER SERVICE SCHEDULECRAWLER LOWER SERVICE SCHEDULE

8 HRS.8 HRS.

8 HRS.

SERVICE REQUIREDSERVICE REQUIRED

SERVICE REQUIRED

SERVICE REQUIREDSERVICE REQUIRED

Tracks - Tracks -

Tracks - Inspect for damaged shoes/missing or

Tracks - Tracks -

loose bolts. Check master link for missing/loose

bolts. Inspect links for missing/leaking oil plugs.

Sprockets -Sprockets -

Sprockets - Check for wear/missing or broken

Sprockets -Sprockets segments. Check for loose or missing hardware.

Recoil Mechanism GuardRecoil Mechanism Guard

Recoil Mechanism Guard - Check for damage and

Recoil Mechanism GuardRecoil Mechanism Guard

loose or missing bolts.

Track Roller Guard Track Roller Guard

Track Roller Guard - Check for damage and

Track Roller Guard Track Roller Guard loose or missing bolts.

Idlers/RollersIdlers/Rollers

Idlers/Rollers - Check for wear/leaks near shaft.

Idlers/RollersIdlers/Rollers

Final Drive Final Drive

Final Drive - Change oil after first 100 hours of

Final Drive Final Drive service, - every 1000 hours after that. Check oil level every 100 hours.

Track Idler YokeTrack Idler Yoke

Track Idler Yoke - Ensure idler yoke fully extended.

Track Idler YokeTrack Idler Yoke

8 HRS.8 HRS. DAILYDAILY

DAILY

DAILYDAILY

50 HRS.50 HRS.

50 HRS.

50 HRS.50 HRS.

WEEKLYWEEKLY

WEEKLY

WEEKLYWEEKLY

100 HRS.100 HRS.

100 HRS.

100 HRS.100 HRS.

MONTHLYMONTHLY

MONTHLY

MONTHLYMONTHLY

400 HRS.400 HRS.

400 HRS.

400 HRS.400 HRS.

2 MONTHS2 MONTHS

2 MONTHS

2 MONTHS2 MONTHS

1000 HRS.1000 HRS.

1000 HRS.

1000 HRS.1000 HRS.

6 MONTHS6 MONTHS

6 MONTHS

6 MONTHS6 MONTHS

Track Roller Frame Track Roller Frame

Track Roller Frame - Check for wear/cracks/broken

Track Roller Frame Track Roller Frame welds.

Final DriveFinal Drive

Final Drive - Drain, then fill with oil. Replace seals/

Final DriveFinal Drive

gaskets.

NOTE:NOTE:

NOTE: Use the intervals on Service Schedule when operating in normal conditions. Service the

NOTE:NOTE:

machine at shorter intervals when operating in very hot, cold, dusty, or humid conditions.

475 A CRL 800-00167

page 19page 19

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LUBRICATION POINTSLUBRICATION POINTS

LUBRICATION POINTS

LUBRICATION POINTSLUBRICATION POINTS

(PERFORM DAILY)(PERFORM DAILY)

(PERFORM DAILY)

(PERFORM DAILY)(PERFORM DAILY)

GREASEGREASE

GREASE

GREASEGREASE

GEAR FLUID ORGEAR FLUID OR

GEAR FLUID OR

GEAR FLUID ORGEAR FLUID OR ENGINE OILENGINE OIL

ENGINE OIL

ENGINE OILENGINE OIL

Pump Drive (except direct drive models) - EP 80-90 gear fluid.

Track Drive Gearbox - EP 80-90 gear fluid. Crawler Final Drive - SAE 30 CD/TO-2 engine oil. Crawler Front Idlers - SAE 30 CD/TO-2 engine oil. Crawler Track Rollers and Carrier Rollers - SAE 30 CD/TO-2 engine oil.

Swing Motor Gearbox: EP 80-90 gear fluid (fill until oil is as high as top of cluster

bearings - see service manual for more information) (if lube reservoir is used, maintain at half full).

1 Grapple Arms 2 Grapple Rotator 3 Grapple Cylinders 4 Grapple Hanger (2 fittings) 5 Main Boom Pivot 6 Stick Boom Pivot 7 Live Heel Boom Pivot 8 Main Boom Cylinders 9 Stick Boom Cylinder 10 Live Heel Boom Cylinders 11 Turntable Bearing and Pinion

12 Swing Motor Gearbox

13 Pump Drive 14 Track Drive Gearbox 15 Crawler Final Drive 16 Crawler Front Idlers 17 Crawler Track Rollers and

*See Turntable Bearing

Lubrication on next page.

Carrier Rollers

1313

1212

1414

(Gear Fluid)(Gear Fluid)

(Gear Fluid)

(Gear Fluid)(Gear Fluid)

1515

(Engine Oil)(Engine Oil)

(Engine Oil)

(Engine Oil)(Engine Oil)

1717

(Engine Oil)(Engine Oil)

(Engine Oil)

(Engine Oil)(Engine Oil)

1010

1111

1010

1616

(Engine Oil)(Engine Oil)

(Engine Oil)

(Engine Oil)(Engine Oil)

475 A CRL 800-00167

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LUBRICATION POINTS CONTINUED...

TURNTABLE BEARING LUBRICATIONTURNTABLE BEARING LUBRICATION

TURNTABLE BEARING LUBRICATION

TURNTABLE BEARING LUBRICATIONTURNTABLE BEARING LUBRICATION

Turntable Bearing must be greased daily. Use a grease with a lithium base, EP additives, and rust inhibitors.

- Above 32 degrees F =Use #2 grease

- Below 32 degrees F = Use #1 grease

These lube points, (Turntable Bearing and Swing Motor Pinion) can be greased from the grease fittings on the floor of the cab. Do not use a high pressure grease gun, as it may damage seals. Use a hand grease gun.

Rotate the machine slightly between each shot of grease for complete distribution of the grease throughout the Bearing.

Rotate the machine at least two complete revolutions for each fitting. Three shots of grease per fitting should be sufficient, on a daily basis.

Pinion LubricationPinion Lubrication

Pinion Lubrication

Pinion LubricationPinion Lubrication PointPoint

Point

PointPoint

HeadHead

Head

HeadHead

Bearing Lubrication PointBearing Lubrication Point

Bearing Lubrication Point

Bearing Lubrication PointBearing Lubrication Point

Cab DeckCab Deck

Cab Deck

Cab DeckCab Deck

Cab RiserCab Riser

Cab Riser

Cab RiserCab Riser

Head Base PlateHead Base Plate

Head Base Plate

Head Base PlateHead Base Plate

475 A CRL 800-00167

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FLUID SPECIFICATIONSFLUID SPECIFICATIONS

FLUID SPECIFICATIONS

FLUID SPECIFICATIONSFLUID SPECIFICATIONS

GREASEGREASE

GREASE

GREASEGREASE

Use grease shown on chart below, depending on the expected air temperature range.

AIR TEMPERATURE RANGEAIR TEMPERATURE RANGE

AIR TEMPERATURE RANGE

AIR TEMPERATURE RANGEAIR TEMPERATURE RANGE

Fahrenheit (F)Fahrenheit (F)

Fahrenheit (F) -67 -40 -22 -4 14 32 50 68 86 104 122

Fahrenheit (F)Fahrenheit (F) Celsius (C)Celsius (C)

Celsius (C) -55 -40 -30 -20 -10 0 10 20 30 40 50

Celsius (C)Celsius (C)

NLGI NO. 2NLGI NO. 2

NLGI NO. 2

NLGI NO. 2NLGI NO. 2

HIGH TEMP. /EPHIGH TEMP. /EP

HIGH TEMP. /EP

HIGH TEMP. /EPHIGH TEMP. /EP

NLGI O OR INLGI O OR I

NLGI O OR I

NLGI O OR INLGI O OR I

ARCTIC GREASEARCTIC GREASE

ARCTIC GREASE

ARCTIC GREASEARCTIC GREASE

HYDRAULIC OILHYDRAULIC OIL

HYDRAULIC OIL

HYDRAULIC OILHYDRAULIC OIL

The following lists some features to look for in an oil. The hydraulic oil for the machine should feature:

- Rust resistant additives to prevent rust formation from moisture condensation.

- Anti-foaming agents to break up air bubbles and prevent "foaming" that may cause sluggish and erratic operation.

- High stability 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 for easy flow at low temperatures without thinning out at high temp's after hours of use.

For operation in different temperatures, refer to the following chart for selection of hydraulic oil.

System Operating TemperatureSystem Operating Temperature

System Operating Temperature

ISO Viscosity GradeISO Viscosity Grade

ISO Viscosity Grade

ISO Viscosity GradeISO Viscosity Grade

46 32° F. to 45° F.

Below 32° F. ambient, consult the factory.Below 32° F. ambient, consult the factory.

Below 32° F. ambient, consult the factory.

Below 32° F. ambient, consult the factory.Below 32° F. ambient, consult the factory.

ENGINE OILENGINE OIL

ENGINE OIL

ENGINE OILENGINE OIL

Refer to the specifications in the engine manufacturer's manuals that are supplied with every new machine.

FUEL SPECIFICATIONSFUEL SPECIFICATIONS

FUEL SPECIFICATIONS

FUEL SPECIFICATIONSFUEL SPECIFICATIONS

Use grade no. 2-D fuel above 40 degrees F. Use grade no. 1-D fuel below 40 degrees F. Use grade no. 1-D fuel for all air temperatures at altitudes.

NOTE: NOTE:

NOTE: Change the engine oil at one half the normal interval if fuel sulfur content exceeds 0.5%. Use fuel with

NOTE: NOTE:

less than 1.0% sulfur. Use fuel with less than 0.5% sulfur if possible. Sediment and water should not exceed 0.10% for maximum filter life.

Average Ambient Temp.Average Ambient Temp.

Average Ambient Temp.

Average Ambient Temp.Average Ambient Temp.

ABOVE 45° F.

System Operating TemperatureSystem Operating Temperature

150° F. Max.

190° F. Max.

The Cetane number should be 40 minimum. A fuel with a higher Cetane number may be required if operating the machine where air temperatures are normally low or where altitudes are high. In cold weather operation, the cloud point should be 10 degrees F. below lowest normal air temperatures.

475 A CRL

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800-00167

FLUID SPECIFICATIONS CONTINUED...

FUEL STORAGEFUEL STORAGE

FUEL STORAGE

FUEL STORAGEFUEL STORAGE

NOTE: NOTE:

NOTE: Diesel fuels stored for a long time may form gum or bacteria and plug filters.

NOTE: NOTE:

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: NOTE:

NOTE: Keep all dirt, scale, water, or other foreign material out of fuel.

NOTE: NOTE:

Store fuel drums on sides with plug up.

ALTERNATIVE LUBRICANTSALTERNATIVE LUBRICANTS

ALTERNATIVE LUBRICANTS

ALTERNATIVE LUBRICANTSALTERNATIVE LUBRICANTS

Conditions in certain geographical areas may require special lubricants and lubrication practices which do not appear in this manual.

LUBRICANT STORAGELUBRICANT STORAGE

LUBRICANT STORAGE

LUBRICANT STORAGELUBRICANT STORAGE

The machine can operate at top efficiency only if clean lubricants are used. Use a clean container to handle all lubricants. Store them in an area protected from dust, moisture, and other contaminants. Store drums on sides.

WARNING WARNING

WARNING

WARNING WARNING

Diesel fuel or hydraulic fluid under pressure can penetrate the skin or eyes.Diesel fuel or hydraulic fluid under pressure can penetrate the skin or eyes.

Diesel fuel or hydraulic fluid under pressure can penetrate the skin or eyes.

Diesel fuel or hydraulic fluid under pressure can penetrate the skin or eyes.Diesel fuel or hydraulic fluid under pressure can penetrate the skin or eyes. Fluid leaks under pressure may not be visible. Use a piece of cardboard orFluid leaks under pressure may not be visible. Use a piece of cardboard or

Fluid leaks under pressure may not be visible. Use a piece of cardboard or

Fluid leaks under pressure may not be visible. Use a piece of cardboard orFluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find leaks but do not use bare hand. Wear safety goggles. If fluidwood to find leaks but do not use bare hand. Wear safety goggles. If fluid

wood to find leaks but do not use bare hand. Wear safety goggles. If fluid

wood to find leaks but do not use bare hand. Wear safety goggles. If fluidwood to find leaks but do not use bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention.enters skin or eyes, get immediate medical attention.

enters skin or eyes, get immediate medical attention.

enters skin or eyes, get immediate medical attention.enters skin or eyes, get immediate medical attention.

475 A CRL 800-00167

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SPECIAL TORQUE SPECIFICATIONSSPECIAL TORQUE SPECIFICATIONS

SPECIAL TORQUE SPECIFICATIONS

SPECIAL TORQUE SPECIFICATIONSSPECIAL TORQUE SPECIFICATIONS

WARNING WARNING

WARNING

WARNING WARNING

Loose or overtorqued bolts can cause death, severe injury, or propertyLoose or overtorqued bolts can cause death, severe injury, or property

Loose or overtorqued bolts can cause death, severe injury, or property

Loose or overtorqued bolts can cause death, severe injury, or propertyLoose or overtorqued bolts can cause death, severe injury, or property damage. Maintain proper bolt torque. Visually check bolts daily. Checkdamage. Maintain proper bolt torque. Visually check bolts daily. Check

damage. Maintain proper bolt torque. Visually check bolts daily. Check

damage. Maintain proper bolt torque. Visually check bolts daily. Checkdamage. Maintain proper bolt torque. Visually check bolts daily. Check torque every 50 hours.torque every 50 hours.

torque every 50 hours.

torque every 50 hours.torque every 50 hours.

WARNING WARNING

WARNING

WARNING WARNING

In critical applications (such as Turntable Bearing Bolts and any grade 8 orIn critical applications (such as Turntable Bearing Bolts and any grade 8 or

In critical applications (such as Turntable Bearing Bolts and any grade 8 or

In critical applications (such as Turntable Bearing Bolts and any grade 8 orIn 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 mustgrade 9 bolts), once the old bolts and nuts have been loosened, they must

grade 9 bolts), once the old bolts and nuts have been loosened, they must

grade 9 bolts), once the old bolts and nuts have been loosened, they mustgrade 9 bolts), once the old bolts and nuts have been loosened, they must be replaced rather than re-tightened and re-torqued. Original clampingbe replaced rather than re-tightened and re-torqued. Original clamping

be replaced rather than re-tightened and re-torqued. Original clamping

be replaced rather than re-tightened and re-torqued. Original clampingbe replaced rather than re-tightened and re-torqued. Original clamping force cannot be achieved using the old bolts and nuts.force cannot be achieved using the old bolts and nuts.

force cannot be achieved using the old bolts and nuts.

force cannot be achieved using the old bolts and nuts.force cannot be achieved using the old bolts and nuts.

LUBRICATE WITH ANTI-SEIZE COMPOUND PART NO. 514-00700LUBRICATE WITH ANTI-SEIZE COMPOUND PART NO. 514-00700

LUBRICATE WITH ANTI-SEIZE COMPOUND PART NO. 514-00700

LUBRICATE WITH ANTI-SEIZE COMPOUND PART NO. 514-00700LUBRICATE WITH ANTI-SEIZE COMPOUND PART NO. 514-00700

Swing Motor Mounting Bolts ........................................................................... 64 Ft. Lbs.

Swing Motor Gearbox Mounting Bolts ............................................................. 310 Ft. Lbs.

Turntable Bearing Bolts (Do not re-use old bolts/nuts.).................................... 500 Ft. Lbs

Crawler Carbody Mounting Bolts (secure the carbody to the crawler tracks):

- Standard bolts ........................................................................................... 545 Ft. Lbs.

- Metric bolts ............................................................................................... 924 Ft. Lbs.

For Grapple Torques, see Grapple Service Manual.

CRAWLER BOLT TORQUECRAWLER BOLT TORQUE

CRAWLER BOLT TORQUE

CRAWLER BOLT TORQUECRAWLER BOLT TORQUE

The Crawler Carbody Mounting Bolts, which mount the carbody to the crawler tracks, should be checked and retorqued, if necessary, every 50 hours.

For standard bolts: torque to 545 Ft. Lbs of lubed torque. For metric bolts: torque to 924 Ft. Lbs. of lubed torque.

See Figure 1.

CRAWLER LOWER ASSEMBLYCRAWLER LOWER ASSEMBLY

CRAWLER LOWER ASSEMBLY

CRAWLER LOWER ASSEMBLYCRAWLER LOWER ASSEMBLY

TRACKSTRACKS

TRACKS

TRACKSTRACKS

CARBODYCARBODY

CARBODY

CARBODYCARBODY MOUNTINGMOUNTING

MOUNTING

MOUNTINGMOUNTING BOLTSBOLTS

BOLTS

BOLTSBOLTS

475 A CRL 800-00167

FIGURE 2FIGURE 2

FIGURE 2

FIGURE 2FIGURE 2

page 24page 24

page 24

page 24page 24

CRAWLER CARBODYCRAWLER CARBODY

CRAWLER CARBODY

CRAWLER CARBODYCRAWLER CARBODY

GENERAL TORQUE SPECIFICATIONSGENERAL TORQUE SPECIFICATIONS

GENERAL TORQUE SPECIFICATIONS

GENERAL TORQUE SPECIFICATIONSGENERAL TORQUE SPECIFICATIONS

See Special Torque Specifications that pertain specifically to this machine.

WARNING WARNING

WARNING

WARNING WARNING

Grade 9 bolts must be usedGrade 9 bolts must be used

Grade 9 bolts must be used

Grade 9 bolts must be usedGrade 9 bolts must be used with Grade 9 washers.with Grade 9 washers.

with Grade 9 washers.

with Grade 9 washers.with Grade 9 washers.

WARNING WARNING

WARNING

WARNING WARNING

Do not re-use grade 8 or gradeDo not re-use grade 8 or grade

Do not re-use grade 8 or grade

Do not re-use grade 8 or gradeDo not re-use grade 8 or grade 9 bolts or nuts - replace with9 bolts or nuts - replace with

9 bolts or nuts - replace with

9 bolts or nuts - replace with9 bolts or nuts - replace with new ones.new ones.

new ones.

new ones.new ones.

WARNING WARNING

WARNING

WARNING WARNING

Loose or overtorqued bolts canLoose or overtorqued bolts can

Loose or overtorqued bolts can

Loose or overtorqued bolts canLoose or overtorqued bolts can cause death, severe injury, orcause death, severe injury, or

cause death, severe injury, or

cause death, severe injury, orcause death, severe injury, or property damage. Maintainproperty damage. Maintain

property damage. Maintain

property damage. Maintainproperty damage. Maintain proper bolt torque. Visuallyproper bolt torque. Visually

proper bolt torque. Visually

proper bolt torque. Visuallyproper bolt torque. Visually check bolts daily. Checkcheck bolts daily. Check

check bolts daily. Check

check bolts daily. Checkcheck bolts daily. Check torque every 50 hours.torque every 50 hours.

torque every 50 hours.

torque every 50 hours.torque every 50 hours.

This is lubed torque.

Lubricate with anti-seize compound part no. 514-

00700.

GRADE 5GRADE 5

GRADE 5

GRADE 5GRADE 5

SAE GRADE 5SAE GRADE 5

SAE GRADE 5

SAE GRADE 5SAE GRADE 5

RECOMMENDEDRECOMMENDED

RECOMMENDED

RECOMMENDEDRECOMMENDED

TORQUE FOOTTORQUE FOOT

TORQUE FOOT

TORQUE FOOTTORQUE FOOT

POUNDSPOUNDS

POUNDS

POUNDSPOUNDS

GRADE 8GRADE 8

GRADE 8

GRADE 8GRADE 8

SAE GRADE 8SAE GRADE 8

SAE GRADE 8

SAE GRADE 8SAE GRADE 8

RECOMMENDEDRECOMMENDED

RECOMMENDED

RECOMMENDEDRECOMMENDED

TORQUE FOOTTORQUE FOOT

TORQUE FOOT

TORQUE FOOTTORQUE FOOT

POUNDSPOUNDS

POUNDS

POUNDSPOUNDS

LUBRICATEDLUBRICATED

LUBRICATED

DRYDRY

DRY

DIA.DIA.

DIA.

DIA.DIA.

1/4 9 10 5 6 5/16 17 20 10 12 3/8 31 35 19 21 7/16 50 55 30 33 1/2 75 85 45 51 9/16 110 120 66 72 5/8 150 170 90 100 3/4 265 300 160 180 7/8 400 435 240 260 1 600 650 360 390 1-1/8 800 900 480 540 1-1/4 1120 1240 670 745 1-3/8 1470 1670 880 1000 1-1/2 1950 2200 1170 1320

DIA.DIA.

DIA.

DIA.DIA.

1/4 12 14 7 9 5/16 25 27 15 17 3/8 44 49 26 30 7/16 70 78 42 47 1/2 107 120 64 72 9/16 154 171 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 2134

DIA.DIA.

DIA.

DIA.DIA.

DRYDRY

COARSECOARSE

COARSE

COARSECOARSE

DRYDRY

DRY

DRYDRY

COARSECOARSE

COARSE

COARSECOARSE

DRYDRY

DRY

DRYDRY

COARSECOARSE

COARSE

COARSECOARSE

FINEFINE

FINE

FINEFINE

FINE

FINEFINE

FINE

FINEFINE

LUBRICATEDLUBRICATED

COARSECOARSE

COARSE

COARSECOARSE

LUBRICATEDLUBRICATED

LUBRICATED

LUBRICATEDLUBRICATED

COARSECOARSE

COARSE

COARSECOARSE

LUBRICATEDLUBRICATED

LUBRICATED

LUBRICATEDLUBRICATED

COARSECOARSE

COARSE

COARSECOARSE

FINEFINE

FINE

FINEFINE

FINE

FINEFINE

FINE

FINEFINE

GRADE 9GRADE 9

GRADE 9

GRADE 9GRADE 9

(MIN. 8 RADIAL(MIN. 8 RADIAL

(MIN. 8 RADIAL

(MIN. 8 RADIAL(MIN. 8 RADIAL

MARKS ONMARKS ON

MARKS ON

MARKS ONMARKS ON

HEAD) GRADE 9HEAD) GRADE 9

HEAD) GRADE 9

HEAD) GRADE 9HEAD) GRADE 9

(BOW-MALLOY)(BOW-MALLOY)

(BOW-MALLOY)

(BOW-MALLOY)(BOW-MALLOY)

RECOMMENDEDRECOMMENDED

RECOMMENDED

RECOMMENDEDRECOMMENDED

TORQUE FOOTTORQUE FOOT

TORQUE FOOT

TORQUE FOOTTORQUE FOOT

POUNDSPOUNDS

POUNDS

POUNDSPOUNDS

475 A CRL

page 25page 25

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800-00167

1/4 17 19 10 12 5/16 34 37 20 22 3/8 60 68 36 41 7/16 96 108 58 65 1/2 145 165 87 100 9/16 210 235 125 140 5/8 290 330 175 200 3/4 515 575 310 345 7/8 830 980 500 590 1 1250 1350 750 810 1-1/8 1750 1950 1050 1170 1-1/4 2500 2750 1500 1650 1-3/8 3250 3700 1950 2220 1-1/2 4350 4850 2600 2900

B. HYDRAULIC SYSTEMB. HYDRAULIC SYSTEM

B. HYDRAULIC SYSTEM

B. HYDRAULIC SYSTEMB. HYDRAULIC SYSTEM

MAINTENANCEMAINTENANCE

MAINTENANCE

MAINTENANCEMAINTENANCE

475 A CRL 800-00167

page 26page 26

page 26

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MaintenanceMaintenance

Maintenance

HYDRAULIC SCHEMATICHYDRAULIC SCHEMATIC

HYDRAULIC SCHEMATIC

HYDRAULIC SCHEMATICHYDRAULIC SCHEMATIC

607-00006607-00006

607-00006

607-00006607-00006

475 A CRL 800-00167

page 27page 27

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HYDRAULIC PRESSURE SETTINGSHYDRAULIC PRESSURE SETTINGS

HYDRAULIC PRESSURE SETTINGS

HYDRAULIC PRESSURE SETTINGSHYDRAULIC PRESSURE SETTINGS

RELIEF VALVESRELIEF VALVES

RELIEF VALVES

RELIEF VALVESRELIEF 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 CAUTION

CAUTION

CAUTION CAUTION

The relief valve pressure setting has been arrivedThe relief valve pressure setting has been arrived

The relief valve pressure setting has been arrived

The relief valve pressure setting has been arrivedThe relief valve pressure setting has been arrived at by our engineers after considerable experienceat by our engineers after considerable experience

at by our engineers after considerable experience

at by our engineers after considerable experienceat by our engineers after considerable experience with and testing of this loader. The setting willwith and testing of this loader. The setting will

with and testing of this loader. The setting will

with and testing of this loader. The setting willwith and testing of this loader. The setting will provide maximum safety and efficiency of operation.provide maximum safety and efficiency of operation.

provide maximum safety and efficiency of operation.

provide maximum safety and efficiency of operation.provide maximum safety and efficiency of operation. DO NOT ALTER THIS RELIEF SETTING! Relief settingsDO NOT ALTER THIS RELIEF SETTING! Relief settings

DO NOT ALTER THIS RELIEF SETTING! Relief settings

DO NOT ALTER THIS RELIEF SETTING! Relief settingsDO NOT ALTER THIS RELIEF SETTING! Relief settings increased beyond this setting could be dangerousincreased beyond this setting could be dangerous

increased beyond this setting could be dangerous

increased beyond this setting could be dangerousincreased beyond this setting could be dangerous to life, limb and property.to life, limb and property.

to life, limb and property.

to life, limb and property.to life, limb and property.

Altering the settings on a new machine will voidAltering the settings on a new machine will void

Altering the settings on a new machine will void

Altering the settings on a new machine will voidAltering the settings on a new machine will void the warranty.the warranty.

the warranty.

the warranty.the warranty.

The following is a list of pressure settings used on your Barko Loader. Any questions should be directed to the factory. Phone 715-392-5641.

THE BOOM AND TRAVEL PUMPS:THE BOOM AND TRAVEL PUMPS:

THE BOOM AND TRAVEL PUMPS:

THE BOOM AND TRAVEL PUMPS:THE BOOM AND TRAVEL PUMPS:

Pump Compensators .................................................. 4250 PS I

THE GRAPPLE PUMP:THE GRAPPLE PUMP:

THE GRAPPLE PUMP:

THE GRAPPLE PUMP:THE GRAPPLE PUMP:

Pump Compensator .................................................... 2500 PSI

GRAPPLE ROTATE PRESSURE :GRAPPLE ROTATE PRESSURE :

GRAPPLE ROTATE PRESSURE :

GRAPPLE ROTATE PRESSURE :GRAPPLE ROTATE PRESSURE :

Continuous Rotation Grapples: .......................................... 750 PSI set at cushion valve on grapple motor.

Non-continuous Rotation Grapples: ................................... 1500 PSI set at cushion valve on grapple.

THE SWING PUMP:THE SWING PUMP:

THE SWING PUMP:

THE SWING PUMP:THE SWING PUMP:

High Pressure Reliefs ................................................. 4500 PSI Right

................................................................................... 4500 PSI Left

Charge Pressure ......................................................... 320 PSI minimum to 580 PSI maximum.

Swing System Pressure ............................................. 4000 PSI at controller.

THE SERVO SYSTEM:THE SERVO SYSTEM:

THE SERVO SYSTEM:

THE SERVO SYSTEM:THE SERVO SYSTEM:

At the Servo Relief Valve ........................................... 500 PSI

THE GRAPPLE FUNCTION VALVE:THE GRAPPLE FUNCTION VALVE:

THE GRAPPLE FUNCTION VALVE:

THE GRAPPLE FUNCTION VALVE:THE GRAPPLE FUNCTION VALVE:

Main Relief ................................................................. 3000 PSI

475 A CRL 800-00167

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HYDRAULIC PRESSURE SETTINGS CONTINUED...

BOOM AND TRAVEL FUNCTION VALVESBOOM AND TRAVEL FUNCTION VALVES

BOOM AND TRAVEL FUNCTION VALVES

BOOM AND TRAVEL FUNCTION VALVESBOOM AND TRAVEL FUNCTION VALVES The most important servicing required on the Boom & Travel Function Valves is the pressure setting. Each valve "bank" has a Main Relief witha special setting, and Port Reliefs with different settings for each one. The following is a list of pressure settings along with a diagram to show where each setting is applied.

Main Boom - up (butt end of main boom cylinder) ............................. 4800 PS I at the Port Relief

Main Boom - down (rod end of main boom cylinder) .......................... 3300 PSI at the Port Relief

.........................................................................................................

Secondary Boom - up (butt end of secondary boom cylinder) ............ 5600 PSI at the Port Relief

Secondary Boom - down (rod end of secondary boom cylinder) ........ 4800 P SI at the Port Relief

Live Heel Boom - up (rod end of live heel boom cylinder) ................. 5600 PSI at the Port Relief

Live Heel Boom - down (butt end of live heel boom cylinder) .............1850 PSI at the Port Relief

Main Reliefs ...................................................................................... 4600 PS I

NONENONE

48004800

NONE

4800

NONENONE

NONE

FAST STICK LINEFAST STICK LINE

FAST STICK LINE

FAST STICK LINEFAST STICK LINE

SECSEC

SEC

MAINMAIN

MAIN

TRAVELTRAVEL

TRAVEL

33003300

3300

NONENONE

NONE

4600 PSI MAIN RELIEF4600 PSI MAIN RELIEF

4600 PSI MAIN RELIEF

4600 PSI MAIN RELIEF4600 PSI MAIN RELIEF

NONENONE

NONE

4600 PSI MAIN RELIEF4600 PSI MAIN RELIEF

4600 PSI MAIN RELIEF

4600 PSI MAIN RELIEF4600 PSI MAIN RELIEF

56005600

48004800

4800

SECSEC

SEC

56005600

5600

HEELHEEL

HEEL

18501850

1850

NONENONE

NONE

TRAVELTRAVEL

TRAVEL

NONENONE

NONE

475 A CRL 800-00167

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HYDRAULIC PRESSURE ADJUSTMENTHYDRAULIC PRESSURE ADJUSTMENT

HYDRAULIC PRESSURE ADJUSTMENT

HYDRAULIC PRESSURE ADJUSTMENTHYDRAULIC PRESSURE ADJUSTMENT

PROCEDUREPROCEDURE

PROCEDURE

PROCEDUREPROCEDURE

Use this illustration as a reference for pump locations, for the following procedures.Use this illustration as a reference for pump locations, for the following procedures.

Use this illustration as a reference for pump locations, for the following procedures.

Use this illustration as a reference for pump locations, for the following procedures.Use this illustration as a reference for pump locations, for the following procedures.

BOOM & TRAVELBOOM & TRAVEL

BOOM & TRAVEL

BOOM & TRAVELBOOM & TRAVEL PUMP (UPPER)PUMP (UPPER)

PUMP (UPPER)

PUMP (UPPER)PUMP (UPPER)

BOOM & TRAVELBOOM & TRAVEL

BOOM & TRAVEL

BOOM & TRAVELBOOM & TRAVEL PUMP (LOWER)PUMP (LOWER)

PUMP (LOWER)

PUMP (LOWER)PUMP (LOWER)

SWING PUMPSWING PUMP

SWING PUMP

SWING PUMPSWING PUMP

GRAPPLEGRAPPLE

GRAPPLE

GRAPPLEGRAPPLE PUMPPUMP

PUMP

PUMPPUMP

PUMP

PUMPPUMP DRIVEDRIVE

DRIVE

DRIVEDRIVE

WARNING WARNING

WARNING

WARNING WARNING

When setting pressure, use caution to avoid excessiveWhen setting pressure, use caution to avoid excessive

When setting pressure, use caution to avoid excessive

When setting pressure, use caution to avoid excessiveWhen setting pressure, use caution to avoid excessive hydraulic pressures which could damage componentshydraulic pressures which could damage components

hydraulic pressures which could damage components

hydraulic pressures which could damage componentshydraulic pressures which could damage components and endanger personnel.and endanger personnel.

and endanger personnel.

and endanger personnel.and endanger personnel.

SERVOSERVO

SERVO

SERVOSERVO PUMPPUMP

PUMP

PUMPPUMP

1. Adjust maximum displacement on the Boom & Travel Pumps by turning the maximum displacement screw with a 6mm Allen wrench until 13mm (1/2 inch) of the screw extends beyond the jam nut.

NOTE:NOTE:

NOTE: The minimum displacement screw is set at

NOTE:NOTE:

the factory and should not be touched.

2. On the Grapple Pump, remove the cap and turn the load sense adjusting screw (with a 3mm Allen wrench) completely in, and then tighten the jam nut.

3. While monitoring the Swing Pump charge PSI, which must be 320 - 580 PSI at maximum engine RPM, check the maximum engine RPM which should be 2150 - 2250 (high idle).

4. All pressures are to be set at high idle.

BOOM & TRAVEL PUMPBOOM & TRAVEL PUMP

BOOM & TRAVEL PUMP

BOOM & TRAVEL PUMPBOOM & TRAVEL PUMP

JAMJAM

JAM

JAMJAM NUTNUT

NUT

NUTNUT

MAXIMUMMAXIMUM

MAXIMUM

MAXIMUMMAXIMUM DISPLACEMENTDISPLACEMENT

DISPLACEMENT

DISPLACEMENTDISPLACEMENT SCREWSCREW

SCREW

SCREWSCREW

GRAPPLE PUMPGRAPPLE PUMP

GRAPPLE PUMP

GRAPPLE PUMPGRAPPLE PUMP

MINIMUMMINIMUM

MINIMUM

MINIMUMMINIMUM DISPLACEMENTDISPLACEMENT

DISPLACEMENT

DISPLACEMENTDISPLACEMENT SCREWSCREW

SCREW

SCREWSCREW

(Set at(Set at

(Set at

(Set at(Set at factory)factory)

factory)

factory)factory)

LOAD SENSELOAD SENSE

LOAD SENSE

LOAD SENSELOAD SENSE ADJUSTINGADJUSTING

ADJUSTING

ADJUSTINGADJUSTING SCREWSCREW

SCREW

SCREWSCREW

JAM NUTJAM NUT

JAM NUT

JAM NUTJAM NUT

475 A CRL 800-00167

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HYDRAULIC PRESSURE ADJUSTMENT PROCEDURE CONTINUED...

SERVO MANIFOLDSERVO MANIFOLD

SERVO MANIFOLD

SERVO MANIFOLDSERVO MANIFOLD

5. Set the servo pressure to 500 PSI at high idle.

6. Raise the swing system pressure at the controller to 4800 PSI in order to adjust the relief valves.

7. Set the pressure at the Swing Pump relief valves to 4500 PSI.

8. Then reset the swing system pressure at the Controller back to 4000 PSI.

NOTE:NOTE:

NOTE: 4000 PSI is the maximum factory

NOTE:NOTE:

recommended swing pressure.

SWING PUMPSWING PUMP

SWING PUMP

SWING PUMPSWING PUMP

RELIEFRELIEF

RELIEF

RELIEFRELIEF VALVE "B"VALVE "B"

VALVE "B"

VALVE "B"VALVE "B"

RELIEFRELIEF

RELIEF

RELIEFRELIEF VALVE "A"VALVE "A"

VALVE "A"

VALVE "A"VALVE "A"

TURN TO SETTURN TO SET

TURN TO SET

TURN TO SETTURN TO SET PRESSUREPRESSURE

PRESSURE

PRESSUREPRESSURE

ADJUST SWINGADJUST SWING

ADJUST SWING

ADJUST SWINGADJUST SWING SYSTEMSYSTEM

SYSTEM

SYSTEMSYSTEM PRESSUREPRESSURE

PRESSURE

PRESSUREPRESSURE

CONTROLLERCONTROLLER

CONTROLLER

CONTROLLERCONTROLLER

CHARGE PRESSURECHARGE PRESSURE

CHARGE PRESSURE

CHARGE PRESSURECHARGE PRESSURE CHECK PORTCHECK PORT

CHECK PORT

CHECK PORTCHECK PORT

SERVO RELIEFSERVO RELIEF

SERVO RELIEF

SERVO RELIEFSERVO RELIEF VALVEVALVE

VALVE

VALVEVALVE ((

mounted tomounted to

(

mounted to

((

mounted tomounted to

servo manifold)servo manifold)

servo manifold)

servo manifold)servo manifold)

SERVO PUMPSERVO PUMP

SERVO PUMP

SERVO PUMPSERVO PUMP

9. On the Grapple Pump, remove the cap and turn in the pressure adjusting screw on the compensator with a 4mm Allen wrench, raising the grapple pressure to 3200 PSI.

10. Adjust the main relief on the Grapple Valve to 3000 PSI.

GRAPPLE PUMPGRAPPLE PUMP

GRAPPLE PUMP

GRAPPLE PUMPGRAPPLE PUMP

PRESSUREPRESSURE

PRESSURE

PRESSUREPRESSURE ADJUSTINGADJUSTING

ADJUSTING

ADJUSTINGADJUSTING SCREWSCREW

SCREW

SCREWSCREW

COMPENSATORCOMPENSATOR

COMPENSATOR

COMPENSATORCOMPENSATOR

GRAPPLE VALVEGRAPPLE VALVE

GRAPPLE VALVE

GRAPPLE VALVEGRAPPLE VALVE

MAIN RELIEFMAIN RELIEF

MAIN RELIEF

MAIN RELIEFMAIN RELIEF

475 A CRL 800-00167

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HYDRAULIC PRESSURE ADJUSTMENT PROCEDURE CONTINUED...

11. Then reset the grapple pump compensator to 2500 PSI.

NOTE:NOTE:

NOTE: 2500 PSI is the maximum factory

NOTE:NOTE:

recommended pressure for the grapple pump.

12. Raise the main relief PSI settings on both Boom & Travel Function Valves above 5600 PSI by removing the acorn nut (cap), loosening the jam nut, and turning the exposed adjusting screw with a screwdriver, all the way in and then back out a quarter turn.

GRAPPLE PUMPGRAPPLE PUMP

GRAPPLE PUMP

GRAPPLE PUMPGRAPPLE PUMP

PRESSUREPRESSURE

PRESSURE

PRESSUREPRESSURE ADJUSTINGADJUSTING

ADJUSTING

ADJUSTINGADJUSTING SCREWSCREW

SCREW

SCREWSCREW

COMPENSATORCOMPENSATOR

COMPENSATOR

COMPENSATORCOMPENSATOR

BOOM & TRAVEL VALVEBOOM & TRAVEL VALVE

BOOM & TRAVEL VALVE

BOOM & TRAVEL VALVEBOOM & TRAVEL VALVE (secondary shown)(secondary shown)

(secondary shown)

(secondary shown)(secondary shown)

13. On the

New StyleNew Style

New Style Boom & Travel Pumps, with

New StyleNew Style machine running and gauges on the pressure check ports, raise the compensator setting above 5600 PSI by loosening the jam nut and turning the adjusting screw in with a 3mm Allen wrench. Then retighten the jam nut.

NOTE:NOTE:

NOTE: On

NOTE:NOTE:

Old StyleOld Style

Old Style Boom & Travel Pumps, before

Old StyleOld Style raising the compensator setting as described below in item 13, be sure to back out the small adjusting screw on the conpensator, using a 3mm Allen Wrench, as far as it will go and then tighten the jam nut.

13. On the

Old StyleOld Style

Old Style Boom & Travel Pumps, with

Old StyleOld Style machine running and gauges on the pressure check ports, raise the compensator setting above 5600 PSI by loosening the adjusting nut and turning the threaded sleeve in. Then retighten the adjusting nut.

MAIN RELIEFMAIN RELIEF

MAIN RELIEF

MAIN RELIEFMAIN RELIEF

BOOM & TRAVEL PUMP (NEW STYLE)BOOM & TRAVEL PUMP (NEW STYLE)

BOOM & TRAVEL PUMP (NEW STYLE)

BOOM & TRAVEL PUMP (NEW STYLE)BOOM & TRAVEL PUMP (NEW STYLE)

COMPENSATORCOMPENSATOR

COMPENSATOR

COMPENSATORCOMPENSATOR

BOOM & TRAVEL PUMP (OLD STYLE)BOOM & TRAVEL PUMP (OLD STYLE)

BOOM & TRAVEL PUMP (OLD STYLE)

BOOM & TRAVEL PUMP (OLD STYLE)BOOM & TRAVEL PUMP (OLD STYLE)

THREADED SLEEVETHREADED SLEEVE

THREADED SLEEVE

THREADED SLEEVETHREADED SLEEVE

JAM NUTJAM NUT

JAM NUT

JAM NUTJAM NUT

ACORNACORN

ACORN

ACORNACORN NUTNUT

NUT

NUTNUT

ADJUSTINGADJUSTING

ADJUSTING

ADJUSTINGADJUSTING SCREWSCREW

SCREW

SCREWSCREW

JAM NUTJAM NUT

JAM NUT

JAM NUTJAM NUT

ADJUSTINGADJUSTING

ADJUSTING

ADJUSTINGADJUSTING SCREWSCREW

SCREW

SCREWSCREW

JAM NUTJAM NUT

JAM NUT

JAM NUTJAM NUT

ADJUSTINGADJUSTING

ADJUSTING

ADJUSTINGADJUSTING NUTNUT

NUT

NUTNUT

475 A CRL 800-00167

page 32page 32

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COMPENSATORCOMPENSATOR

COMPENSATOR

COMPENSATORCOMPENSATOR

HYDRAULIC PRESSURE ADJUSTMENT PROCEDURE CONTINUED...

14. To stall the tracks, disconnect the brake lines inside the drive motor compartment where it connects to the brake assembly and plug the lines with a #6 o-ring plug (Barko part number 569-00460, two are required). Set the relief valves on the Travel Counterbalance Valves (which are mounted on the Track Drive Motors) to 4800 PSI, both directions.

15. Raise the main boom to it's full upright position and retract the scondary boom into the machine. While holding the pumps at full pressure with the boom circuits adjust the engine RPM droop to 1900 - 2000 RPM by adjusting the speed sense cartridge with a 4mm Allen wrench.

NOTENOTE

NOTE: Turning the screw in (clockwise) will reduce

NOTENOTE

the engine droop.

TRAVEL COUNTERBALANCE VALVETRAVEL COUNTERBALANCE VALVE

TRAVEL COUNTERBALANCE VALVE

TRAVEL COUNTERBALANCE VALVETRAVEL COUNTERBALANCE VALVE

RELIEF VALVERELIEF VALVE

RELIEF VALVE

RELIEF VALVERELIEF VALVE

RELIEF VALVE

RELIEF VALVERELIEF VALVE

SWING PUMPSWING PUMP

SWING PUMP

SWING PUMPSWING PUMP

SPEED SENSESPEED SENSE

SPEED SENSE

SPEED SENSESPEED SENSE SCREWSCREW

SCREW

SCREWSCREW

16. Check port relief settings:

MAIN: Raise - 4800 PSI

Lower - 3300 PSI

SECONDARY: Raise - 5600 PSI

Lower - 4800 PSI

HEEL: Raise - 5600 PSI

Lower - 1850 PSI

STICK : Raise - 5600 PSI (Tri-Knuckle Lower - 4800 PSI Boom)

17. Set both main reliefs on the Boom & Travel Function Valves to 4800 PSI.

MAINMAIN

MAIN

MAINMAIN LOWERLOWER

LOWER

LOWERLOWER

HEELHEEL

HEEL

HEELHEEL

RAISERAISE

RAISE

RAISERAISE

SEC.SEC.

SEC.

SEC.SEC. LOWERLOWER

LOWER

LOWERLOWER

PORT RELIEFSPORT RELIEFS

PORT RELIEFS

PORT RELIEFSPORT RELIEFS

BOOM & TRAVELBOOM & TRAVEL

BOOM & TRAVEL

BOOM & TRAVELBOOM & TRAVEL VALVEVALVE

VALVE

VALVEVALVE (secondary)(secondary)

(secondary)

(secondary)(secondary)

BOOM &BOOM &

BOOM &

BOOM &BOOM & TRAVELTRAVEL

TRAVEL

TRAVELTRAVEL VALVEVALVE

VALVE

VALVEVALVE (main)(main)

(main)

(main)(main)

MAINMAIN

MAIN

MAINMAIN RAISERAISE

RAISE

RAISERAISE

BOOM & TRAVELBOOM & TRAVEL

BOOM & TRAVEL

BOOM & TRAVELBOOM & TRAVEL VALVEVALVE

VALVE

VALVEVALVE (secondary)(secondary)

(secondary)

(secondary)(secondary)

HEELHEEL

HEEL

HEELHEEL LOWERLOWER

LOWER

LOWERLOWER

SEC.SEC.

SEC.

SEC.SEC. RAISERAISE

RAISE

RAISERAISE

475 A CRL 800-00167

page 33page 33

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JAM NUTJAM NUT

JAM NUT

JAM NUTJAM NUT

MAIN RELIEFMAIN RELIEF

MAIN RELIEF

MAIN RELIEFMAIN RELIEF

ACORN NUTACORN NUT

ACORN NUT

ACORN NUTACORN NUT

HYDRAULIC PRESSURE ADJUSTMENT PROCEDURE CONTINUED...

18. Lower the Boom & Travel Pump's compensator pressure adjustment settings to 4250 PSI.

NOTE:NOTE:

NOTE: 4250 PSI is the maximum factory

NOTE:NOTE:

recommended pressure for the Boom and

Travel Pumps.

BOOM & TRAVEL PUMP (NEW STYLE)BOOM & TRAVEL PUMP (NEW STYLE)

BOOM & TRAVEL PUMP (NEW STYLE)

BOOM & TRAVEL PUMP (NEW STYLE)BOOM & TRAVEL PUMP (NEW STYLE)

COMPENSATORCOMPENSATOR

COMPENSATOR

COMPENSATORCOMPENSATOR

BOOM & TRAVEL PUMP (OLD STYLE)BOOM & TRAVEL PUMP (OLD STYLE)

BOOM & TRAVEL PUMP (OLD STYLE)

BOOM & TRAVEL PUMP (OLD STYLE)BOOM & TRAVEL PUMP (OLD STYLE)

THREADEDTHREADED

THREADED

THREADEDTHREADED

SLEEVESLEEVE

SLEEVE

SLEEVESLEEVE

ADJUSTINGADJUSTING

ADJUSTING

ADJUSTINGADJUSTING SCREWSCREW

SCREW

SCREWSCREW

JAM NUTJAM NUT

JAM NUT

JAM NUTJAM NUT

19. On units equipped with hydraulic motor drive generators for magnets, adjust generator speed by turning maximum volume screw. Turning screw out (counterclockwise) will increase generator speed. The factory recommended spec is 1750 RPM - 230 volts, no load.

GRAPPLE PUMPGRAPPLE PUMP

GRAPPLE PUMP

GRAPPLE PUMPGRAPPLE PUMP

ADJUSTINGADJUSTING

ADJUSTING

ADJUSTINGADJUSTING NUTNUT

NUT

NUTNUT

COMPENSATORCOMPENSATOR

COMPENSATOR

COMPENSATORCOMPENSATOR

MAXIMUMMAXIMUM

MAXIMUM

MAXIMUMMAXIMUM VOLUMEVOLUME

VOLUME

VOLUMEVOLUME SCREWSCREW

SCREW

SCREWSCREW

475 A CRL 800-00167

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HYDRAULIC RESERVOIR MAINTENANCEHYDRAULIC RESERVOIR MAINTENANCE

HYDRAULIC RESERVOIR MAINTENANCE

HYDRAULIC RESERVOIR MAINTENANCEHYDRAULIC RESERVOIR MAINTENANCE

The supply source for the hydraulic system, the oil reservoir, is located on the frame on the right side of the machine. The reservoir features return line filters and suction screens to keep the oil clean. Filters are cleanable, and/or replaceable. A sight gauge for checking oil level is located on the left side of the reservoir.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

INSPECTIONINSPECTION

INSPECTION

INSPECTIONINSPECTION COVERCOVER

COVER

COVERCOVER

GASKETGASKET

GASKET

GASKETGASKET

FILLER CAPFILLER CAP

FILLER CAP

FILLER CAPFILLER CAP

When making repairs onWhen making repairs on

When making repairs on

When making repairs onWhen making repairs on hydraulic system, keep allhydraulic system, keep all

hydraulic system, keep all

hydraulic system, keep allhydraulic system, keep all parts clean and removeparts clean and remove

parts clean and remove

parts clean and removeparts clean and remove all dirt from the areaall dirt from the area

all dirt from the area

all dirt from the areaall dirt from the area before you begin dis-before you begin dis-

before you begin dis-

before you begin dis-before you begin disassembly. Use caps andassembly. Use caps and

assembly. Use caps and

assembly. Use caps andassembly. Use caps and plugs to keep dirt out ofplugs to keep dirt out of

plugs to keep dirt out of

plugs to keep dirt out ofplugs to keep dirt out of tubelines and openings.tubelines and openings.

tubelines and openings.

tubelines and openings.tubelines and openings.

RETURNRETURN

RETURN

RETURNRETURN FILTERSFILTERS

FILTERS

FILTERSFILTERS

SIGHTSIGHT

SIGHT

SIGHTSIGHT GAUGEGAUGE

GAUGE

GAUGEGAUGE

DRAIN PLUGSDRAIN PLUGS

DRAIN PLUGS

DRAIN PLUGSDRAIN PLUGS

TEMPERATURETEMPERATURE

TEMPERATURE

TEMPERATURETEMPERATURE LEVEL SENDERLEVEL SENDER

LEVEL SENDER

LEVEL SENDERLEVEL SENDER

SUCTIONSUCTION

SUCTION

SUCTIONSUCTION STRAINERSSTRAINERS

STRAINERS

STRAINERSSTRAINERS

SHUT-OFFSHUT-OFF

SHUT-OFF

SHUT-OFFSHUT-OFF VALVESVALVES

VALVES

VALVESVALVES

Check oil level in reservoir before each period of operation, or daily. If, at any time, you find the level is low, check the loader for leaks around tubes, hoses, fittings, and couplings.

475 A CRL

page 35page 35

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800-00167

HYDRAULIC RESERVOIR MAINTENANCE CONTINUED...

HYDRAULIC OIL CHANGING PROCEDUREHYDRAULIC OIL CHANGING PROCEDURE

HYDRAULIC OIL CHANGING PROCEDURE

HYDRAULIC OIL CHANGING PROCEDUREHYDRAULIC OIL CHANGING PROCEDURE

This procedure should be used once during the breaking in period of a new loader (after one week, or 50 hours of operation) and then every six months, or 1000 hours.

Throughout the oil changing procedure remember that cleanliness is absolutely necessary. Hands, tools, funnels, 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 cylinders.

DRAINING THE RESERVOIRDRAINING THE RESERVOIR

DRAINING THE RESERVOIR

DRAINING THE RESERVOIRDRAINING THE RESERVOIR

1. First, be sure boom is lowered to the ground and secure.

2. Remove the reservoir drain plug to drain the oil.

FILLER CAPFILLER CAP

FILLER CAP

INSPECTIONINSPECTION

INSPECTION

INSPECTIONINSPECTION COVERCOVER

COVER

COVERCOVER

GASKETGASKET

GASKET

GASKETGASKET

FILLER CAPFILLER CAP

When making repairs onWhen making repairs on

When making repairs on

When making repairs onWhen making repairs on hydraulic system, keep allhydraulic system, keep all

hydraulic system, keep all

hydraulic system, keep allhydraulic system, keep all parts clean and removeparts clean and remove

parts clean and remove

parts clean and removeparts clean and remove all dirt from the areaall dirt from the area

all dirt from the area

all dirt from the areaall dirt from the area before you begin dis-before you begin dis-

before you begin dis-

before you begin dis-before you begin disassembly. Use caps andassembly. Use caps and

assembly. Use caps and

assembly. Use caps andassembly. Use caps and plugs to keep dirt out ofplugs to keep dirt out of

plugs to keep dirt out of

plugs to keep dirt out ofplugs to keep dirt out of tubelines and openings.tubelines and openings.

tubelines and openings.

tubelines and openings.tubelines and openings.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

RETURNRETURN

RETURN

RETURNRETURN FILTERSFILTERS

FILTERS

FILTERSFILTERS

SIGHTSIGHT

SIGHT

SIGHTSIGHT GAUGEGAUGE

GAUGE

GAUGEGAUGE

DRAIN PLUGSDRAIN PLUGS

DRAIN PLUGS

DRAIN PLUGSDRAIN PLUGS

TEMPERATURETEMPERATURE

TEMPERATURE

TEMPERATURETEMPERATURE LEVEL SENDERLEVEL SENDER

LEVEL SENDER

LEVEL SENDERLEVEL SENDER

SUCTIONSUCTION

SUCTION

SUCTIONSUCTION STRAINERSSTRAINERS

STRAINERS

STRAINERSSTRAINERS

475 A CRL 800-00167

page 36page 36

page 36

page 36page 36

SHUT-OFFSHUT-OFF

SHUT-OFF

SHUT-OFFSHUT-OFF VALVESVALVES

VALVES

VALVESVALVES

HYDRAULIC RESERVOIR MAINTENANCE CONTINUED...

CLEANING THE RESERVOIRCLEANING THE RESERVOIR

CLEANING THE RESERVOIR

CLEANING THE RESERVOIRCLEANING THE RESERVOIR

1. Clean the area around the inspection cover on tank, and then remove the cover.

2. Remove the suction strainer from inside the reservoir. Clean it with a solvent.

3. Remove all dirt and sediment from inside the reservoir.

4. Clean the oil filler screen and check for damage. If damaged, replace the screen.

5. After everything in and around the reservoir is completely clean, replace the suction strainer, drain plug, and inspection cover.

FILLING THE RESERVOIRFILLING THE RESERVOIR

FILLING THE RESERVOIR

FILLING THE RESERVOIRFILLING THE RESERVOIR

1. With the drain plug in place and tightened, refill the tank with the recommended oil. Be sure the filler

opening screen is in place and clean.

2. Start the engine, running it slowly until the new oil circulates throughout the system.

3. With all the control valves in neutral, run the engine until the pump quiets down, then add more oil, if

necessary.

4. As an operator works the booms and grapple, add more oil as needed to maintain proper level in

reservoir. This will work the air out of the system and prevent cavitation, which is caused by air bubbles in the oil as it passes through a pump.

5. Check the oil level again after the loader has been operating for an hour or two.

INSPECTIONINSPECTION

INSPECTION

GASKETGASKET

GASKET

GASKETGASKET

RETURNRETURN

RETURN

RETURNRETURN FILTERSFILTERS

FILTERS

FILTERSFILTERS

SIGHTSIGHT

SIGHT

SIGHTSIGHT GAUGEGAUGE

GAUGE

GAUGEGAUGE

INSPECTIONINSPECTION COVERCOVER

COVER

COVERCOVER

FILLER CAPFILLER CAP

FILLER CAP

FILLER CAPFILLER CAP

TEMPERATURETEMPERATURE

TEMPERATURE

TEMPERATURETEMPERATURE LEVEL SENDERLEVEL SENDER

LEVEL SENDER

LEVEL SENDERLEVEL SENDER

SUCTIONSUCTION

SUCTION

SUCTIONSUCTION STRAINERSSTRAINERS

STRAINERS

STRAINERSSTRAINERS

DRAIN PLUGSDRAIN PLUGS

DRAIN PLUGS

DRAIN PLUGSDRAIN PLUGS

475 A CRL 800-00167

page 37page 37

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SHUT-OFF VALVESSHUT-OFF VALVES

SHUT-OFF VALVES

SHUT-OFF VALVESSHUT-OFF VALVES

HYDRAULIC OIL FILTER MAINTENANCEHYDRAULIC OIL FILTER MAINTENANCE

HYDRAULIC OIL FILTER MAINTENANCE

HYDRAULIC OIL FILTER MAINTENANCEHYDRAULIC OIL FILTER MAINTENANCE

A. THE "RETURN" FILTERSA. THE "RETURN" FILTERS

A. THE "RETURN" FILTERS

A. THE "RETURN" FILTERSA. THE "RETURN" FILTERS

Two Return Filters are used, which are mounted together with a "manifold" on the top of the Hydraulic Oil Reservoir. See illustration below.

COVERCOVER

COVER

MANIFOLDMANIFOLD

MANIFOLD

MANIFOLDMANIFOLD

COVERCOVER

DIVERTER BYPASSDIVERTER BYPASS

DIVERTER BYPASS

DIVERTER BYPASSDIVERTER BYPASS VALVEVALVE

VALVE

VALVEVALVE

HEADHEAD

HEAD

HEADHEAD

ELEMENTELEMENT

ELEMENT

ELEMENTELEMENT

BOWLBOWL

BOWL

BOWLBOWL

KEY TO CLEAN FLUIDSKEY TO CLEAN FLUIDS

KEY TO CLEAN FLUIDS

KEY TO CLEAN FLUIDSKEY TO CLEAN FLUIDS Regular maintenance of filter elements is the key to clean fluid and long component life. Filters do not function when elements are clogged with contaminant to the point of bypass. Therefore, it its important to do three things:

1. Check the Filter Indicator frequently to determine when the element needs servicing.

2. Make sure the filter is fitted with the correct replacement element. The correct replacement element should be listed on the filter nameplate.

3. A periodic fluid sample of the system should be analyzed.

SERVICING ELEMENTSSERVICING ELEMENTS

SERVICING ELEMENTS

SERVICING ELEMENTSSERVICING ELEMENTS

1. Shut down the system and relieve all pressure in the filter line.

2. Loosen the hex head cap screws on the cover. Turn slightly to clear cover screws and remove the cover.

Allow excess fluid to drain.

3. Remove the diverter/bypass valve assembly.

4. Remove the element from the diverter/bypass valve assembly.

A. Disposable: Replace element if a disposable paper or synthetic media is used.

B. Cleanable: Soak the element in ultrasonic cleaner for fifteen minutes. If an ultrasonic cleaner is

not available, soak in hot soapy water and ammonia solution for fifteen minutes. Swish around and blow dry from the outside in.

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HYDRAULIC OIL FILTER MAINTENANCE CONTINUED...

5. Replace element on the diverter/bypass valve assembly and install in the filter housing. Make sure that the diverter o-ring seats properly into the head.

6. Check to make sure the notch on the diverter/bypass valve assembly lines up with the notch in the head.

7. Inspect the cover o-ring and replace it if necessary.

8. Replace the cover and tighten the hex head cap screws until they are snug. Do not over tighten these screws.

B. THE " SERVO" FILTERB. THE " SERVO" FILTER

B. THE " SERVO" FILTER

B. THE " SERVO" FILTERB. THE " SERVO" FILTER

The servo filter has an indicator to show when filter needs servicing. Check indicator daily to ensure proper service intervals.

CHANGING FILTER ELEMENTCHANGING FILTER ELEMENT

CHANGING FILTER ELEMENT

CHANGING FILTER ELEMENTCHANGING FILTER ELEMENT

1. Unscrew filter bowl from filter head.

2. Replace old element with new one inside filter bowl. Screw filter bowl with element inside to filter head.

CAUTION CAUTION

CAUTION

CAUTION CAUTION

These filter elements are not re-usable.These filter elements are not re-usable.

These filter elements are not re-usable.

These filter elements are not re-usable.These filter elements are not re-usable.

INDICATORINDICATOR

INDICATOR

INDICATORINDICATOR

FILTER HEADFILTER HEAD

FILTER HEAD

FILTER HEADFILTER HEAD

FILTER ELEMENTFILTER ELEMENT

FILTER ELEMENT

FILTER ELEMENTFILTER ELEMENT

FILTER BOWLFILTER BOWL

FILTER BOWL

FILTER BOWLFILTER BOWL

FILTER ELEMENT REPLACEMENT INTERVALSFILTER ELEMENT REPLACEMENT INTERVALS

FILTER ELEMENT REPLACEMENT INTERVALS

FILTER ELEMENT REPLACEMENT INTERVALSFILTER ELEMENT REPLACEMENT INTERVALS On new machine filter elements should be replaced after 50 hours of operation and then every 400 hours of operation after that.

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HYDRAULIC OIL FILTER MAINTENANCE CONTINUED...

C. THE "SUCTION" FILTERC. THE "SUCTION" FILTER

C. THE "SUCTION" FILTER

C. THE "SUCTION" FILTERC. THE "SUCTION" FILTER

The suction filter is mounted to the reservoir and contains a replaceable filter element which simply unscrews from the filter head to be replaced.

CAUTION CAUTION

CAUTION

CAUTION CAUTION

These filter elements are not re-usable.These filter elements are not re-usable.

These filter elements are not re-usable.

These filter elements are not re-usable.These filter elements are not re-usable.

INDICATORINDICATOR

INDICATOR

INDICATORINDICATOR

FILTER HEADFILTER HEAD

FILTER HEAD

FILTER HEADFILTER HEAD

SEALSEAL

SEAL

SEALSEAL

FILTER ELEMENTFILTER ELEMENT

FILTER ELEMENT

FILTER ELEMENTFILTER ELEMENT

FILTER ELEMENT REPLACEMENT INTERVALSFILTER ELEMENT REPLACEMENT INTERVALS

FILTER ELEMENT REPLACEMENT INTERVALS

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ELIMINATING AIR FROM THE SYSTEMELIMINATING AIR FROM THE SYSTEM

ELIMINATING AIR FROM THE SYSTEM

ELIMINATING AIR FROM THE SYSTEMELIMINATING 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.

CAUSESCAUSES

CAUSES

CAUSESCAUSES

The most common places for air to be introduced into a hydraulic system or for aeration to occur are listed below:

1. Damaged inlet line; loose or defective fittings or seals at any component.

2. Damaged return line; loose or defective fittings or seals at any component.

3. Damaged or worn cylinder rod, packing or seals.

4. Cracked junction blocks, tees or piping.

NOTE: NOTE:

NOTE: Because fluid acts as a sealant at atmospheric pressure, when system drops below atmospheric pressure air

NOTE: NOTE:

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 means of bleed off.

7. Return fluid discharged above fluid level in reservoir. Poor baffling in the reservoir can also cause turbulence and

resultant introduction of air.

8. Air trapped in system during original filling, or when adding fluid for makeup.

DAMAGE TO THE SYSTEMDAMAGE TO THE SYSTEM

DAMAGE TO THE SYSTEM

DAMAGE TO THE SYSTEMDAMAGE TO THE SYSTEM

The condition listed in the previous paragraph all contribute to inducing air into a hydraulic system. This aeration can cause jerky and uneven movement in pumps and motors, seizure, overheating, and possibly eventual failure.

HOW TO AVOID AERATIONHOW TO AVOID AERATION

HOW TO AVOID AERATION

HOW TO AVOID AERATIONHOW TO AVOID AERATION

Regular inspection and regular maintenance are the best ways to prevent air from being introduced into a hydraulic system. Keeping all connections and fittings tight is the easiest way to avoid the introduction of air.

Return fluid entering the reservoir will create aeration if it is discharged above the main body of the fluid in the tank. To prevent this condition, maintain sufficient fluid in the tank to keep the return line submerged. The pump intake line should always be below the fluid surface for the same reason.

Improved service life depends on maintaining proper conditions within the system.

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HYDRAULIC FITTINGS, HOSES AND TUBINGHYDRAULIC FITTINGS, HOSES AND TUBING

HYDRAULIC FITTINGS, HOSES AND TUBING

HYDRAULIC FITTINGS, HOSES AND TUBINGHYDRAULIC FITTINGS, HOSES AND 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.

Replace any tubelines which are bent or have become flat. There will be a restriction of fluid flow which will make hydraulic action slow and cause heat. Replace hoses which show signs of wear, damage, or weather-cracked rubber.

CAUTION CAUTION

CAUTION

CAUTION CAUTION

When making repairs on hydraulic system keep allWhen making repairs on hydraulic system keep all

When making repairs on hydraulic system keep all

When making repairs on hydraulic system keep allWhen making repairs on hydraulic system keep all parts clean and remove all dirt from the area beforeparts clean and remove all dirt from the area before

parts clean and remove all dirt from the area before

parts clean and remove all dirt from the area beforeparts clean and remove all dirt from the area before you begin disassembly. Use caps and plugs toyou begin disassembly. Use caps and plugs to

you begin disassembly. Use caps and plugs to

you begin disassembly. Use caps and plugs toyou begin disassembly. Use caps and plugs to keep dirt out of tubelines and openings.keep dirt out of tubelines and openings.

keep dirt out of tubelines and openings.

keep dirt out of tubelines and openings.keep dirt out of tubelines and openings.

PIPE THREAD SEALERPIPE THREAD SEALER

PIPE THREAD SEALER

PIPE THREAD SEALERPIPE THREAD SEALER

The main causes of air being introduced into a hydraulic system are loose connections and fittings. This not only creates 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 an adequate pipe thread sealer at all connections and fittings.

While other pipe thread sealers may meet specifications, the methods which Barko uses are Teflon tape, and Locktite Teflon Thread Sealer.

The sealer will form a flexible, non-hardening seal that can be easily broken at any time without stripping the threads or damaging the pipes or fittings. It will also provide a non-shrinking bond that will inhibit rust or corrosion in the threads and will not gall, seize, or block the threads.

APPLICATIONAPPLICATION

APPLICATION

APPLICATIONAPPLICATION

The pipe thread sealer is intended for use on threaded steel pipe in fixed installations. It can be easily applied by the tube it comes in. This sealer is intended for use with petroleum fluids only. Apply sealer sparingly and leave the first two threads near the end of the pipe or fitting bare.

Barko recommends the use of pipe thread sealer on all exterior pipe plug threads and pipe fittings.

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HYDRAULIC CYLINDER MAINTENANCEHYDRAULIC CYLINDER MAINTENANCE

HYDRAULIC CYLINDER MAINTENANCE

HYDRAULIC CYLINDER MAINTENANCEHYDRAULIC 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.

BUSHINGBUSHING

BUSHING

BUSHINGBUSHING

GREASE FITTINGGREASE FITTING

GREASE FITTING

GREASE FITTINGGREASE FITTING

PISTONPISTON

PISTON

PISTONPISTON

STROKESTROKE

STROKE

STROKESTROKE LIMITERLIMITER

LIMITER

LIMITERLIMITER

SEAL SERVICINGSEAL SERVICING

SEAL SERVICING

SEAL SERVICINGSEAL SERVICING

1. Remove cylinder from the machine.

2. Remove the bolts/screws from the gland. NOTE: Some cylinders have screw-on gland caps, held in place with an allen head set screw. If so, remove

set screw and then removing gland cap using an adjustable chain wrench.

3. Remove hydraulic supply and return lines (including load lock valves if applicable) from cylinder to allow free

movement of rod.

4. Remove rod assembly from the cylinder barrel.

5. Unscrew the nut from the piston end of the rod and remove the piston and gland.

6. Before removing old seals, note position they are in for proper reassembly (see diagram on next page).

7. Clean and inspect all parts. If worn or damaged, 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. Heating item # 10, 7, and the stiff portion of # 1 in a 200° oven for 5 minutes will make it more pliable. Some kits may contain extra seals. When installing the wear rings, items # 2 & 6, put the cuts on opposite sides.

9. Start gland on rod and hammer on until it is past the stub.

10. Slide piston onto stub, ensure O-ring # 3 is on stub and piston is in proper orientation (small recess is O-ring side,

large recess is nut side).

11. Tighten nut to torque listed in parts manual.

12. Oil new cylinder seals lightly before installing rod assembly in cylinder barrel, oil barrel if necessary.

13. Reinstall gland cap, tighten bolts in a cross pattern to torque specified in parts manual.

14. Reinstall on machine and reattach hydraulics lines.

GLANDGLAND

GLAND

GLANDGLAND

HEX HEAD CAPHEX HEAD CAP

HEX HEAD CAP

HEX HEAD CAPHEX HEAD CAP

SCREWSSCREWS

SCREWS

SCREWSSCREWS

RODROD

ROD

RODROD

BARRELBARREL

BARREL

BARRELBARREL (butt & tube assy)

NUTNUT

NUT

NUTNUT

GREASE FITTINGGREASE FITTING

GREASE FITTING

GREASE FITTINGGREASE FITTING

BUSHINGBUSHING

BUSHING

BUSHINGBUSHING

6 Bolt Torque Pattern

8 Bolt Torque Pattern

10 Bolt Torque Pattern

NOTE: The more common cylinders use the following tool sizes:

Hex head cap screws require 15/16" wrench. Nut requires 3-1/8" wrench.

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Piston and Gland shown may not be type used on

your machine but are shown as a reference.

1111

PistonPiston

Piston

PistonPiston

1010

GlandGland

Gland

GlandGland

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. Depending upon manufacture date item 5 and 7 may be on either side of item 6

ITEM NO.ITEM NO.

ITEM NO.

ITEM NO.ITEM NO.

11 22

22 33

33 44

44 55

55 66

66 77

77 88

88 99

99 1010

1010 1111

1111

DESCRIPTIONDESCRIPTION

DESCRIPTION

DESCRIPTIONDESCRIPTION

SEAL-PISTONSEAL-PISTON

SEAL-PISTON

SEAL-PISTONSEAL-PISTON WEAR RINGWEAR RING

WEAR RING

WEAR RINGWEAR RING O-RINGO-RING

O-RING

O-RINGO-RING BACK-UP RINGBACK-UP RING

BACK-UP RING

BACK-UP RINGBACK-UP RING SQUARE RING ROD BUFFERSQUARE RING ROD BUFFER

SQUARE RING ROD BUFFER

SQUARE RING ROD BUFFERSQUARE RING ROD BUFFER WEAR RINGWEAR RING

WEAR RING

WEAR RINGWEAR RING SEALSEAL

SEAL

SEALSEAL SEAL ROD DEEPSEAL ROD DEEP

SEAL ROD DEEP

SEAL ROD DEEPSEAL ROD DEEP WIPERWIPER

WIPER

WIPERWIPER MODULAR BACKUP RINGMODULAR BACKUP RING

MODULAR BACKUP RING

MODULAR BACKUP RINGMODULAR BACKUP RING O-RINGO-RING

O-RING

O-RINGO-RING

QTY. QTY.

QTY.

QTY. QTY.

SEAL PLIERS (PART # 412-00409) BEING USEDSEAL PLIERS (PART # 412-00409) BEING USED

SEAL PLIERS (PART # 412-00409) BEING USED

SEAL PLIERS (PART # 412-00409) BEING USEDSEAL PLIERS (PART # 412-00409) BEING USED TO BEND SEAL FOR INSTALLATION.TO BEND SEAL FOR INSTALLATION.

TO BEND SEAL FOR INSTALLATION.

TO BEND SEAL FOR INSTALLATION.TO BEND SEAL FOR INSTALLATION.

11 22

22 11

11 11

11 22

22 11

11 11

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COLLECTOR MAINTENANCECOLLECTOR MAINTENANCE

COLLECTOR MAINTENANCE

COLLECTOR MAINTENANCECOLLECTOR MAINTENANCE

All hydraulic components below the turntable bearing continue to be operable during rotation of the upper assembly because of the hydraulic collector. Located on the rotating turntable assembly, the collector is so designed as to allow the flow of hydraulic oil to the cylinders at all points in the turntable rotation. (On most stationary electric machines, an electric collector is used.)

COLLECTOR SHOWN MAY NOT BE TYPE USED ON YOUR MACHINE BUT IS SHOWN AS A REFERENCE.COLLECTOR SHOWN MAY NOT BE TYPE USED ON YOUR MACHINE BUT IS SHOWN AS A REFERENCE.

COLLECTOR SHOWN MAY NOT BE TYPE USED ON YOUR MACHINE BUT IS SHOWN AS A REFERENCE.

COLLECTOR SHOWN MAY NOT BE TYPE USED ON YOUR MACHINE BUT IS SHOWN AS A REFERENCE.COLLECTOR SHOWN MAY NOT BE TYPE USED ON YOUR MACHINE BUT IS SHOWN AS A REFERENCE.

BARRELBARREL

BARREL

BARRELBARREL

SPOOLSPOOL

TORQUE ARMTORQUE ARM

TORQUE ARM

TORQUE ARMTORQUE ARM MOUNTINGMOUNTING

MOUNTING

MOUNTINGMOUNTING PLATEPLATE

PLATE

PLATEPLATE

TORQUE ARMTORQUE ARM

TORQUE ARM

TORQUE ARMTORQUE ARM

SPOOL

SPOOLSPOOL

SEALSSEALS

SEALS

SEALSSEALS

RETAININGRETAINING

RETAINING

RETAININGRETAINING PLATEPLATE

PLATE

PLATEPLATE

SAFETYSAFETY

SAFETY

SAFETYSAFETY WIREWIRE

WIRE

WIREWIRE

SCREWSSCREWS

SCREWS

SCREWSSCREWS

SAFETY WIRESAFETY WIRE

SAFETY WIRE

SAFETY WIRESAFETY WIRE

SERVICINGSERVICING

SERVICING

SERVICINGSERVICING

When seals inside collector wear out, a new seal kit must be purchased from your Barko dealer. (Seal kit numbers are in parts manual on collector parts list.) Port numbers are stamped into collector for easy reference.

HYDRAULIC COLLECTOR SEAL KIT INSTRUCTIONSHYDRAULIC COLLECTOR SEAL KIT INSTRUCTIONS

HYDRAULIC COLLECTOR SEAL KIT INSTRUCTIONS

HYDRAULIC COLLECTOR SEAL KIT INSTRUCTIONSHYDRAULIC COLLECTOR SEAL KIT INSTRUCTIONS

DISASSEMBLYDISASSEMBLY

DISASSEMBLY

DISASSEMBLYDISASSEMBLY

- Remove safety wire and screws from spool retaining plate on top of collector.

- Remove spool from barrel using proper driving equipment, being careful not to damage seal lands or polished inside diameter of barrel.

- Remove seals from spool by cutting with sharp knife, being careful not to damage spool lands. If teflon rings are used, they must be cut off also and the expansion ring under the teflon ring should be replaced (the expansion ring can be cut off or stretched).

CLEAN AND INSPECTCLEAN AND INSPECT

CLEAN AND INSPECT

CLEAN AND INSPECTCLEAN AND INSPECT

- Clean all components thoroughly.

- Inspect for damage to port threads, screw holes and threads, hole elongation, broken spool lands,etc.. Replace or repair damaged components as necessary.

- Barrel with grooves worn deeper than .007 is no longer safely usable.

- Below are four different collector sizes. Find yours, and be sure that the spool lands on your collector are not worn deeper than .004 below the standard spool land depth given. Spool with lands worn deeper than .004 is no longer safely usable.

(7" spool O.D. = 6.985 spool land depth) (5" spool O.D. = 4.985 spool land depth) (6" spool O.D. = 5.985 spool land depth) (3-1/2" spool O.D. = 3.485 spool land depth)

- Seal grooves of .160 standard width worn beyond .185 at outside diameter are no longer safely usable.

- Grooves of .130 standard width beyond .150 at outside diameter are no longer safely usable.

- Loaded lip seal grooves of .275 standard width worn beyond .325 at outside diameter are no longer safely usable.

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HYDRAULIC COLLECTOR MAINTENANCE CONTINUED...

COLLECTOR SHOWN MAY NOT BE TYPE USED ON YOUR MACHINE BUT IS SHOWN AS A REFERENCE.COLLECTOR SHOWN MAY NOT BE TYPE USED ON YOUR MACHINE BUT IS SHOWN AS A REFERENCE.

COLLECTOR SHOWN MAY NOT BE TYPE USED ON YOUR MACHINE BUT IS SHOWN AS A REFERENCE.

COLLECTOR SHOWN MAY NOT BE TYPE USED ON YOUR MACHINE BUT IS SHOWN AS A REFERENCE.COLLECTOR SHOWN MAY NOT BE TYPE USED ON YOUR MACHINE BUT IS SHOWN AS A REFERENCE.

BEARING GUIDE RINGBEARING GUIDE RING

BEARING GUIDE RING

LOADED LIP SEALLOADED LIP SEAL

LOADED LIP SEAL

LOADED LIP SEALLOADED LIP SEAL

BEARING GUIDE RINGBEARING GUIDE RING

BEARING GUIDE RING

BEARING GUIDE RINGBEARING GUIDE RING

SQUARE SEALSQUARE SEAL

SQUARE SEAL

SQUARE SEALSQUARE SEAL

O-RINGO-RING

O-RING

O-RINGO-RING

BEARING GUIDE RINGBEARING GUIDE RING

LOADED LIPLOADED LIP

LOADED LIP

LOADED LIPLOADED LIP SEALSEAL

SEAL

SEALSEAL

TOP OFTOP OF

TOP OF

TOP OFTOP OF COLLECTORCOLLECTOR

COLLECTOR

COLLECTORCOLLECTOR

ASSEMBLYASSEMBLY

ASSEMBLY

ASSEMBLYASSEMBLY

1. All parts must be clean and free of oil and dust.

2. Install o-rings, loaded lip seals, or teflon rings on spool. See below for teflon rings:

TEFLON RING INSTALLATION:

NOTE:NOTE:

NOTE: If any teflon rings are used, they must be heated in order to stretch them properly for installation.

NOTE:NOTE:

Heat teflon rings to 200-400 degrees Fahrenheit.

WARNING WARNING

WARNING

WARNING WARNING

Do not heat teflon rings beyond 400 degrees Fahrenheit.Do not heat teflon rings beyond 400 degrees Fahrenheit.

Do not heat teflon rings beyond 400 degrees Fahrenheit.

Do not heat teflon rings beyond 400 degrees Fahrenheit.Do not heat teflon rings beyond 400 degrees Fahrenheit. If teflon rings are heated beyond 400 degrees FahrenheitIf teflon rings are heated beyond 400 degrees Fahrenheit

If teflon rings are heated beyond 400 degrees Fahrenheit

If teflon rings are heated beyond 400 degrees FahrenheitIf teflon rings are heated beyond 400 degrees Fahrenheit they will give off harmful toxic fumes.they will give off harmful toxic fumes.

they will give off harmful toxic fumes.

they will give off harmful toxic fumes.they will give off harmful toxic fumes.

When the right temperature is reached the teflon ring will act like a rubber band when shaken.

Using heat resistant gloves, grasp teflon ring and slip over end of spool to groove. Speed is essential before contracting occurs.

Ensure ring is not twisted in groove. NOTE:NOTE:

NOTE: Rings that may be loose on spool may be sized by compressing with suitable hose clamp. Then

NOTE:NOTE:

remove clamp before proceeding.

ASSEMBLY CONTINUED...ASSEMBLY CONTINUED...

ASSEMBLY CONTINUED...

ASSEMBLY CONTINUED...ASSEMBLY CONTINUED...

3. Install the two bearing guide rings at each end as shown.

4. Install the square seals on top of o-rings. Be careful not to over-stretch the seals.

5. Inspect for proper seal alignment and install spool in barrel using suitable assembly equipment.

6. Reinstall retaining plate and screws. Tighten screws.

7. Install safety wire on top end of collector.

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VALVE MAINTENANCE (A20/A35 CONTROL VALVES)VALVE MAINTENANCE (A20/A35 CONTROL VALVES)

VALVE MAINTENANCE (A20/A35 CONTROL VALVES)

VALVE MAINTENANCE (A20/A35 CONTROL VALVES)VALVE MAINTENANCE (A20/A35 CONTROL VALVES)

SERVICING THE CONTROL VALVESSERVICING THE CONTROL VALVES

SERVICING THE CONTROL VALVES

SERVICING THE CONTROL VALVESSERVICING THE CONTROL VALVES

Remove the valve bank from the equipment and disconnect all hoses, fittings, control handles, and linkage connectors that might be attached to the valve. Plug all ports and thoroughly clean the valve bank’s exterior, after which the port plugs can be removed.

VALVE BANK DISASSEMBLYVALVE BANK DISASSEMBLY

VALVE BANK DISASSEMBLY

VALVE BANK DISASSEMBLYVALVE BANK DISASSEMBLY

STEP 1 - MARK THE VALVE BANKSTEP 1 - MARK THE VALVE BANK

STEP 1 - MARK THE VALVE BANK

STEP 1 - MARK THE VALVE BANKSTEP 1 - MARK THE VALVE BANK This step is the most critical step in the disassembly procedure. It should be followed very closely to ensure that the valve bank is properly reassembled after repairs have been made. See Figure 1.

Figure 1Figure 1

Figure 1

Figure 1Figure 1

A. Take a waterproof, quick-drying marker and mark each casting with a sequential number. Start by marking the inlet

casting as #1 and finish by marking the outlet with the highest number.

B. Then mark the port boss closest to the back cap on each work section with a “B” (for back cap end).

C. Next mark the port boss closest to the spool clevis on each work section with a “C” (for clevis end).

D. Lastly, if relief valves must be removed from the valve bank they should be marked with the number of the casting and

port to which they belong. Inlet and mid-inlet relief valves are marked with their casting number only.

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A20/A35 CONTROL VALVE MAINTENANCE CONTINUED...

STEP 2 - TIE BOLTSSTEP 2 - TIE BOLTS

STEP 2 - TIE BOLTS

STEP 2 - TIE BOLTSSTEP 2 - TIE BOLTS Remove the four (4) tie bolts which hold the bank together and separate the sections.

NOTENOTE

NOTE: VA valve fasteners thread into the outlet casting. VG valve fasteners pass through the entire bank and

NOTENOTE

have a hex nut and washer fastened at both ends.

STEP 3 - SECTION SEALSSTEP 3 - SECTION SEALS

STEP 3 - SECTION SEALS

STEP 3 - SECTION SEALSSTEP 3 - SECTION SEALS The inlet, mid-inlet and each parallel work section have four (4) section seals (Items 1 & 2, Figure 2) on the downstream mating face. A series work section has three (3) section seals on its downstream mating face (Items 1 & 3, Figure 2). These section seals should be removed and discarded.

MilledMilled

Milled

MilledMilled ReliefRelief

Relief

ReliefRelief

Milled ReliefMilled Relief

Milled Relief

Milled ReliefMilled Relief

Parallel Lo-Boy SectionParallel Lo-Boy Section

Parallel Lo-Boy Section

Parallel Lo-Boy SectionParallel Lo-Boy Section

Series Hi-Boy SectionSeries Hi-Boy Section

Series Hi-Boy Section

Series Hi-Boy SectionSeries Hi-Boy Section

Figure 2Figure 2

Figure 2

Figure 2Figure 2

STEP 4 - VALVE BACK CAPSTEP 4 - VALVE BACK CAP

STEP 4 - VALVE BACK CAP

STEP 4 - VALVE BACK CAPSTEP 4 - VALVE BACK CAP Remove the two (2) cap screws (Item 4) which fasten the back cap to the work section and then remove the back cap (Item

5). See Figure 3-4.

STEP 5 - CONTROL SPOOL AND SEALSSTEP 5 - CONTROL SPOOL AND SEALS

STEP 5 - CONTROL SPOOL AND SEALS

STEP 5 - CONTROL SPOOL AND SEALSSTEP 5 - CONTROL SPOOL AND SEALS Grasp the spring end of the spool with a clean rag and pull the spool with a twisting motion. Generally the rear retainer plate (Item 6) backup ring (Item 7) and spool seal (Item 8) will come out with the spool.

CAUTION CAUTION

CAUTION

CAUTION CAUTION

For detented spool models, be careful not to remove the detentFor detented spool models, be careful not to remove the detent

For detented spool models, be careful not to remove the detent

For detented spool models, be careful not to remove the detentFor detented spool models, be careful not to remove the detent poppet sleeve (Item 17, Figure 3-4) unless it is to be serviced. Nextpoppet sleeve (Item 17, Figure 3-4) unless it is to be serviced. Next

poppet sleeve (Item 17, Figure 3-4) unless it is to be serviced. Next

poppet sleeve (Item 17, Figure 3-4) unless it is to be serviced. Nextpoppet sleeve (Item 17, Figure 3-4) unless it is to be serviced. Next remove the two retainer screws (Item 9) from the spool clevis end ofremove the two retainer screws (Item 9) from the spool clevis end of

remove the two retainer screws (Item 9) from the spool clevis end of

remove the two retainer screws (Item 9) from the spool clevis end ofremove the two retainer screws (Item 9) from the spool clevis end of the work section. Then remove the two retainer plates (Item 6), thethe work section. Then remove the two retainer plates (Item 6), the

the work section. Then remove the two retainer plates (Item 6), the

the work section. Then remove the two retainer plates (Item 6), thethe work section. Then remove the two retainer plates (Item 6), the backup ring (Item 7) and the spool seal (Item 8). The spool shouldbackup ring (Item 7) and the spool seal (Item 8). The spool should

backup ring (Item 7) and the spool seal (Item 8). The spool should

backup ring (Item 7) and the spool seal (Item 8). The spool shouldbackup ring (Item 7) and the spool seal (Item 8). The spool should now be tagged or marked with its work section’s identification numbernow be tagged or marked with its work section’s identification number

now be tagged or marked with its work section’s identification number

now be tagged or marked with its work section’s identification numbernow be tagged or marked with its work section’s identification number (from Step 1). Spool seals (Item 8) and backup rings (Item 7) should be(from Step 1). Spool seals (Item 8) and backup rings (Item 7) should be

(from Step 1). Spool seals (Item 8) and backup rings (Item 7) should be

(from Step 1). Spool seals (Item 8) and backup rings (Item 7) should be(from Step 1). Spool seals (Item 8) and backup rings (Item 7) should be discarded.discarded.

discarded.

discarded.discarded.

475 A CRL 800-00167

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A20/A35 CONTROL VALVE MAINTENANCE CONTINUED...

STEP 6 - TRANSITION CHECKSTEP 6 - TRANSITION CHECK

STEP 6 - TRANSITION CHECK

STEP 6 - TRANSITION CHECKSTEP 6 - TRANSITION CHECK The transition check is located in the bottom center of the work section housing. Remove the check valve cap (Item 10) and its o-ring seal (Item 11) then remove the check spring (Item 12) and the check valve poppet (Item 13).

NOTE:NOTE:

NOTE: Only cylinder (ports blocked in neutral) work sections have a transition check.

NOTE:NOTE:

SPOOL DISASSEMBLYSPOOL DISASSEMBLY

SPOOL DISASSEMBLY

SPOOL DISASSEMBLYSPOOL DISASSEMBLY

STEP 7-SPRING CENTERED SPOOLSTEP 7-SPRING CENTERED SPOOL

STEP 7-SPRING CENTERED SPOOL

STEP 7-SPRING CENTERED SPOOLSTEP 7-SPRING CENTERED SPOOL These parts should not be removed from the spool unless they need to be replaced. Once the spool is free of the work section housing, it must be handled carefully to avoid damage. Place the spool in a soft jawed vise and remove the stripper bolt (Item 14) with a wrench. Cautious application of heat may be required to free the stripper bolt because an anaerobic thread adhesive is used in its assembly.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

TOO MUCH HEAT MAY DISTORT THE SPOOL. As theTOO MUCH HEAT MAY DISTORT THE SPOOL. As the

TOO MUCH HEAT MAY DISTORT THE SPOOL. As the

TOO MUCH HEAT MAY DISTORT THE SPOOL. As theTOO MUCH HEAT MAY DISTORT THE SPOOL. As the stripper bolt threads disengage the spring (Item 15) andstripper bolt threads disengage the spring (Item 15) and

stripper bolt threads disengage the spring (Item 15) and

stripper bolt threads disengage the spring (Item 15) andstripper bolt threads disengage the spring (Item 15) and spring guides (item 16) will pop free of the spool.spring guides (item 16) will pop free of the spool.

spring guides (item 16) will pop free of the spool.

spring guides (item 16) will pop free of the spool.spring guides (item 16) will pop free of the spool.

TYPICAL VALVE SECTIONTYPICAL VALVE SECTION

TYPICAL VALVE SECTION

TYPICAL VALVE SECTIONTYPICAL VALVE SECTION

475 A CRL 800-00167

Figure 3-4 Figure 3-4

Figure 3-4

Figure 3-4 Figure 3-4

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A20/A35 CONTROL VALVE MAINTENANCE CONTINUED...

PARTS LIST ( for figures 2 and 3-4 ) PARTS LIST ( for figures 2 and 3-4 )

PARTS LIST ( for figures 2 and 3-4 )

PARTS LIST ( for figures 2 and 3-4 ) PARTS LIST ( for figures 2 and 3-4 )

ITEMITEM

ITEM

ITEMITEM

DESCRIPTIONDESCRIPTION

DESCRIPTION

DESCRIPTIONDESCRIPTION

Parallel Section Seals* See Figure 2

1. Square Seal 3

2. Square Seal 1

Series Section Seals See Figure 2

1. Square Seal 2

3. Square Seal 1

Parallel and Series Section Component Parts. See Figure 3-4

4. Back Cap Screw 2

5. Back Cap 1

6. Retainer Plate 3

7. Backup Ring 2

8. Spool Seal 2

9. Retainer Plate Screw 2

10. Check Valve Cap 1 Or Valve Cap (F.I.N.) 1

11. **O-Ring Seal 1

12. **Check Spring 1

13. **Check Valve Poppet 1

14. Stripper Bolt 1

15. Centering Spring 1

16. Spring Guide 2

17. Detent Sleeve 1

18. Detent Ball 2

19. Detent Spring 1

20. Detent Poppet Retainer 1

QTY.QTY.

QTY.

QTY.QTY.

* Parallel Sealing Face includes inlets and mid-lets ** Not required in Float-in-neutral Sections

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A20/A35 CONTROL VALVE MAINTENANCE CONTINUED...

STEP 8 - DETENTED SPOOLSTEP 8 - DETENTED SPOOL

STEP 8 - DETENTED SPOOL

STEP 8 - DETENTED SPOOLSTEP 8 - DETENTED SPOOL Again these parts should not be removed from the spool unless they need to be replaced.

- Wrap the detent sleeve (Item 17) with a clean rag. Grip the rag covered sleeve and pull firmly. As the sleeve moves backwards, the detent balls (Item 18) and the detent spring (Item 19) will pop free. The rag should capture these parts and prevent their loss.

- Next clamp the spool in a soft jawed vise and remove the detent poppet retainer (Item 20) use an under sized bar through the detent ball bore as a wrench. Cautious application of heat may again be required because an anaerobic adhesive is also used in the retainer’s assembly.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

TOO MUCH HEAT MAY DISTORT THE SPOOL!TOO MUCH HEAT MAY DISTORT THE SPOOL!

TOO MUCH HEAT MAY DISTORT THE SPOOL!

TOO MUCH HEAT MAY DISTORT THE SPOOL!TOO MUCH HEAT MAY DISTORT THE SPOOL!

CLEANING, INSPECTION, AND REPAIRCLEANING, INSPECTION, AND REPAIR

CLEANING, INSPECTION, AND REPAIR

CLEANING, INSPECTION, AND REPAIRCLEANING, INSPECTION, AND REPAIR

1. Inspect the spool bores, check seats, and spools for deep scratches, gouges, or excessive wear. If any of these conditions exist, replace the section. Minor surface damage on the control spool and check poppet may be carefully polished away with very fine crocus cloth.

2. Examine the machined surfaces of the valve housing for nicks and burrs that could cause leakage between sections. Lightly stone these surfaces to remove any rough spots.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

A shallow milled relief area (noted in Figure 2)A shallow milled relief area (noted in Figure 2)

A shallow milled relief area (noted in Figure 2)

A shallow milled relief area (noted in Figure 2)A shallow milled relief area (noted in Figure 2) extends across the o-ring face of the valve housing.extends across the o-ring face of the valve housing.

extends across the o-ring face of the valve housing.

extends across the o-ring face of the valve housing.extends across the o-ring face of the valve housing. It should not be stoned or ground off.It should not be stoned or ground off.

It should not be stoned or ground off.

It should not be stoned or ground off.It should not be stoned or ground off.

3. Wash all parts thoroughly in a clean solvent and blow dry before beginning reassembly. Pay special attention to the number and letters marked on the parts in Step 1. If any marks are removed during cleaning, remark immediately.

VALVE BANK REASSEMBLYVALVE BANK REASSEMBLY

VALVE BANK REASSEMBLY

VALVE BANK REASSEMBLYVALVE BANK REASSEMBLY

Reverse the procedures outlined in Steps 1 through 8. Also follow the additional instructions listed below.

SPOOL ASSEMBLY- SPRING CENTEREDSPOOL ASSEMBLY- SPRING CENTERED

SPOOL ASSEMBLY- SPRING CENTERED

SPOOL ASSEMBLY- SPRING CENTEREDSPOOL ASSEMBLY- SPRING CENTERED

- Clamp the control spool in a soft jawed vise. Apply a small amount of Loctite 262 or equivalent anaerobic adhesive to the stripper bolt (Item 14) before assembly.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

Follow the adhesive manufacturer’s instructionsFollow the adhesive manufacturer’s instructions

Follow the adhesive manufacturer’s instructions

Follow the adhesive manufacturer’s instructionsFollow the adhesive manufacturer’s instructions for proper cleaning and curing. Failure to cleanfor proper cleaning and curing. Failure to clean

for proper cleaning and curing. Failure to clean

for proper cleaning and curing. Failure to cleanfor proper cleaning and curing. Failure to clean and prepare parts properly may result in assemblyand prepare parts properly may result in assembly

and prepare parts properly may result in assembly

and prepare parts properly may result in assemblyand prepare parts properly may result in assembly

failure.failure.

failure.

failure.failure.

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A20/A35 CONTROL VALVE MAINTENANCE CONTINUED...

- Assemble the spring (Item 15), spring guides (Item 16) and stripper bolt (Item 14) onto the spool (Reverse of Step

7). Lightly coat the spring assembly with high temperature grease to prevent rusting.

SPOOL ASSEMBLY - DETENTEDSPOOL ASSEMBLY - DETENTED

SPOOL ASSEMBLY - DETENTED

SPOOL ASSEMBLY - DETENTEDSPOOL ASSEMBLY - DETENTED

- Clamp the control spool in a soft jawed vise. Apply a small amount of Loctite 262 or equivalent anaerobic adhesive to the detent poppet retainer (Item 20) and thread it into the control spool.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

Follow the adhesive manufacturer’s instruction forFollow the adhesive manufacturer’s instruction for

Follow the adhesive manufacturer’s instruction for

Follow the adhesive manufacturer’s instruction forFollow the adhesive manufacturer’s instruction for proper cleaning and curing. Failure to clean andproper cleaning and curing. Failure to clean and

proper cleaning and curing. Failure to clean and

proper cleaning and curing. Failure to clean andproper cleaning and curing. Failure to clean and prepare parts properly may result in assembly failure.prepare parts properly may result in assembly failure.

prepare parts properly may result in assembly failure.

prepare parts properly may result in assembly failure.prepare parts properly may result in assembly failure.

- Then lightly coat the detent balls (Item 18), detent spring (Item 19) and detent sleeve (Item 17) with high temperature grease.

- Next place the detent balls and spring into the detent poppet retainer as shown in Step 8 and partially compress them with a small clamp.

- Now slide the detent sleeve into position, pushing the clamp out of the way at the same time.

VALVE SECTION ASSEMBLYVALVE SECTION ASSEMBLY

VALVE SECTION ASSEMBLY

VALVE SECTION ASSEMBLYVALVE SECTION ASSEMBLY

- Apply a light coating of clean hydraulic oil to the valve spool.

- Place the retaining plates (Item 6), new backup rings (Item 7) and new spool seals (Item 8) in position as shown in Figure 3-4.

- Carefully insert the spool into the housing. Make sure that the spool and housing are in the proper orien tation (see Step 1).

- Place Loctite 262 or its equivalent on the back cap screws (Item 4) and front retainer screws (Item 9) threading them into the valve housing.

When installing the transition check refer to Step 6. Torque cap screws to 80 - 90 ft. lbs.

VALVE BANK ASSEMBLYVALVE BANK ASSEMBLY

VALVE BANK ASSEMBLY

VALVE BANK ASSEMBLYVALVE BANK ASSEMBLY

- Return all relief valves to their proper positions (see Step 1).

- Coat the section seals (Items 1 & 2 or Items 1 & 3) with grease and place them in their grooves (Figure 2).

- Place the valve sections on the tie bolts in their proper sequence (see Step 1).

- Torque the tie bolts in a cross pattern to:

VA20-29 foot pounds VG20-42 foot pounds VA35-34 foot pounds VG35-75 foot pounds

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A20/A35 CONTROL VALVE MAINTENANCE CONTINUED...

SYSTEM OVERLOAD RELIEF VALVESYSTEM OVERLOAD RELIEF VALVE

SYSTEM OVERLOAD RELIEF VALVE

SYSTEM OVERLOAD RELIEF VALVESYSTEM OVERLOAD RELIEF VALVE

The main relief valve protects the hydraulic system against overload pressures. It is located in the inlet housing and it also can be found in mid-inlet sections used in the valve bank. Figure 5 illustrates the arrangement of the parts and serviceable seals. This is a cartridge type relief valve and is removed from the control valve as an assembly for replacement or service.

ITEMITEM

ITEM

ITEMITEM

1 O-RING 2 2 O-RING 1 3 BACKUP RING 1 4 GASKET WASHER 1

WORK PORT RELIEF VALVE OPTIONSWORK PORT RELIEF VALVE OPTIONS

WORK PORT RELIEF VALVE OPTIONS

WORK PORT RELIEF VALVE OPTIONSWORK PORT RELIEF VALVE OPTIONS

- Pilot Operated Screw Adjustable Anti-Cavitation Function

The full-flow work port relief valve normally functions when the valve spool is in the neutral position. Fluid is discharged from the work port passage to the tank return passage of the valve section. The pressure setting is normally higher than that of the main relief valve.

The pressure setting is normally higher than that of the main relief valve. The two work port relief valves shown below can be used in any hi-boy section in both the VA/VG20 and VA/VG 35 if the section has the appropriate machining.

NOTE:NOTE:

NOTE: When installing relief valves, torque them to 80 - 90 ft. lbs.

NOTE:NOTE:

DESCRIPTIONDESCRIPTION

DESCRIPTION

DESCRIPTIONDESCRIPTION

Figure 5Figure 5

Figure 5

Figure 5Figure 5

QTY.QTY.

QTY.

QTY.QTY.

Figure 6Figure 6

Figure 6

Figure 6Figure 6

475 A CRL 800-00167

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Figure 7Figure 7

Figure 7

Figure 7Figure 7

A20/A35 CONTROL VALVE MAINTENANCE CONTINUED...

SERVICE INSTRUCTIONS FOR VA/VG REMOTE CONTROL OPERATORSSERVICE INSTRUCTIONS FOR VA/VG REMOTE CONTROL OPERATORS

SERVICE INSTRUCTIONS FOR VA/VG REMOTE CONTROL OPERATORS

SERVICE INSTRUCTIONS FOR VA/VG REMOTE CONTROL OPERATORSSERVICE INSTRUCTIONS FOR VA/VG REMOTE CONTROL OPERATORS

Read these instructions carefully. Failure to follow these procedures can result in poor performance and/or product failure. Make sure all work is done in a clean area.

Figure 8Figure 8

Figure 8

Figure 8Figure 8

SECTION DISASSEMBLY - SECTION DISASSEMBLY -

SECTION DISASSEMBLY - SEE FIGURE 8.

SECTION DISASSEMBLY - SECTION DISASSEMBLY -

1. Remove cap screws (8) from both ends of the valve section.

2. Remove end caps (6), seal (10) and end cap tube (11) from each end of casting.

3. Remove seal retainer (2) and seals (1 & 10) from the clevis end of the spool assembly.

4. Remove spool and spring package assembly from valve section. Remove seal retainer (2) and seals (1 & 10) to replace seals.

5. If stripper bolt (3) must be removed from the spool for replacement of parts, it may be necessary to apply heat to the hex nut and stripper bolt to loosen adhesive that was applied to the threads. Use heat carefully to avoid warping spool.

PREPARATION OF PARTSPREPARATION OF PARTS

PREPARATION OF PARTS

PREPARATION OF PARTSPREPARATION OF PARTS

1. Clean adhesive from threads of spool, stripper bolt, housing, cap screw holes and hex nut with Loctite Chisel Gasket Remover.

2. Wash all parts in solvent to remove grease and oil. Blow dry.

SECTION ASSEMBLY - SECTION ASSEMBLY -

SECTION ASSEMBLY - SEE FIGURE 8

SECTION ASSEMBLY - SECTION ASSEMBLY -

Failure to follow these recommended assemblyFailure to follow these recommended assembly

Failure to follow these recommended assembly

Failure to follow these recommended assemblyFailure to follow these recommended assembly instructions can result in poor performance and/orinstructions can result in poor performance and/or

instructions can result in poor performance and/or

instructions can result in poor performance and/orinstructions can result in poor performance and/or failure of the product. Product should be thoroughlyfailure of the product. Product should be thoroughly

failure of the product. Product should be thoroughly

failure of the product. Product should be thoroughlyfailure of the product. Product should be thoroughly tested to ensure proper operation before the valvetested to ensure proper operation before the valve

tested to ensure proper operation before the valve

tested to ensure proper operation before the valvetested to ensure proper operation before the valve is put into service.is put into service.

is put into service.

is put into service.is put into service.

475 A CRL 800-00167

CAUTION CAUTION

CAUTION

CAUTION CAUTION

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A20/A35 CONTROL VALVE MAINTENANCE CONTINUED...

NOTE:NOTE:

NOTE: If stripper bolt (3) was not removed from spool, proceed to Step 6.

NOTE:NOTE:

1. Place spool in a soft-jawed vise, threaded end up.

2. Spray the threads of the new stripper bolt (3) and hex nut (9) with LOCQUIC Primer Grade NF and let dry. Apply Loctite 262 Red to threads.

3. Slide one of the spring retainers (7) on to the end of the stripper bolt (3) with the longest threads. Screw the stripper bolt into the valve spool as far as it will go. BE SURE THE SPRING GUIDE SLIDES FREELY.

4. Slide the springs (4 & 5) over the stripper bolt. Install the other spring retainer and compress the springs so that the hex nut (9) can be screwed onto the stripper bolt. BE SURE THE SPRING RETAINER SLIDES FREELY.

5. Torque the hex nut (9) to 175 in. lbs. ( 25 in. lbs.) and set the spool assembly aside to cure for a minimum of 8-hours. After curing, test the hex nut to be sure it withstands 125 in. lbs. of breakaway torque.

6. Apply light grease to seals. Assemble o-ring (10) on OD of seal retainer (2) and o-ring (1) in the end of the seal retainer.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

Seals are similar in size. Be sure to insert sealsSeals are similar in size. Be sure to insert seals

Seals are similar in size. Be sure to insert seals

Seals are similar in size. Be sure to insert sealsSeals are similar in size. Be sure to insert seals 1 & 10 in their proper position. They are not1 & 10 in their proper position. They are not

1 & 10 in their proper position. They are not

1 & 10 in their proper position. They are not1 & 10 in their proper position. They are not interchangeable.interchangeable.

interchangeable.

interchangeable.interchangeable.

7. Install one seal retainer with o-rings on spool. Then slide the spool into the housing.

8. Lightly grease o-ring (10) and install it on the valve cap (6).

9. Install end cap tube (11) on seal retainer (2). Then slip end cap (6) on the end cap tube (11).

10. Spray threads of the cap screws (8) and the cap screw holes in the housing with LOCQUIC Primer Grade NF and let dry.

11. Apply Loctite 262 Red to threads of the two cap screws (8). Insert them through valve cap (6) and screw them into the valve housing. Tighten cap screws evenly and torque to 175 in. lbs. ( 17 in. lbs.).

12. Install seal retainer (2) with seals on clevis end of spool. Install end cap tube (11) and valve cap (6) as in Figure 8.

13. Install two cap screws (8), tighten evenly and torque to 175 in. lbs. ( 17 in. lbs.) to complete assembly.

TROUBLESHOOTING ON NEXT PAGE.TROUBLESHOOTING ON NEXT PAGE.

TROUBLESHOOTING ON NEXT PAGE.

TROUBLESHOOTING ON NEXT PAGE.TROUBLESHOOTING ON NEXT PAGE.

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A20/A35 CONTROL VALVE MAINTENANCE CONTINUED...

TROUBLESHOOTING CHARTTROUBLESHOOTING CHART

TROUBLESHOOTING CHART

TROUBLESHOOTING CHARTTROUBLESHOOTING CHART

PROBABLE CAUSEPROBABLE CAUSE

PROBABLE CAUSE

TROUBLETROUBLE

TROUBLE

TROUBLETROUBLE

Oil leaks between sections. Pinched or blown section seal.

Oil leaks at either end of spool.

Spring - centered spools do not return to neutral.

Load will not hold. Cylinder leaking or worn.

PROBABLE CAUSEPROBABLE CAUSE

Stud fasteners not correctly torqued.

Mounting plate not level.

Over pressurized tank core.

Worn or damaged spool seals.

Broken centering spring.

Misalignment of operating linkage.

Foreign particles in system.

Port relief valve not holding.

REMEDYREMEDY

REMEDY

REMEDYREMEDY

Replace seal.

Replace seals and retorque.

Loosen mounting bolts and shim as required.

Correct high back-pressure condition. Replace seals.

Replace spring.

Check linkage for mechanical binding. Clean valve & system.

Check cylinder. Repair.

Remove & clean or replace.

Load drops when spool moved from neutral.

No motion, slow or erratic system operation.

Spool or housing scored or worn excessively.

Dirt or foreign particles lodged between check valve poppet and seat.

Scored or sticking check valve poppet.

Worn pump.

Defective cylinder or motor.

Low reservoir oil level.

Clogged suction strainer.

Suction line restricted.

Relief valve not properly set.

Relief valve poppet or seat scored & sticking.

Replace section.

Disassemble, clean, & reassemble.

Replace poppet.

Check flow & pressure.

Repair or replace.

Add oil to specs.

Clean or replace.

Check lines.

Check pressure setting.

Replace relief valve.

Valve spool not shifted to full stroke.

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800-00167

Check spool linkage travel.

PUMP MAINTENANCE (SWING)PUMP MAINTENANCE (SWING)

PUMP MAINTENANCE (SWING)

PUMP MAINTENANCE (SWING)PUMP MAINTENANCE (SWING)

REMOVAL AND INSPECTION OF CHARGE PUMPREMOVAL AND INSPECTION OF CHARGE PUMP

REMOVAL AND INSPECTION OF CHARGE PUMP

REMOVAL AND INSPECTION OF CHARGE PUMPREMOVAL AND INSPECTION OF CHARGE PUMP

Before removing charge pump mounting bolts, mark position of charge pump housing in relation to port block.

NOTE:NOTE:

NOTE: Charge pumps are same for right and left hand rotation pumps. However, charge pump must be mounted with

NOTE:NOTE: correct orientation or charge pump will not supply oil into closed loop.

Loosen screws with metric Allen wrench (6 mm Allen wrench for all pump sizes except 125, which uses an 8 mm Allen wrench).

Remove charge pump housing and inspect for wear or damage to gear set and o-ring seal. Grease seal prior to reassembly.

Withdraw pinion shaft and inspect gear teeth and bearing surfaces for abnormal wear. Torque values for bolts when replacing charge pump are as follows:

PUMP SIZE TORQUE (in. lb.)

40 220 56 220 90 220 125 440

If serious wear or damage has occured to one componenet in charge pump, complete charge pump assembly must be replaced because components are a matched set.

REPLACEMENT OF SHAFT SEALREPLACEMENT OF SHAFT SEAL

REPLACEMENT OF SHAFT SEAL

REPLACEMENT OF SHAFT SEALREPLACEMENT OF SHAFT SEAL

Remove retaining ring with snap ring pliers.

With two screw drivers carefully pry up on shaft seal housing to remove.

Replace o-ring and radial seal. Lubricate parts before assembly.

NOTE:NOTE:

NOTE: On pump size 125, use care when replacing shaft seal. The O.D. of the pump shaft is approx. the same

NOTE:NOTE: diameter as seal I.D., and therefore, seal could be damaged when sliding over spline surfaces.

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CHARGE PUMP

PUMP MAINTENANCE (BOOM & TRAVEL)PUMP MAINTENANCE (BOOM & TRAVEL)

PUMP MAINTENANCE (BOOM & TRAVEL)

PUMP MAINTENANCE (BOOM & TRAVEL)PUMP MAINTENANCE (BOOM & TRAVEL)

SEAL KITS AND COMPONENTSEAL KITS AND COMPONENT

SEAL KITS AND COMPONENT

SEAL KITS AND COMPONENTSEAL KITS AND COMPONENT

GROUPSGROUPS

GROUPS

GROUPSGROUPS

1. Seal kit for Drive Shaft.

2. Complete seal kit.

3. Subplate with control cylinder.

4. Rotary group.

SEALING THE DRIVESHAFTSEALING THE DRIVESHAFT

SEALING THE DRIVESHAFT

SEALING THE DRIVESHAFTSEALING THE DRIVESHAFT

1. Tape up driveshaft, remove retaining ring and/or sealing ring.

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BOOM & TRAVEL PUMP MAINTENANCE CONTINUED...

2. Lift off end ring.

3. Inspect dust and sealing lip (1), o-ring (2), o-ring groove (3), running area (4), and o-ring contact area (5).

4. Fit the shaft seal (dry) with insertion sleeve (1). Use shim (2) only if running groove is deep.

5. Fill the space between the dust and sealing lip (1) with grease.

6. Retaining ring (1), end ring (2), shaft seal (4), o-ring (5).

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BOOM & TRAVEL PUMP MAINTENANCE CONTINUED...

FITTING O-RINGSFITTING O-RINGS

FITTING O-RINGS

FITTING O-RINGSFITTING O-RINGS

7. O-ring in groove: Do not fill groove (1) with grease. Grease o-ring. Fill on the side with the chamfer (2).

8. O-ring behind thread or recess: Tape up recess or thread.

SEALING THE CONTROL DEVICESEALING THE CONTROL DEVICE

SEALING THE CONTROL DEVICE

SEALING THE CONTROL DEVICESEALING THE CONTROL DEVICE

1. Control Device - spring side: Remove from subplate.

2. Inspect the sealing face (1), groove (2), and

o-ring (3).

3. Control Device - piston side:

Mark cover and housing (1), and remove from subplate.

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BOOM & TRAVEL PUMP MAINTENANCE CONTINUED...

4. Inspect the groove (1), o-ring (2), sealing face (3), and recess (4).

5. Before reassembling, fit the o-ring in the groove (1) with grease. Grease the piston ring (2).

SEALING THE SUBPLATESEALING THE SUBPLATE

SEALING THE SUBPLATE

SEALING THE SUBPLATESEALING THE SUBPLATE

1. Mark position (1). DO NOT USE A SCREWDRIVER TO DISMANTLE THE SEALING FACE! Disassemble from inside the suction port (2).

2. Inspect the sublplate sealing face (1), gasket (2), and housing sealing face (3).

3. Inspect cylinder running areas (1), and lens sliding surfaces (2). Do not remove cylinder.

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BOOM & TRAVEL PUMP MAINTENANCE CONTINUED...

4. Fit the control lens (1) in the sliding surface with grease. Swivel the rotary group in the housing according to the position of the control lens.

5. Lay the gasket on flat. No fluid seal - seal thickness has been allowed for in the rotary group adjustment.

Reassemble subplate.

REPLACING THE ROTARY GROUPREPLACING THE ROTARY GROUP

REPLACING THE ROTARY GROUP

REPLACING THE ROTARY GROUPREPLACING THE ROTARY GROUP

1. Remove the subplate (as described earlier).

2. Remove cylinder (1), with four cup springs (2) and spring washer (3).

3. Remove shaft seal and back-up washer.

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BOOM & TRAVEL PUMP MAINTENANCE CONTINUED...

4. Draw out rotary group.

5. Check that outer rings (1) in housing are not twisted and that the housing is not damaged.

6. Check that lens sliding surface (1), is free of scoring and not worn.

7. Reassemble rotary group and shaft seal and backup washer, by heating the housing to approximately 80 degrees Celsius, and inserting rotary group.

8. Draw rotary group against retaining ring.

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BOOM & TRAVEL PUMP MAINTENANCE CONTINUED...

9. Reassemble subplate onto housing.

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PUMP MAINTENANCE (SERVO)PUMP MAINTENANCE (SERVO)

PUMP MAINTENANCE (SERVO)

PUMP MAINTENANCE (SERVO)PUMP MAINTENANCE (SERVO)

Refer to Figure A below for the following procedures.

ItemItem

QtyQty

Item

Qty

ItemItem

QtyQty

1 4 SCREW 2 4 WASHER, flat 3 1 PLUG

* 4 1 SEAL, ring

5 1 PLATE, wear

* 6 1 SEAL

7 2 PIN, dowel

* 8 1 SEAL, shaft

PREPARATION FOR DISASSEMBLYPREPARATION FOR DISASSEMBLY

PREPARATION FOR DISASSEMBLY

PREPARATION FOR DISASSEMBLYPREPARATION FOR DISASSEMBLY

Overhaul pump only in a clean, dust-free location , using clean tools and equipment. Dirt or grit will damage highly machined surfaces and will result in leakage or premature failure of pump.

Before beginning disassembly, scribe match marks on body and cover to insure pump will be reassembled in same manner as it was shipped from factory. If body rear cover is replaced during overhaul, scribe a match mark on new part in same location as on part it replaced.

DescriptionDescription

Description

DescriptionDescription

Figure AFigure A

Figure A

Figure AFigure A

ItemItem

QtyQty

Item

Qty

ItemItem

QtyQty

10 1 COVER 11 1 DRIVEN GEAR 12 1 SPLINED DRIVE GEAR 13 1 ASSEMBLY, body

* 14 1 SEAL

15 1 THRUST PLATE

SEAL KIT (includes all starred (*) items)

DescriptionDescription

Description

DescriptionDescription

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SERVO PUMP MAINTENANCE CONTINUED...

DISASSEMBLY OF PUMPDISASSEMBLY OF PUMP

DISASSEMBLY OF PUMP

DISASSEMBLY OF PUMPDISASSEMBLY OF PUMP

1. Clean outside of pump with a good grade solvent and dry thoroughly.

2. On models with splined drive shaft, proceed to step 3.

3. Secure unit in vise (use light clamping pressure) with shaft end down; remove cap screws and washers.

NOTE: NOTE:

NOTE: During disassembly, take special note of wear patterns on wear plate, thrust plate, and body. Relate these

NOTE: NOTE: patterns to inlet and outlet sides of pump. Large port in rear cover always corresponds to inlet side of pump. Inlet side can be further identified by gear contact pattern in body (gear) bore. Wear plate will have a somewhat heavier wear pattern on inlet side. Thrust plate will also have a pattern that can be established for reassembly. Also note that long journal of driven gear is toward front of pump.

4. Separate rear cover from body by supporting pump, shaft end up, on mounting flanges and pressing on drive shaft end in arbor press, or tap drive shaft with a plastic mallet.

CAUTION CAUTION

CAUTION

CAUTION CAUTION

Use on hand to support rear cover from underneath, since cover and internalUse on hand to support rear cover from underneath, since cover and internal

Use on hand to support rear cover from underneath, since cover and internal

Use on hand to support rear cover from underneath, since cover and internalUse on hand to support rear cover from underneath, since cover and internal parts will drop suddenly when dowels are disengaged.parts will drop suddenly when dowels are disengaged.

parts will drop suddenly when dowels are disengaged.

parts will drop suddenly when dowels are disengaged.parts will drop suddenly when dowels are disengaged.

An alternate method of removing rear cover is to pry simultaneously with two large screwdrivers in relieved areas between body and cover.

CAUTION CAUTION

CAUTION

CAUTION CAUTION

At no time should screwdrivers be inserted further into pump body more thanAt no time should screwdrivers be inserted further into pump body more than

At no time should screwdrivers be inserted further into pump body more than

At no time should screwdrivers be inserted further into pump body more thanAt no time should screwdrivers be inserted further into pump body more than depth of relieved areas. Any burr must be removed from body and/or coverdepth of relieved areas. Any burr must be removed from body and/or cover

depth of relieved areas. Any burr must be removed from body and/or cover

depth of relieved areas. Any burr must be removed from body and/or coverdepth of relieved areas. Any burr must be removed from body and/or cover after this operation to assure a good seal between body and cover.after this operation to assure a good seal between body and cover.

after this operation to assure a good seal between body and cover.

after this operation to assure a good seal between body and cover.after this operation to assure a good seal between body and cover.

5. Holding pump shaft end down, remove rear cover. Dowel pins may remain either with body or rear cover.

NOTE: NOTE:

NOTE: Cover gasket and thrust plate may or may not remain with rear cover. Should they remain with body, remove

NOTE: NOTE: gasket and lift out thrust plate before proceeding.

6. Lift out driven gear, drive gear, and wear plate.

7. Invert pump body with shaft seal up. Remove shaft seal by prying it out with a large screwdriver.

CAUTION CAUTION

CAUTION

CAUTION CAUTION

Care should be taken not to damage (gouge) shaft seal bore, because this willCare should be taken not to damage (gouge) shaft seal bore, because this will

Care should be taken not to damage (gouge) shaft seal bore, because this will

Care should be taken not to damage (gouge) shaft seal bore, because this willCare should be taken not to damage (gouge) shaft seal bore, because this will result in shaft seal leakage.result in shaft seal leakage.

result in shaft seal leakage.

result in shaft seal leakage.result in shaft seal leakage.

PARTS INSPECTIONPARTS INSPECTION

PARTS INSPECTION

PARTS INSPECTIONPARTS INSPECTION

1. Wash all parts and dry thoroughly.

2. Inspect wear plate and thrust plate. Replace if scoring or uneven wear is observed.

NOTE:NOTE:

NOTE: Somewhat heavier wear pattern is normal on low pressure (inlet) side of plates. However, there should be no

NOTE:NOTE: heavy scoring in this area.

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3. Remove pressure loading seal and Nylatron from wear plate. This seal may be two-piece or one-piece design. In

either case, discard old seal or seals. All replacement seals are two-piece design and should be installed into groove. The seal should extend a minimum of .0005" (.127 mm) beyond surface of wear plate. Do not push seals below wear plate surface at any point.

4. Inspect bushings in body and cover. Replace cover or body if bushing are heavily scored or burned.

5. Inspect gear journals and faces. Replace if faces or journals are scored or worn.

6. Inspect body for wear and scoring. If gear contact wear on low pressure side (inlet) exceeds .005" (.127 mm) depth,

replace body. If body is usable, lightly remove wipe burr with suitable de-burring tool.

PUMP REASSEMBLYPUMP REASSEMBLY

PUMP REASSEMBLY

PUMP REASSEMBLYPUMP REASSEMBLY

NOTE:NOTE:

NOTE: The installation of new parts contained in seal kit are recommended at each overhaul of pump.

NOTE:NOTE:

1. Place body on flat plate with shaft seal bore up. See Figure 1. Install new shaft seal. Press seal into bore to depth

of approximately 1/16" (1.52 mm) with a seal pressing tool. Pack area between double lip of seal with Lubriplate or equivalent grease.

ShaftShaft

Shaft

ShaftShaft

Shaft

ShaftShaft SealSeal

Seal

SealSeal

Figure 1Figure 1

Figure 1

Figure 1Figure 1

Arbor PressArbor Press

Arbor Press

Arbor PressArbor Press

Seal PressingSeal Pressing

Seal Pressing

Seal PressingSeal Pressing ToolTool

Tool

ToolTool

ShaftShaft SealSeal

Seal

SealSeal

MountingMounting

Mounting

MountingMounting FaceFace

Face

FaceFace

1/16"1/16"

1/16"

1/16"1/16" (1.52mm)(1.52mm)

(1.52mm)

(1.52mm)(1.52mm)

Figure 2Figure 2

Figure 2

Figure 2Figure 2

InstallationInstallation

Installation

InstallationInstallation sleevesleeve

sleeve

sleevesleeve slipped overslipped over

slipped over

slipped overslipped over spline.spline.

spline.

spline.spline.

BearingBearing

Bearing

BearingBearing

Shaft SealShaft Seal

Shaft Seal

Shaft SealShaft Seal

Drive GearDrive Gear

Drive Gear

Drive GearDrive Gear

NOTE: NOTE:

NOTE: Drive shaft

NOTE: NOTE: installation sleeve wall thickness should be approx. 0.010" (.25 mm).

Figure 3Figure 3

Figure 3

Figure 3Figure 3

Drive ShaftDrive Shaft

Drive Shaft

Drive ShaftDrive Shaft InstallationInstallation

Installation

InstallationInstallation SleeveSleeve

Sleeve

SleeveSleeve

2. Invert body so that gear bores are up. Install wear plate in bottom of bore, making sure that pressure loading seals

are positioned properly in seal grooves and installed against bottom of bore surface.

3. Lubricate bushings in body and face of wear plate with SAE 10 oil.

4. Apply Lubriplate or equivalent to outer surface of drive shaft installation sleeve. See Figure 3. Insert sleeve into

shaft seal from front of pump until sleeve contacts drive gear bushing. Install drive gear and driven gear with long journal toward shaft seal of pump.

5. Lubricate rear gear faces and journals with SAE 10 oil and install thrust plate in its original position, bronze face

toward gears.

6. Apply a small amount of grease to rear cover seal and install into groove.

7. Lubricate rear cover bushings with SAE 10 oil and install rear cover matching scribe marks on cover and body.

8. Position pump with shaft end down, install rear cover.

9. Insert cap screws and washer; torque to 34 to 38 Ft. Lbs.

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10.On models equipped with keyed drive shaft, install snap ring on drive shaft and install drive key.

11.Check that drive shaft turns with adjustable wrench without evidence of mechanical bind.

BREAK-IN PROCEDUREBREAK-IN PROCEDURE

BREAK-IN PROCEDURE

BREAK-IN PROCEDUREBREAK-IN PROCEDURE

TEST STAND METHOD:TEST STAND METHOD:

TEST STAND METHOD:

TEST STAND METHOD:TEST STAND METHOD:

1. Run pump for 1 minute at minimum pressure.

2. Raise discharge pressure to 500 PSI (34.5 bar) for 5 seconds, then lower to minimum for 5 seconds. Continue cycle for 1 minute.

3. Repeat step but increase pressure in 500 PSI (34.5 bar) increments until maximum operating pressure is obtained. Check flow.

ALTERNATE ON-EQUIPMENT METHOD:ALTERNATE ON-EQUIPMENT METHOD:

ALTERNATE ON-EQUIPMENT METHOD:

ALTERNATE ON-EQUIPMENT METHOD:ALTERNATE ON-EQUIPMENT METHOD:

1. Mount pump on equipment and operate for 2 minutes at minimum pressure and one-quarter engine speed.

2. Increase discharge pressure to relief setting with control valve. Hold for 5 seconds and release. Continue cycle for 2 minutes.

3. Repeat step 2 for 3 minutes at one-half engine speed.

4. Repeat step 2 for 3 minutes at full engine speed.

5. With engine at idle speed, check pump and hydraulic system for leaks. No shaft leakage sufficient to form a drop is permissible. No external leakage is permissible.

CAUTION CAUTION

CAUTION

CAUTION CAUTION

If a new body is installed, break-in of pump will result in wipe chipsIf a new body is installed, break-in of pump will result in wipe chips

If a new body is installed, break-in of pump will result in wipe chips

If a new body is installed, break-in of pump will result in wipe chipsIf a new body is installed, break-in of pump will result in wipe chips (which is normal) to be expelled from pump outlet. These small aluminum(which is normal) to be expelled from pump outlet. These small aluminum

(which is normal) to be expelled from pump outlet. These small aluminum

(which is normal) to be expelled from pump outlet. These small aluminum(which is normal) to be expelled from pump outlet. These small aluminum chips can go thru hydraulic system. A high pressure filter with a suitablechips can go thru hydraulic system. A high pressure filter with a suitable

chips can go thru hydraulic system. A high pressure filter with a suitable

chips can go thru hydraulic system. A high pressure filter with a suitablechips can go thru hydraulic system. A high pressure filter with a suitable flow characteristic to match pump output flow should be installed at outletflow characteristic to match pump output flow should be installed at outlet

flow characteristic to match pump output flow should be installed at outlet

flow characteristic to match pump output flow should be installed at outletflow characteristic to match pump output flow should be installed at outlet of pump. This precaution will assure these chips do not result in otherof pump. This precaution will assure these chips do not result in other

of pump. This precaution will assure these chips do not result in other

of pump. This precaution will assure these chips do not result in otherof pump. This precaution will assure these chips do not result in other component failure.component failure.

component failure.

component failure.component failure.

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MOTOR MAINTENANCE (DRIVE)MOTOR MAINTENANCE (DRIVE)

MOTOR MAINTENANCE (DRIVE)

MOTOR MAINTENANCE (DRIVE)MOTOR MAINTENANCE (DRIVE)

Figure 1: Internal view of drive motor.

Figure 1Figure 1

Figure 1

Figure 1Figure 1

SHAFT SEAL REPLACEMENTSHAFT SEAL REPLACEMENT

SHAFT SEAL REPLACEMENT

SHAFT SEAL REPLACEMENTSHAFT SEAL REPLACEMENT

See Figure 2.

1. Remove front cover mounting bolts.

2. With two screwdrivers, carefully pry off front cover.

3. Remove o-ring and shaft seal from front cover and dispose of them.

4. Lubricate new o-ring and shaft seal.

5. Replace front cover with new shaft seal and o-ring preassembled.

6. Replace front cover mounting bolts and tighten front cover to housing.

475 A CRL 800-00167

Figure 2Figure 2

Figure 2

Figure 2Figure 2

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SWING MOTOR GEARBOX MAINTENANCE (S10A)SWING MOTOR GEARBOX MAINTENANCE (S10A)

SWING MOTOR GEARBOX MAINTENANCE (S10A)

SWING MOTOR GEARBOX MAINTENANCE (S10A)SWING MOTOR GEARBOX MAINTENANCE (S10A)

INTRODUCTIONINTRODUCTION

INTRODUCTION

INTRODUCTIONINTRODUCTION

This manual is a step-by-step guide to assembly and disassembly of torque-hub units. It is designed for the customer or shop mechanic who is repairing a particular model of torque-hub final drive.

Users of this manual should note that each part mentioned is followed by an identification number enclosed in parentheses. These part numbers may be referred to in the Parts List section of this manual and on the crosssectional view of this unit.

Any specialized tools normally used to assemble this unit are noted in the assembly procedures. However, it is not mandatory that these tools be used in this unit’s assembly. Bearing cups and cones can be pressed using a punch and hammer along their top edges. Seals can be pressed by laying a board flat on top of the seal and them hammering the board down until it meets the hub. Studs can be hammered into stud holes. Should you use these methods, be very careful not to damage parts when using a punch and/or hammer.

Users should familiarize themselves with the procedures for roll and leak testing and bolt tightening and torquing found on the following two pages before getting started.

SAFETYSAFETY

SAFETY

SAFETYSAFETY

Standard safety practices should be followed during the disassembly and assembly procedures described. Safety glasses and safety shoes should be worn. Heavy, heat resistant gloves should be used when heated components are handled. Be especially alert when you see the word CAUTION. This indicates that a particular operation could cause personal injury if not performed properly or if certain safety procedures are not followed.

ROLL AND LEAK TESTINGROLL AND LEAK TESTING

ROLL AND LEAK TESTING

ROLL AND LEAK TESTINGROLL AND LEAK TESTING

Torque-hub units should always be roll and leak tested before disassembly and after assembly to make sure that the unit’s gears and sealants are working properly. The following information briefly outlines what to look for when performing these tests.

THE ROLL TESTTHE ROLL TEST

THE ROLL TEST

THE ROLL TESTTHE ROLL TEST The purpose of a roll test is to determine if the unit’s gears are rotating freely and properly. You should be able to rotate the gears in your unit by applying a constant force to the roll checker. If you feel more drag in the gears only at certain points, then the gears are not rolling freely and should be examined for proper installation or defects. Some gear packages roll with more difficulty than others. Do not be concerned if the gears in your unit seem to roll hard as long as they roll with consistency.

THE LEAK TESTTHE LEAK TEST

THE LEAK TEST

THE LEAK TESTTHE LEAK TEST The purpose of a leak test is to make sure the unit is air tight. You can tell if your unit has a leak if the pressure gauge reading on your air checker starts to fall once the unit has been pressurized. Leaks will most likely occur at the main seal or wherever o-rings or gaskets are located. The exact location of a leak can usually be detected by brushing a soap and water solution around the main seal and where o-rings or gaskets meet the exterior of the unit then checking for air bubbles. If a leak is detected in a seal, o-ring, or gasket, the part must be replaced.

TIGHTENING AND TORQUING BOLTSTIGHTENING AND TORQUING BOLTS

TIGHTENING AND TORQUING BOLTS

TIGHTENING AND TORQUING BOLTSTIGHTENING AND TORQUING BOLTS

If an air impact wrench is used to tighten bolts, extreme care should be taken to insure that the bolts are not tightened beyond their indicated torque specification. Never use an impact wrench to tighten should bolts; all shoulder bolts should be tightened by hand.

The following steps describe the proper procedure for tightening and torquing bolts or socket head cap screws in a bolt circle.

1. Tighten (but do not torque) bolt “A” until snug.

2. Go to the opposite side of the bolt circle and tighten bolt “B” until equally snug.

3. Continue around the bolt circle and tighten the remaining bolts.

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S10A SWING MOTOR GEARBOX MAINTENANCE CONTINUED...

4. Now use a torque wrench to apply the specified torque to bolt “A”.

5. Continue around the bolt circle and apply an equal torque to the remaining bolts.

Cross Sectional View of GearboxCross Sectional View of Gearbox

Cross Sectional View of Gearbox

Cross Sectional View of GearboxCross Sectional View of Gearbox

ITEM ITEM

ITEM

ITEM ITEM

QTY.QTY.

QTY.

QTY.QTY.

DESCRIPTIONDESCRIPTION

DESCRIPTION

DESCRIPTIONDESCRIPTION

1 1 HUB-SHAFT SUB-ASSEMBLY 1A 1 OUTPUT SHAFT 1B 1 SEAL 1C 1 BEARING CUP 1D 1 BEARING CONE 1E 1 BEARING CUP 1F 1 BEARING CONE 1G 1 HUB 1H 1 TANGED WASHER 1I 1 LOCK WASHER 1J 1 LOCK NUT 1L 1 PLUG 1M 1 PIPE PLUG 1N 2 MAGNETIC PIPE PLUG 2 1 INTERNAL GEAR 3 1 CARRIER ASSEMBLY 3A 1 CARRIER 3B 3 ROLL PIN 3C 6 BEARING CUP 3D 6 BEARING CONE

Figure 1Figure 1

Figure 1

Figure 1Figure 1

ITEMITEM

ITEM

ITEMITEM

QTY.QTY.

QTY.

QTY.QTY.

DESCRIPTIONDESCRIPTION

DESCRIPTION

DESCRIPTIONDESCRIPTION

3E 3 PLANET SHAFT 3F 3 CLUSTER GEAR 3G 3 SPACER 3H 3 RETAINING RING 4 1 RING GEAR 5 2 O-RING 6 1 COVER 6I 2 MAGNETIC PIPE PLUG 8 1 THRUST WASHER 13 1 INPUT GEAR 15 4 THRUST WASHER 16 2 THRUST BEARING 17 16 BOLT 18 4 SHOULDER BOLT 22 4 LOCK WASHER 23 16 LOCK WASHER 24 1 ID PLATE 25 4 DRIVE SCREW

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S10A SWING MOTOR GEARBOX MAINTENANCE CONTINUED...

MAIN DISASSEMBLY - PART ONEMAIN DISASSEMBLY - PART ONE

MAIN DISASSEMBLY - PART ONE

MAIN DISASSEMBLY - PART ONEMAIN DISASSEMBLY - PART ONE

1. Remove pipe plugs (1M) and drain the oil from the unit.

2. Loosen and remove bolts (17).

3. Loosen and remove shoulder bolts (18).

4. Remove lock washers (23) and (22) from bolt (17) and shoulder bolt (18) holes.

5. Remove pipe plugs (6I).

6. Lift cover (6) off of ring gear (4) using hoist and eye-bolts.

7. At this point, begin cover disassembly.

COVER DISASSEMBLYCOVER DISASSEMBLY

COVER DISASSEMBLY

COVER DISASSEMBLYCOVER DISASSEMBLY

1. Remove o-ring (5) from rim around inside of cover (6).

2. Remove thrust washer (8).

3. Remove thrust washer (15).

4. At this point, begin main disassembly part two.

MAIN DISASSEMBLY-PART TWOMAIN DISASSEMBLY-PART TWO

MAIN DISASSEMBLY-PART TWO

MAIN DISASSEMBLY-PART TWOMAIN DISASSEMBLY-PART TWO

1. Remove thrust bearing (16) from counterbore of carrier (3A).

2. Remove thrust washer (15) from the counterbore of carrier (3A).

3. Remove ring gear (4) from mesh with carrier (3A).

4. Using hoist, remove carrier assembly (3) from mesh with internal gear (2) and set aside.

5. Remove input gear (13).

6. Remove thrust washer (15).

7. Remove thrust bearing (16).

8. Remove thrust washer (15).

9. Remove o-ring (5) from the counterbore around rim of hub (1G).

10. Remove pipe plug (1L) from hub (1G).

11. Remove internal gear (2) from hub (1G) using hoist.

12. Using hammer and punch, knock lock washer (1I) tang out of slot of lock nut (1J).

13. Loosen lock nut (1J) using lock nut wrench.

14. Remove lock nut (1J) from shaft (1A).

15.Remove lock washer (1I) from shaft (1A).

16. Remove tanged washer (1H) from shaft (1A).

17. Press output shaft (1A) out of hub (1G), and set aside.

18. Place internal gear end of output shaft (1A) down, and remove seal (1B).

19. Remove bearing cone (1D) from output shaft (1A).

20. Remove bearing cone (1F).

21. Remove bearing cups (1C) and (1E) from hub (1G).

22. Remove pipe plugs (1N) from hub (1G).

23. At this point, the main disassembly is complete.

CARRIER DISASSEMBLYCARRIER DISASSEMBLY

CARRIER DISASSEMBLY

CARRIER DISASSEMBLYCARRIER DISASSEMBLY

1. Remove retaining ring (3H) that holds planet shaft (3E) in carrier (3A)

2. Slide carrier (3A) so one set of holes containing cluster gear (3F) is off edge of work surface. Drive

planet shaft (3E) down out of carrier (3A).

3. Remove spacer (3G) from on top of cluster gear (3F).

4. Slide cluster gear (3F) out of carrier (3A).

5. Remove dowel pin (3B) from side of carrier (3A).

6. Remove bearing cone (3D) from cluster gear (3F).

7. Turn cluster gear (3F) over and remove other bearing cone (3D).

8. Remove bearing cup (3C) from cluster gear (3F).

9. Turn cluster gear (3F) over and remove other bearing cup (3C).

10. Repeat steps 1 to 9 to disassemble the other cluster gears.

11. At this point, the carrier disassembly is complete.

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CARRIER SUB-ASSEMBLYCARRIER SUB-ASSEMBLY

CARRIER SUB-ASSEMBLY

CARRIER SUB-ASSEMBLYCARRIER SUB-ASSEMBLY

1. Place cluster gear (3F) onto your work surface, either side up. Press bearing cup (3C) into one side of cluster gear using cup pressing tool.

2. Turn cluster gear (3F) over onto it’s other side. Press other bearing cup (3C) into other side of cluster

gear (3F) using cup pressing tool.

3. Place one bearing cone (3D) into one bearing cup (3C) on each end of cluster gear (3F).

4. Place the carrier (3A) on the edge of the table with one set of holes hanging over the edge. The side with

the small roll pin (3B) hole in the side should be down.

5. Place cluster gear assembly with bearings (3F) into carrier (3A) with large gear end up.

6. Slide planet shaft (3E), small end up, into holes through carrier (3A) and cluster gear (3F), from the

bottom.

7. While holding planet shaft (3E) in position, slide the correct spacer (3G) onto the planet shaft (3E).

CAUTION CAUTION

CAUTION

CAUTION CAUTION

Safety glasses should be worn during this step.Safety glasses should be worn during this step.

Safety glasses should be worn during this step.

Safety glasses should be worn during this step.Safety glasses should be worn during this step.

8. Place carrier (3A) all the way onto the table or work surface and put something under the planet shaft

(3E) to hold it in position while installing the retaining ring (3H). Use retaining ring pliers to install retaining ring.

9. Line up roll pin (3B) hole in the carrier (3A) and planet shaft slot (3E).

CAUTION CAUTION

CAUTION

CAUTION CAUTION

Safety glasses should be worn during this step.Safety glasses should be worn during this step.

Safety glasses should be worn during this step.

Safety glasses should be worn during this step.Safety glasses should be worn during this step.

10. Drive the roll pin (3B) into its hole in carrier (3A). Use a punch to drive roll pin flush to carrier surface

(3A).

11 .Measure the end play of the cluster gear (3F) with a dial indicator. Pry up on the bottom of the cluster

gear to get the reading. The reading should not exceed .003. If it does, contact the manufacturer.

12. After getting a reading of .001, .002, or .003, use a stamp and stamp 1 (for .001), 2 (for .002), or 3 (for .003) next to the cluster gear (3F) on carrier so others will know what the dial reading was.

13. Repeat steps 1 to 12 for two remaining cluster gears.

14. At this time, the carrier subassembly is complete.

HUB-SHAFT SUB-ASSEMBLYHUB-SHAFT SUB-ASSEMBLY

HUB-SHAFT SUB-ASSEMBLY

HUB-SHAFT SUB-ASSEMBLYHUB-SHAFT SUB-ASSEMBLY

1. Place output shaft (1A) on work surface with the threaded end up.

2. Using cone pressing tool press the large end of bearing cone (1D) against the shoulder of output shaft (1A).

NOTE:NOTE:

NOTE: Bearing cone may be heated so it can be slipped on, but do NOT exceed 250 degrees F. Once

NOTE:NOTE:

bearing cone has cooled, make sure it is against the output shaft shoulder.

3. Place hub (1G) with it’s small end up on the work surface.

4. Using cup pressing tool press bearing cup (1C) into the hub counterbore.

5. Turn hub (1G) over. Using cup pressing tool press bearing cup (1E) into the counterbore of hub (1G).

6. Place output shaft (1A) into torquing fixture with the threaded end up.

7. Using hoist, place the hub (1G) with it’s small end down onto the output shaft (1A) so the bearings are in

contact.

8. Place bearing cone (1F) with the small end down onto the output shaft (1A).

9. Using cone pressing tool, press bearing cone (1F) onto output shaft (1A), rotating hub (1G) at the same

time, so the bearings are properly seated. Use enough pressure to put a slight drag on the hub.

10. Now remove the pressure on the bearing cone (1F) and check the rolling torque of the bearing assembly

as shown in Diagram 1. The rolling torque must fall between 40-50 ft. lbs. The torque wrench must be

pulled smoothly towards you and kept tangent to the bolt circle as shown in Diagram 1.

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S10A SWING MOTOR GEARBOX MAINTENANCE CONTINUED...

Checking Rolling TorqueChecking Rolling Torque

Checking Rolling Torque

Checking Rolling TorqueChecking Rolling Torque

Diagram 1Diagram 1

Diagram 1

Diagram 1Diagram 1

11. Once the rolling torque has been determined, apply a liberal coat of oil to the bearing cones (1F, 1D) and bearing cups (1C, 1E). Do not get oil on the threads of output shaft. Wipe threads to make sure threads are clean for next step.

12. Spray output (1A) threads with “Primer T”. Allow two to three minutes drying time.

13. Spray lock nut (1J) with “Primer T”. Allow two to three minutes drying time.

14. Place tanged washer (1H) over the output shaft (1A) and against the bearing cone (1F), with the tang in the groove.

15. Place lock washer (1I) over the output shaft (1A) with the tang facing away from the bearing cone (1F). Make sure the tang is in the slot.

16. Apply a heavy bead of "Locktite 277" to the thread on locknut (1J).

NOTE: Locktite is an anaerobic adhesive. Once it is out of contact with the air, it sets. Therefore, once the

locknut has been placed on the output shaft, it must be tightened immediately or it will be impossible to turn.

17. Thread locknut (1J) onto thte output shaft (1A). Make sure the chamferred or sloped side is facing toward the lockwasher (1I). Tighten the locknut until it is hand tight.

Staking the LocknutStaking the Locknut

Staking the Locknut

Staking the LocknutStaking the Locknut

475 A CRL 800-00167

Diagram 2Diagram 2

Diagram 2

Diagram 2Diagram 2

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S10A SWING MOTOR GEARBOX MAINTENANCE CONTINUED...

18. Using locknut wrench tighten locknut (1J) to 300-350 Ft. Lbs., rotating the locknut until the locknut's slot is aligned with a tang of the lockwasher (1I).

19. Bend one of the tangs on the lockwasher (1I) into the aligned slot on the locknut (1J).

20. Wipe the excess Locktite from the parts.

21. Stake the locknut (1J) in four equally spaced places as shown in Diagram 2.

22. Turn the hub (1G) over and apply a generous amount of oil to the seal shoulder of output shaft (1A).

23. Using seal pressing tool press the seal (1B) with it’s open face down, into the hub (1G) counterbore.

24. At this point, the hub-shaft subassembly is complete.

MAIN ASSEMBLY - PART ONEMAIN ASSEMBLY - PART ONE

MAIN ASSEMBLY - PART ONE

MAIN ASSEMBLY - PART ONEMAIN ASSEMBLY - PART ONE

1. Put “Anti-Seize” on pipe plugs (1N).

2. Install pipe plugs (1N), hand tight, into the top of hub (1G).

3. Put “Anti-Seize” on pipe plugs (1M).

4. Install pipe plugs (1M) into the side of hub (1G).

5. Turn hub (1G) over, so it rests on the output shaft (1A).

6. Mark the location of bottom pipe plug (1N) holes, using chalk or marker, on the outside of hub (1G).

7. Mark the location of four shoulder bolt holes (18) on the hub.

8. Spray a coat of oil inside the hub (1G).

9. Using hoist, lower internal gear (2) onto the hub-shaft subassembly until splines are in contact.

10. Spray a light coat of oil inside internal gear (2).

11. Place thrust washer (15) onto shoulder of output shaft (1A).

12. Place thrust bearing (16) onto thrust washer (15).

13. Place thrust washer (15) over thrust bearing (16).

14. Set input gear (13) onto the output shaft (1A).

15. Apply grease to o-ring (5).

16. Place greased o-ring (5) into the counterbore of hub (1G).

17. Place the input carrier (3) on a flat surface. Locate gear teeth with a punch mark on them. Place all teeth with a punch mark on them to 12 o’clock position (See Diagram 3 on next page). Put a timing fixture on the input carrier (3). This will hold the gear teeth in the twelve o’clock position when the carrier is lifted and in stalled into the hub.

18. Use hoist to lift assembled input carrier (3). Guide input gear (13) into assembled input carrier (3), starting from the bottom. Note that input shaft (13) must be held while carrier is being lowered into hub

(1G).

19. Using hoist, place assembled input carrier (3) into hub (1G). Remove the timing fixture.

20. Place ring gear (4), with the side with an X on it up, into mesh with the cluster gear (3F). Line up the X

with the marked shoulder bolt hole.

21. Oil top of input carrier (3).

22. Install thrust washer (15) onto top of carrier (3).

23. Place thrust bearing (16) onto top of thrust washer (15).

24. Now begin cover subassembly in next section.

COVER SUB-ASSEMBLYCOVER SUB-ASSEMBLY

COVER SUB-ASSEMBLY

COVER SUB-ASSEMBLYCOVER SUB-ASSEMBLY

1. Place cover (6) on your work surface, tapped holes side down.

2. Grease one side of thrust washer (8).

3. Place thrust washer (8) in inside diameter of cover (6).

4. Grease o-ring (5).

5. Place greased o-ring (5) into the counterbore of cover (6).

6. Placed greased thrust washer (15) on shoulder of cover (6).

7. At this point, the cover subassembly is complete.

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Gear Teeth to 12 O'clock PositionGear Teeth to 12 O'clock Position

Gear Teeth to 12 O'clock Position

Gear Teeth to 12 O'clock PositionGear Teeth to 12 O'clock Position

12 O'CLOCK POSITION12 O'CLOCK POSITION

12 O'CLOCK POSITION

12 O'CLOCK POSITION12 O'CLOCK POSITION

VIEWED STANDING HEREVIEWED STANDING HERE

VIEWED STANDING HERE

VIEWED STANDING HEREVIEWED STANDING HERE

Diagram 3Diagram 3

Diagram 3

Diagram 3Diagram 3

MAIN ASSEMBLY - PART TWOMAIN ASSEMBLY - PART TWO

MAIN ASSEMBLY - PART TWO

MAIN ASSEMBLY - PART TWOMAIN ASSEMBLY - PART TWO

1. Using hoist, place cover (6) onto ring gear (4). Rotate cover until both pipe plugs (6I) are located in line with marked location of pipe plugs (1N) on shaft side of hub. (See Diagram 4: Pipe plug timing).

Pipe Plug TimingPipe Plug Timing

Pipe Plug Timing

Pipe Plug TimingPipe Plug Timing

Diagram 4Diagram 4

Diagram 4

Diagram 4Diagram 4

2. Put lock washers (22) over shoulder bolt holes on hub.

3. Put in four shoulder bolts (18) and tighten.

4. Put lock washer (23) over bolt holes on hub.

5. Put in 16 bolts (17) and tighten.

6. Torque shoulder bolts (18) and bolts (17) to 100 ft. lbs.

7. Put “Anti-Seize” on pipe plugs (6I).

8. Install pipe plugs (6I) hand tight into cover (6).

9. Put in pipe plugs (1L) into side of hub (1G).

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S10A SWING MOTOR GEARBOX MAINTENANCE CONTINUED...

10. Roll test the unit in both clockwise and counterclockwise directions. Perform the same number of turns in each direction as the ratio of the unit. The ratio is the same as the last two digits in the model number found on the ID tag of the unit. For example, if the model number is S10AC4470, then it should be rolled 70 times in both directions.

11. Leak test the unit at a pressure of 8 P.S.I. for 2-3 minutes.

12. At this point, the main assembly is complete.

FILLING WITH OIL AND OILFILLING WITH OIL AND OIL

FILLING WITH OIL AND OIL

FILLING WITH OIL AND OILFILLING WITH OIL AND OIL CHANGE INTERVALSCHANGE INTERVALS

CHANGE INTERVALS

CHANGE INTERVALSCHANGE INTERVALS

For normal applications, use EP90 gear fluid.

MinimumMinimum

Minimum

MinimumMinimum

1.02 inches1.02 inches

1.02 inches

1.02 inches1.02 inches

Fill until oil is as high as top of cluster bearings - see illustration at right.

Check oil level daily.

Initial oil change should be done after 50 hours of operating time. Change every 400 hours after that.

MaximumMaximum

Maximum

MaximumMaximum .65 inches.65 inches

.65 inches

.65 inches.65 inches

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SWING BRAKE MAINTENANCESWING BRAKE MAINTENANCE

SWING BRAKE MAINTENANCE

SWING BRAKE MAINTENANCESWING BRAKE MAINTENANCE

BRAKE FUNCTIONBRAKE FUNCTION

BRAKE FUNCTION

BRAKE FUNCTIONBRAKE FUNCTION

The brake is designed to fit with a gearbox and a hydraulic motor. The common mounting surfaces of the brake, the motor, and the gearbox are machined to close tolerances and should be protected from damage during installation and removal.

INSTALLATION INSTRUCTIONSINSTALLATION INSTRUCTIONS

INSTALLATION INSTRUCTIONS

INSTALLATION INSTRUCTIONSINSTALLATION INSTRUCTIONS

1. Place the gasket onto the mounting face of the brake.

2. Place the brake shaft into the gearbox with the brake bleeder screw in the vertical position, if possible.

3. Move the brake into position with gearbox assuring proper gasket location. Align the mounting bolt holes by rotating the engaged brake into position. If this is not possible, the brake may be rotated after pressure has been applied to the brake inlet. This will release the brake and allow it to be rotated into position.

4. Similarly place a gasket onto the flange of the motor.

5. Insert the shaft of the motor into the brake and push into position, assuring proper gasket location.

6. Insert four half-inch bolts (Grade 5) through the motor flange, the gasket, the brake, the second gasket,

and into the threaded hole in the gearbox mounting flange. Ensure that the bolts are not too long so that they do not bottom out in the gearbox before clamping.

7. Run bolts in alternately, to prevent binding, until snug. Then torque the bolts to 75-85 lb-ft. shafts must slide together freely — DO NOT use bolts to force the unit together.

8. With motor and brake bolted into position, remove cap plug and connect “inlet” hydraulic line to brake. (If not done for shaft alignment - Step 3). Brake inlet is .250 tubing OD, straight thread O-ring boss (.438-20 UNF 28 Thread).

9. Bleed air from brake via bleeder screw.

NOTE:NOTE:

NOTE: Maximum pressure to brake is 3000 P.S.I.

NOTE:NOTE:

BRAKE DISASSEMBLY PROCEDUREBRAKE DISASSEMBLY PROCEDURE

BRAKE DISASSEMBLY PROCEDURE

BRAKE DISASSEMBLY PROCEDUREBRAKE DISASSEMBLY PROCEDURE

Refer to Figure 1 on next page.

1. If only the O-ring seals are to be replaced, proceed by removing Bolts (21) alternately, and separating the Power Plate (20) sub-assembly from the brake housing.

NOTE: NOTE:

NOTE: Both

NOTE: NOTE:

NOTE:NOTE:

NOTE: Bearing (3) will remain pressed on Shaft (9) and prohibit removal of stationary and rotating discs.

NOTE:NOTE:

Remove Piston (14) from Power Plate (20) by introducing low pressure air — 15 PSI — into the hydraulic inlet. Make sure piston is directed away from the operator. Remove O-rings (16 and 18) and Backup Rings (15 and 17) from the piston OD and ID grooves. Backup Rings will be damaged and should not be removed if replacement is not planned.

2. If the brake is to be completely disassembled, before removing Bolts (21), remove Retaining Ring from Power Plate (20) and then drive the Shaft (9) out of the power plate end of the brake.

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Figure 1Figure 1

Figure 1

Figure 1Figure 1

Push or tap on the external spline end of the shaft and Shaft (9) and Bearing (3) will be removed as a

sub-assembly. Bearing (3) must be removed from Shaft (9) prior to re-assembly.

3. Then remove Bolts (21) alternately. Disassemble in the following order: Power Plate (20), Gasket (5), Rotating Discs (12), Springs (11), Stationary Discs (13), Primary Disc (not shown), Pins (8), Springs (7), and Retainer (6).

4. Remove Seal (1). The seal will be destroyed by the removal process and must be replaced if removed.

CAUTIONCAUTION

CAUTION

CAUTIONCAUTION

Be careful not to damage the adjacent bearing sealBe careful not to damage the adjacent bearing seal

Be careful not to damage the adjacent bearing seal

Be careful not to damage the adjacent bearing sealBe careful not to damage the adjacent bearing seal while removing Seal (1).while removing Seal (1).

while removing Seal (1).

while removing Seal (1).while removing Seal (1).

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5. Remove Retaining Ring (2) and Bearing (3) from Housing (4).

6. Oil Relief Plug (23) should not be removed from Power Plate (20) unless the hole is contaminated. The plug should then be removed to allow the hole in the power plate to be cleaned.

Figure 1Figure 1

Figure 1

Figure 1Figure 1

BRAKE RE-ASSEMBLY PROCEDUREBRAKE RE-ASSEMBLY PROCEDURE

BRAKE RE-ASSEMBLY PROCEDURE

BRAKE RE-ASSEMBLY PROCEDUREBRAKE RE-ASSEMBLY PROCEDURE

1. All parts must be thoroughly clean prior to re-assembly.

IMPORTANT:IMPORTANT:

IMPORTANT: There may be more parts in a service kit than your brake requires. Check parts list care-

IMPORTANT:IMPORTANT:

fully for the exact quantity. In the case of springs, space the required quantity equally.

3. Generally use the reverse of the disassembly procedure to re-assemble the brake.

4. Cylinder of the power plate, piston, and o-rings must be clean prior to assembly, and pre-lubed with system hydraulic fluid.

5. Assemble Piston (14) into Power Plate (20) using a shop press, being careful not to damage the O-rings or the Teflon back-up rings.

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Visually align the center of the cutouts in Piston (14) with Torque Pin (8) holes in Power Plate (20). Avoid pushing the piston all the way to the bottom of the cylinder in the power plate. Generally, try to keep the top surface of the piston flush to 1/8" below the machined surface of the power plate.

6. When pressing the bearings onto the shaft, press on the inner race of the bearing and support the shaft properly.

7. Press Bearing (3) onto external spline of Shaft (9) and install the sub-assembly into Housing (4). After installing all the internal components of the brake, install Power Plate (20) sub-assembly. Install Bolts (21). Tighten sequentially, one turn at a time, until Power Plate (20) is properly seated. Torque to 75-85 lb-ft. Then press Bearing (3) onto Shaft (9).

8. Rotating discs must be clean and dry. There should be no presence of oil on any lining material or mating surfaces of the stationary discs. Worn or heavily scored rotating discs must be replaced.

9. If replacement of Oil Relief Plug (23) is necessary, replace while Power Plate (20) is disassembled.

Outer surface of Power

Plate (20). Insert Plug (23) (closed end first) from this side.

.000" - .125"

Figure 2Figure 2

Figure 2

Figure 2Figure 2

10. Before installing Seal (1), lubricate the lip of the seal with system hydraulic fluid or other suitable lubricant. Use a shop press to install Seal (1). Face the lip of the seal toward the outside of the brake in order to keep the gear box oil or other external contaminants out of the brake. Press evenly around the OD of the seal and use care to avoid cocking.

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C. ELECTRICAL SYSTEMC. ELECTRICAL SYSTEM

C. ELECTRICAL SYSTEM

C. ELECTRICAL SYSTEMC. ELECTRICAL SYSTEM

MAINTENANCEMAINTENANCE

MAINTENANCE

MAINTENANCEMAINTENANCE

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MaintenanceMaintenance

Maintenance

ELECTRICAL SYSTEM MAINTENANCEELECTRICAL SYSTEM MAINTENANCE

ELECTRICAL SYSTEM MAINTENANCE

ELECTRICAL SYSTEM MAINTENANCEELECTRICAL SYSTEM MAINTENANCE

ELECTRICAL SYSTEM DESCRIPTIONELECTRICAL SYSTEM DESCRIPTION

ELECTRICAL SYSTEM DESCRIPTION

ELECTRICAL SYSTEM DESCRIPTIONELECTRICAL 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. Starting circuit (switch, solenoid, battery, and starter).

NOTE:NOTE:

NOTE: Disconnect battery ground cable before making any repairs to electrical circuits.

NOTE:NOTE:

In addition to the two basic circuits, there is an accessories circuit and operating light circuit(s).

ELECTRICAL SYSTEM INSPECTIONELECTRICAL SYSTEM INSPECTION

ELECTRICAL SYSTEM INSPECTION

ELECTRICAL SYSTEM INSPECTIONELECTRICAL SYSTEM INSPECTION

Check for:

- Clean and tight battery cables. Be sure all cables are clean and tight. Remove any acid or corrosion from battery cables with baking soda and water solution. Cover terminals with grease to prevent corrosion.

- Proper tension on drive belt for alternator. For drive belt adjustment, 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 level in battery. Add distilled water if necessary.

- Proper voltage of battery. Charge if necessary.

NOTE:NOTE:

NOTE: See Electrical Schematic in Parts Manual under ELECTRICAL section for complete electrical system.

NOTE:NOTE:

USING AN EXTRA BATTERY TO START MACHINEUSING AN EXTRA BATTERY TO START MACHINE

USING AN EXTRA BATTERY TO START MACHINE

USING AN EXTRA BATTERY TO START MACHINEUSING 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.

WARNINGWARNING

WARNING

WARNINGWARNING

Lead-acid batteries produce flammable and explosive gases. Keep arcs, sparks,Lead-acid batteries produce flammable and explosive gases. Keep arcs, sparks,

Lead-acid batteries produce flammable and explosive gases. Keep arcs, sparks,

Lead-acid batteries produce flammable and explosive gases. Keep arcs, sparks,Lead-acid batteries produce flammable and explosive gases. Keep arcs, sparks, flames and lighted tobacco away from battery. An explosion may occur if theseflames and lighted tobacco away from battery. An explosion may occur if these

flames and lighted tobacco away from battery. An explosion may occur if these

flames and lighted tobacco away from battery. An explosion may occur if theseflames and lighted tobacco away from battery. An explosion may occur if these warnings are not followed.warnings are not followed.

warnings are not followed.

warnings are not followed.warnings are not followed.

1. Make sure ignition is in "OFF" position.

2. Be sure battery to be used is of same voltage as battery in machine.

3. Battery terminals have identification marks. Positive terminal is marked (+) and negative terminal is marked (-).

WARNINGWARNING

WARNING

WARNINGWARNING

When using an extra battery to "jump" start an engine, make connections inWhen using an extra battery to "jump" start an engine, make connections in

When using an extra battery to "jump" start an engine, make connections in

When using an extra battery to "jump" start an engine, make connections inWhen using an extra battery to "jump" start an engine, make connections in order given in this manual.order given in this manual.

order given in this manual.

order given in this manual.order given in this manual.

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WARNINGWARNING

WARNING

WARNINGWARNING

Do not touch battery terminals with any metal or allow jumper cable ends to touchDo not touch battery terminals with any metal or allow jumper cable ends to touch

Do not touch battery terminals with any metal or allow jumper cable ends to touch

Do not touch battery terminals with any metal or allow jumper cable ends to touchDo not touch battery terminals with any metal or allow jumper cable ends to touch each other. Sparks may occur, causing damage to battery and personal injury.each other. Sparks may occur, causing damage to battery and personal injury.

each other. Sparks may occur, causing damage to battery and personal injury.

each other. Sparks may occur, causing damage to battery and personal injury.each other. Sparks may occur, causing damage to battery and personal injury.

4. Be sure negative terminal (-) of battery is connected to engine with negative battery cable.

5. Connect end of first jumper 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. Connect other end of second jumper cable to a metal part of engine.

DO NOT connect last jumper cable end directly to negative terminal (-) of machine battery. This can cause spark to destroy battery and cause personal injury should battery explode. Connect last jumper cable to a metal part of engine.

WARNING WARNING

WARNING

WARNING WARNING

Batteries contain acid which burns eyes and skin on contact. Wear goggles,Batteries contain acid which burns eyes and skin on contact. Wear goggles,

Batteries contain acid which burns eyes and skin on contact. Wear goggles,

Batteries contain acid which burns eyes and skin on contact. Wear goggles,Batteries contain acid which burns eyes and skin on contact. Wear goggles, protective clothing and rubber gloves to keep acid off body. In case of batteryprotective clothing and rubber gloves to keep acid off body. In case of battery

protective clothing and rubber gloves to keep acid off body. In case of battery

protective clothing and rubber gloves to keep acid off body. In case of batteryprotective clothing and rubber gloves to keep acid off body. In case of battery acid contact, wash immediately with water and seek immediate medical attention.acid contact, wash immediately with water and seek immediate medical attention.

acid contact, wash immediately with water and seek immediate medical attention.

acid contact, wash immediately with water and seek immediate medical attention.acid contact, wash immediately with water and seek immediate medical attention.

7. Check to be sure cables are away from fans and belts.

8. Start machine engine.

9. After engine starts, remove negative jumper cable connected to engine FIRST.

10. Next remove jumper cable from machine battery positive (+) terminal.

11. Then remove jumper cables from extra battery.

WARNINGWARNING

WARNING

WARNINGWARNING

Do not jump start or charge a frozen battery. Warm battery to 60 degrees F (16Do not jump start or charge a frozen battery. Warm battery to 60 degrees F (16

Do not jump start or charge a frozen battery. Warm battery to 60 degrees F (16

Do not jump start or charge a frozen battery. Warm battery to 60 degrees F (16Do not jump start or charge a frozen battery. Warm battery to 60 degrees F (16 degrees C) before connecting to a charger. Unplug charger before connectingdegrees C) before connecting to a charger. Unplug charger before connecting

degrees C) before connecting to a charger. Unplug charger before connecting

degrees C) before connecting to a charger. Unplug charger before connectingdegrees C) before connecting to a charger. Unplug charger before connecting or disconnecting cables at battery. Battery gas can explode and cause serious injury.or disconnecting cables at battery. Battery gas can explode and cause serious injury.

or disconnecting cables at battery. Battery gas can explode and cause serious injury.

or disconnecting cables at battery. Battery gas can explode and cause serious injury.or disconnecting cables at battery. Battery gas can explode and cause serious injury.

INSTALLING A NEW BATTERYINSTALLING A NEW BATTERY

INSTALLING A NEW BATTERY

INSTALLING A NEW BATTERYINSTALLING 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. Clean terminal posts of new battery and cable connections with wire brush.

4. Install new battery in compartment. Install hold-down bar.

5. Install and tighten battery cables. Connect negative cable last to prevent sparks.

WARNINGWARNING

WARNING

WARNINGWARNING

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Do not touch battery terminals with any metal. Sparks may occur, causing damageDo not touch battery terminals with any metal. Sparks may occur, causing damage

Do not touch battery terminals with any metal. Sparks may occur, causing damage

Do not touch battery terminals with any metal. Sparks may occur, causing damageDo not touch battery terminals with any metal. Sparks may occur, causing damage to battery and personal injury.to battery and personal injury.

to battery and personal injury.

to battery and personal injury.to battery and personal injury.

ALTERNATOR DRIVE BELT ADJUSTMENTALTERNATOR DRIVE BELT ADJUSTMENT

ALTERNATOR DRIVE BELT ADJUSTMENT

ALTERNATOR DRIVE BELT ADJUSTMENTALTERNATOR DRIVE BELT ADJUSTMENT

1. Loosen alternator adjusting bolt and mounting bolt. See Figure 1.

2. Move alternator along adjustment bar to adjust tension of belt to have 1/2" movement at 10 pounds of pressure at center of belt.

3. Tighten alternator adjusting bolt and mounting bolt.

After a new drive belt has been installed, it will be necessary to adjust it after 8 hours of machine operation.

Adjusting Belt TensionAdjusting Belt Tension

Adjusting Belt Tension

Adjusting Belt TensionAdjusting Belt Tension

1/2" of movement1/2" of movement

1/2" of movement

1/2" of movement1/2" of movement

BELTBELT

BELT

BELTBELT

ADJUSTING BOLTADJUSTING BOLT

ADJUSTING BOLT

ADJUSTING BOLTADJUSTING BOLT

ADJUSTMENT BARADJUSTMENT BAR

ADJUSTMENT BAR

ADJUSTMENT BARADJUSTMENT BAR

Figure 1Figure 1

Figure 1

Figure 1Figure 1

ALTERNATOR MAINTENANCEALTERNATOR MAINTENANCE

ALTERNATOR MAINTENANCE

ALTERNATOR MAINTENANCEALTERNATOR MAINTENANCE

CHECKING THE WIRINGCHECKING THE WIRING

CHECKING THE WIRING

CHECKING THE WIRINGCHECKING THE WIRING

1. Turn the starter switch on.

2. Connect a volt meter between the ground and: (See Figure 2.)

a) the No. 1 alternator connector. b) the No. 2 alternator connector. c) the "BAT" connector.

AlternatorAlternator

Alternator

AlternatorAlternator

No. 1 terminalNo. 1 terminal

No. 1 terminal

No. 1 terminalNo. 1 terminal

No. 2 terminalNo. 2 terminal

No. 2 terminal

No. 2 terminalNo. 2 terminal

ALTERNATORALTERNATOR

ALTERNATOR

ALTERNATORALTERNATOR

"BAT" terminal"BAT" terminal

"BAT" terminal

"BAT" terminal"BAT" terminal

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Figure 2

Figure 2Figure 2

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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 OUTPUTCHECKING ALTERNATOR OUTPUT

CHECKING ALTERNATOR OUTPUT

CHECKING ALTERNATOR OUTPUTCHECKING ALTERNATOR OUTPUT

1. Disconnect negative battery cable.

2. Remove wire from "BAT" connector on alternator and fasten it to one connector of an ammeter. Fasten other connector of ammeter to "BAT" connector of alternator.

3. Connect battery cable again.

4. Remove hot wire from electric solenoid on fuel injection pump and turn engine with starter for approximately 30 seconds to cause a partial discharge of battery.

5. Install hot wire on electrical solenoid and start engine and run at full engine RPM.

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, check regulator.

CHECKING THE REGULATORCHECKING THE REGULATOR

CHECKING THE REGULATOR

CHECKING THE REGULATORCHECKING THE REGULATOR

1. Use steps 1 through 5 of "Checking Alternator Output".

2. Put a small screwdriver in test hole. See Figure 3.

AlternatorAlternator

Alternator

AlternatorAlternator

No. 2 terminalNo. 2 terminal

No. 2 terminal

No. 1 terminalNo. 1 terminal

No. 1 terminal

No. 1 terminalNo. 1 terminal

"BAT" terminal"BAT" terminal

"BAT" terminal

"BAT" terminal"BAT" terminal

Test HoleTest Hole

Test Hole

Test HoleTest Hole

Figure 3Figure 3

Figure 3

Figure 3Figure 3

No. 2 terminalNo. 2 terminal

3. If the ammeter reading is not within 10 percent of rated amperage (marked on alternator case), regulator may be damaged. Check diode trio, rectifier, stator, or rotor.

Damage to alternator can occur if:

- battery connections are not connected properly.

- wires from alternator are grounded.

- engine is operated with battery cables disconnected.

- cables are connected when using a fast charger or when welding on the loader. (Remove both cables from the battery.)

- extra battery cables (booster cables) are connected wrong.

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ELECTRICAL SYSTEM TROUBLE SHOOTINGELECTRICAL SYSTEM TROUBLE SHOOTING

ELECTRICAL SYSTEM TROUBLE SHOOTING

ELECTRICAL SYSTEM TROUBLE SHOOTINGELECTRICAL SYSTEM TROUBLE SHOOTING

The following trouble shooting chart is provided as an assistance in locating and correcting problems which are most common.

PROBLEMPROBLEM

PROBLEM

PROBLEMPROBLEM

Battery does not hold it's charge.

Alternator will not charge.

Starter will not turn the engine.

KEY TO CORRECT THE CAUSEKEY TO CORRECT THE CAUSE

KEY TO CORRECT THE CAUSE

KEY TO CORRECT THE CAUSEKEY TO CORRECT THE CAUSE

1. Alternator belt is loose or 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. The wiring or the solenoid is damaged.

1,2,3,4,5

1,2,5

2,3,4,6,7,8

CAUSECAUSE

CAUSE

CAUSECAUSE

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D. POWER UNIT MAINTENANCED. POWER UNIT MAINTENANCE

D. POWER UNIT MAINTENANCE

D. POWER UNIT MAINTENANCED. POWER UNIT MAINTENANCE

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MaintenanceMaintenance

Maintenance

ENGINE MAINTENANCEENGINE MAINTENANCE

ENGINE MAINTENANCE

ENGINE MAINTENANCEENGINE MAINTENANCE

The standard source of power for the hydraulic system in this machine is a Cummins 6C diesel engine.

Complete specifications, operating instructions, and maintenance and lubrication information will be found in the Cummins engine manuals which accompanies the machine.

Either of these manuals may also include information on other, similar, engines. Be sure to use only the information which applies to the engine used on your machine.

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PUMP DRIVE MAINTENANCEPUMP DRIVE MAINTENANCE

PUMP DRIVE MAINTENANCE

PUMP DRIVE MAINTENANCEPUMP DRIVE MAINTENANCE

(FOR FUNK PUMP DRIVES)(FOR FUNK PUMP DRIVES)

(FOR FUNK PUMP DRIVES)

(FOR FUNK PUMP DRIVES)(FOR FUNK PUMP DRIVES)

A. TWO, THREE AND FOUR PAD PUMP DRIVESA. TWO, THREE AND FOUR PAD PUMP DRIVES

A. TWO, THREE AND FOUR PAD PUMP DRIVES

A. TWO, THREE AND FOUR PAD PUMP DRIVESA. TWO, THREE AND FOUR PAD PUMP DRIVES

2 PAD PUMP DRIVE2 PAD PUMP DRIVE

2 PAD PUMP DRIVE

2 PAD PUMP DRIVE2 PAD PUMP DRIVE

LUBRICANT RECOMMENDATIONS AND FLUID CHANGING PROCEDURESLUBRICANT RECOMMENDATIONS AND FLUID CHANGING PROCEDURES

LUBRICANT RECOMMENDATIONS AND FLUID CHANGING PROCEDURES

LUBRICANT RECOMMENDATIONS AND FLUID CHANGING PROCEDURESLUBRICANT RECOMMENDATIONS AND FLUID CHANGING PROCEDURES

Lubricant Type:

EP 80-90 gear fluid (except direct drive models).

Lubricant Grade:

Weather Temperature

Below -10 degrees F (-23 degrees C) = Use 75 W. Above -10 degrees F and up to 100 degrees F (37.8 degrees C) = Use 80 W/90. Above 100 degrees F (37.8 degrees C) = Use 85 W/140.

It is recommended that the fluid level be checked daily, 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. Stop engine before checking or adding fluid.

3 PAD PUMP DRIVE3 PAD PUMP DRIVE

3 PAD PUMP DRIVE

3 PAD PUMP DRIVE3 PAD PUMP DRIVE

Figure 1Figure 1

Figure 1

Figure 1Figure 1

4 PAD PUMP DRIVE4 PAD PUMP DRIVE

4 PAD PUMP DRIVE

4 PAD PUMP DRIVE4 PAD PUMP DRIVE

2. Check unit for operational warning tags. Heed all warnings.

3. Clean around fluid fill before checking or adding fluid.

4. Change the fluid after every 400 hours of operation. Also, the fluid in the unit should be changed whenever the fluid level shows traces of dirt or effects of high temperature, evidenced by discoloration or strong odor.

5. Drain the fluid while the unit is still warm, examining for contamination or metal particles.

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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 DISASSEMBLYPUMP DRIVE DISASSEMBLY

PUMP DRIVE DISASSEMBLY

PUMP DRIVE DISASSEMBLYPUMP 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.

1.1.

ENGINEENGINE

ENGINE

1.1.

ENGINEENGINE

2.2.

FLYWHEEL COVERFLYWHEEL COVER

FLYWHEEL COVER

2.2.

FLYWHEEL COVERFLYWHEEL COVER

3.3.

ENGINE ADAPTORENGINE ADAPTOR

ENGINE ADAPTOR

3.3.

ENGINE ADAPTORENGINE ADAPTOR

4.4.

PUMP DRIVEPUMP DRIVE

PUMP DRIVE

4.4.

PUMP DRIVEPUMP DRIVE

5.5.

HYDRAULIC PUMPSHYDRAULIC PUMPS

HYDRAULIC PUMPS

5.5.

HYDRAULIC PUMPSHYDRAULIC PUMPS

FILL HOLEFILL HOLE

FILL HOLE

FILL HOLEFILL HOLE

Figure 2Figure 2

Figure 2

Figure 2Figure 2

3. Remove pump drive from engine by removing capscrews, holding engine adaptor housing to flywheel cover of engine. Remove pump drive straight away from engine.

a. Flex plate driven models:

The drive shaft will remain with either the drive plate or the pump drive box. Be prepared to retrieve drive shaft from either.

4. Pump drive gear box should be positioned so that the hydraulic pump adaptor pads are facing up. Remove place bolts or nuts from studs and lift adaptor pads up from gear box.

5. Lift driven gears and their bearings from pump drive box. This can be done by hand since the bearings are slip fitted to the housing and pump adaptor bores. Bearings are press fitted to gear hubs. It may be necessary to tip gear slightly to clear pinion gear bearing pocket.

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 bearings from pump drive box.

7. Should replacement of oil seal be required, drive oil seal toward engine side of engine adaptor.

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PUMP DRIVE MAINTENANCE CONTINUED...

NOTE:NOTE:

NOTE: Drive in direction of arrow.

NOTE:NOTE:

8. To remove bearings from gear hubs, use gear puller or Arbor Press.

REASSEMBLY OF PUMP DRIVEREASSEMBLY OF PUMP DRIVE

REASSEMBLY OF PUMP DRIVE

REASSEMBLY OF PUMP DRIVEREASSEMBLY OF PUMP DRIVE

For reassembly, use the reverse procedure of 1 through 8.

NOTE:NOTE:

NOTE: Plastic cord used for gasket material under pump adaptor plates and input housing is not reusable.

NOTE:NOTE:

Replace with new material when reassembling. See Figure 3 for installation of cord gasket. Place bolts should not be reused. Clean the old Locktite out of the bolt hole threads. Install new place bolts with Locktite 262, on the engine adaptor and pump pad. Place bolts are used in pump drive pad, torque studs to 150 ft. lbs..

Remove protective paper strip from cord and withRemove protective paper strip from cord and with

Remove protective paper strip from cord and with

Remove protective paper strip from cord and withRemove protective paper strip from cord and with adhesive side next to metal, install around pilot. Crossadhesive side next to metal, install around pilot. Cross

adhesive side next to metal, install around pilot. Cross

adhesive side next to metal, install around pilot. Crossadhesive side next to metal, install around pilot. Cross ends, as shown, behind bolt hole and let ends extendends, as shown, behind bolt hole and let ends extend

ends, as shown, behind bolt hole and let ends extend

ends, as shown, behind bolt hole and let ends extendends, as shown, behind bolt hole and let ends extend beyond flange. Use caution in assembly to case, tobeyond flange. Use caution in assembly to case, to

beyond flange. Use caution in assembly to case, to

beyond flange. Use caution in assembly to case, tobeyond flange. Use caution in assembly to case, to prevent gasket dislocation.prevent gasket dislocation.

prevent gasket dislocation.

prevent gasket dislocation.prevent gasket dislocation.

TYPICAL ADAPTOR PLATETYPICAL ADAPTOR PLATE

TYPICAL ADAPTOR PLATE

TYPICAL ADAPTOR PLATETYPICAL ADAPTOR PLATE

LET ENDS EXTEND BEYOND FLANGELET ENDS EXTEND BEYOND FLANGE

LET ENDS EXTEND BEYOND FLANGE

LET ENDS EXTEND BEYOND FLANGELET ENDS EXTEND BEYOND FLANGE

Do not attempt to reuse this gasket. For assembly useDo not attempt to reuse this gasket. For assembly use

Do not attempt to reuse this gasket. For assembly use

Do not attempt to reuse this gasket. For assembly useDo not attempt to reuse this gasket. For assembly use new gasket material.new gasket material.

new gasket material.

new gasket material.new gasket material.

On flywheel housings involving more than 4 boltOn flywheel housings involving more than 4 bolt

On flywheel housings involving more than 4 bolt

On flywheel housings involving more than 4 boltOn flywheel housings involving more than 4 bolt holes, be sure cord gasket lap joint falls behind oneholes, be sure cord gasket lap joint falls behind one

holes, be sure cord gasket lap joint falls behind one

holes, be sure cord gasket lap joint falls behind oneholes, be sure cord gasket lap joint falls behind one hole location which will be used for a bolt or studhole location which will be used for a bolt or stud

hole location which will be used for a bolt or stud

hole location which will be used for a bolt or studhole location which will be used for a bolt or stud fastener. Do not lap ends behind an unused bolt hole.fastener. Do not lap ends behind an unused bolt hole.

fastener. Do not lap ends behind an unused bolt hole.

fastener. Do not lap ends behind an unused bolt hole.fastener. Do not lap ends behind an unused bolt hole.

CORD GASKETCORD GASKET

CORD GASKET

CORD GASKETCORD GASKET

Figure 3Figure 3

Figure 3

Figure 3Figure 3

REPLACEMENT OF OIL SEALREPLACEMENT OF OIL SEAL

REPLACEMENT OF OIL SEAL

REPLACEMENT OF OIL SEALREPLACEMENT OF OIL SEAL Install oil seal from engine side of engine adaptor. The rubber lip of the oil seal must point toward the inside of pump drive gear box.

NOTE:NOTE:

NOTE: Drive in direction of arrow.

NOTE:NOTE:

Drive Plate Models:

When installing drive plate on flywheel, be sure the long end of the drive plate hub is toward the engine. The hub should slide into the pilot bearing bore of the flywheel to ensure proper alignment of the drive hub and drive shaft.

NOTE:NOTE:

NOTE: Arrow indicates engine side.

NOTE:NOTE:

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B. SINGLE PAD PUMP DRIVESB. SINGLE PAD PUMP DRIVES

B. SINGLE PAD PUMP DRIVES

B. SINGLE PAD PUMP DRIVESB. SINGLE PAD PUMP DRIVES

This type of Pump Drive (See Figure 4), is mounted to the engine (direct drive), and is virtually maintenance free.

Figure 4Figure 4

Figure 4

Figure 4Figure 4

If a Disconnect Clutch (optional) is ordered on your machine, the following maintenance must be done.

C. OPTIONAL DISCONNECT CLUTCHC. OPTIONAL DISCONNECT CLUTCH

C. OPTIONAL DISCONNECT CLUTCH

C. OPTIONAL DISCONNECT CLUTCHC. OPTIONAL DISCONNECT CLUTCH

If clutch does not pull, heats, or operating lever jumps out, adjustment is required. To adjust clutch, remove hand hole plate, turn clutch until adjusting lock pin can be reached. Pull adjusting pin out and turn adjusting 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.

Example of a Pump Drive with a Disconnect ClutchExample of a Pump Drive with a Disconnect Clutch

Example of a Pump Drive with a Disconnect Clutch

Example of a Pump Drive with a Disconnect ClutchExample of a Pump Drive with a Disconnect Clutch

HAND HOLE PLATEHAND HOLE PLATE

HAND HOLE PLATE

HAND HOLE PLATEHAND HOLE PLATE

OPERATING LEVEROPERATING LEVER

OPERATING LEVER

ADJUSTING YOKEADJUSTING YOKE

ADJUSTING YOKE

ADJUSTING YOKEADJUSTING YOKE

Pull pin in thisPull pin in this

Pull pin in this

Pull pin in thisPull pin in this direction (it isdirection (it is

direction (it is

direction (it isdirection (it is spring loaded).spring loaded).

spring loaded).

spring loaded).spring loaded).

OPERATING LEVEROPERATING LEVER

ADJUSTING PINADJUSTING PIN

ADJUSTING PIN

ADJUSTING PINADJUSTING PIN

(mounted inside clutch)(mounted inside clutch)

(mounted inside clutch)

(mounted inside clutch)(mounted inside clutch)

Figure 5Figure 5

Figure 5

Figure 5Figure 5

For cold weather start-up using Disconnect Clutch, see Start-up instructions in Operator's Manual.

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AIR CLEANER MAINTENANCEAIR CLEANER MAINTENANCE

AIR CLEANER MAINTENANCE

AIR CLEANER MAINTENANCEAIR 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. 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 a daily basis or more often in severe conditions:

1. Check to ensure that the air cleaner bonnet is free of leaves, twigs, etc. that are drawn in while the machine is working. (See Figure 1).

NOTE:NOTE:

NOTE: This is especially important in the fall months, as the trees shed their leaves.

NOTE:NOTE:

AIR CLEANER BONNETAIR CLEANER BONNET

AIR CLEANER BONNET

AIR CLEANER BONNETAIR CLEANER BONNET

Figure 1Figure 1

Figure 1

Figure 1Figure 1

2. Empty the pre-cleaner dust cup. Frequency of dust cup service will vary with dust conditions. Emptying The Dust Cup.Emptying The Dust Cup.

See

Emptying The Dust Cup.

Emptying The Dust Cup.Emptying The Dust Cup.

3. Check the restriction indicator daily. When indicated, change the element. See

Air Cleaner Restriction.Air Cleaner Restriction.

Air Cleaner Restriction.

Air Cleaner Restriction.Air Cleaner Restriction.

EMPTYING THE DUST CUPEMPTYING THE DUST CUP

EMPTYING THE DUST CUP

EMPTYING THE DUST CUPEMPTYING THE DUST CUP

Check the dust cup daily for dust build-up. When reinstalling the dust cup, make sure it seals 360 degrees around the air cleaner body and the directional arrows are pointed in the UP position. See Figure 2 on next page.

BAFFLEBAFFLE

BAFFLE

DUST CUPDUST CUP

DUST CUP

DUST CUPDUST CUP

DUST CUP

DUST CUPDUST CUP

ARROWSARROWS

ARROWS

ARROWSARROWS

BAFFLEBAFFLE ASSEMBLYASSEMBLY

ASSEMBLY

ASSEMBLYASSEMBLY

Figure 2Figure 2

Figure 2

Figure 2Figure 2

ELEMENTELEMENT

ELEMENT

ELEMENTELEMENT

CheckingChecking

Checking

CheckingChecking

AIR CLEANERAIR CLEANER

AIR CLEANER

AIR CLEANERAIR CLEANER BODYBODY

BODY

BODYBODY

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AIR CLEANERS WITH VACUATOR VALVEAIR CLEANERS WITH VACUATOR VALVE

AIR CLEANERS WITH VACUATOR VALVE

AIR CLEANERS WITH VACUATOR VALVEAIR CLEANERS WITH VACUATOR VALVE On vacuator valve equipped models, (see figure 3) dust 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.

VACUATOR VALVEVACUATOR VALVE

VACUATOR VALVE

VACUATOR VALVEVACUATOR VALVE

CHECKING AIR CLEANER RESTRICTIONCHECKING AIR CLEANER RESTRICTION

CHECKING AIR CLEANER RESTRICTION

CHECKING AIR CLEANER RESTRICTIONCHECKING AIR CLEANER RESTRICTION

Check the Air Cleaner Restriction Indicator daily for restriction. Restriction is caused by dust and dirt accumulating on the Air Cleaner Element. The method used to check the restriction will depend upon the type of Air Cleaner on the machine.

AIR CLEANERS WITH RESTRICTION INDICATORSAIR CLEANERS WITH RESTRICTION INDICATORS

AIR CLEANERS WITH RESTRICTION INDICATORS

AIR CLEANERS WITH RESTRICTION INDICATORSAIR CLEANERS WITH RESTRICTION INDICATORS These air cleaners have a restriction indicator mounted to the Air Cleaner body (see Figure 4). The indicator plunger will be in the green zone when the Air Cleaner is empty - and will move up towards the red zone when the Air Cleaner is full of dust and dirt. When in the red zone, this means the Air Cleaner element needs to be replaced. See

Replacing The Air Cleaner ElementReplacing The Air Cleaner Element

Replacing The Air Cleaner Element later on.

Replacing The Air Cleaner ElementReplacing The Air Cleaner Element

DUST CUPDUST CUP

DUST CUP

DUST CUPDUST CUP

Figure 3Figure 3

Figure 3

Figure 3Figure 3

RESTRICTIONRESTRICTION

RESTRICTION

RESTRICTIONRESTRICTION INDICATORINDICATOR

INDICATOR

INDICATORINDICATOR

Figure 4Figure 4

Figure 4

Figure 4Figure 4

AIR CLEANERS WITHOUT RESTRICTION INDICATORS:AIR CLEANERS WITHOUT RESTRICTION INDICATORS:

AIR CLEANERS WITHOUT RESTRICTION INDICATORS:

AIR CLEANERS WITHOUT RESTRICTION INDICATORS:AIR CLEANERS WITHOUT RESTRICTION INDICATORS: 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 only when the restriction has reached the maximum allowed by the engine manufacturer. Contact the Barko Service Department for maximum values and any other questions concerning this method.

CAUTION CAUTION

CAUTION

Check the Air Cleaner Assembly daily for cracks,Check the Air Cleaner Assembly daily for cracks,

Check the Air Cleaner Assembly daily for cracks,

Check the Air Cleaner Assembly daily for cracks,Check the Air Cleaner Assembly daily for cracks, loose clamps, or any other damage. If debris is ableloose clamps, or any other damage. If debris is able

loose clamps, or any other damage. If debris is able

loose clamps, or any other damage. If debris is ableloose clamps, or any other damage. If debris is able to bypass the Air Cleaner for any reason, it canto bypass the Air Cleaner for any reason, it can

to bypass the Air Cleaner for any reason, it can

to bypass the Air Cleaner for any reason, it canto bypass the Air Cleaner for any reason, it can damage the engine.damage the engine.

damage the engine.

damage the engine.damage the engine.

REPLACING THE AIR CLEANER ELEMENTREPLACING THE AIR CLEANER ELEMENT

REPLACING THE AIR CLEANER ELEMENT

REPLACING THE AIR CLEANER ELEMENTREPLACING THE AIR CLEANER ELEMENT

For minimum vehicle downtime, replace dirty air cleaner element with a new element. DO NOT TRY TO CLEAN THE ELEMENT! Do not leave air cleaner open to the environment longer than it takes to remove element, inspect and clean inside of air cleaner body, and install a new element.

When restriction indicates that element servicing is required, see the replacement steps on the next page.

CAUTION CAUTION

SAFETY ELEMENT SERVICE (IF APPLICABLE)SAFETY ELEMENT SERVICE (IF APPLICABLE)

SAFETY ELEMENT SERVICE (IF APPLICABLE)

SAFETY ELEMENT SERVICE (IF APPLICABLE)SAFETY ELEMENT SERVICE (IF APPLICABLE)

The safety element is not intended to be cleaned.

For maximum engine protection and air cleaner service life, replace the safety element with a new safety element every third primary element change.

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AIR CLEANER MAINTENANCE CONTINUED...

IMPORTANT STEPS TO FOLLOW EVERY TIME AN AIRIMPORTANT STEPS TO FOLLOW EVERY TIME AN AIR

IMPORTANT STEPS TO FOLLOW EVERY TIME AN AIR

IMPORTANT STEPS TO FOLLOW EVERY TIME AN AIRIMPORTANT STEPS TO FOLLOW EVERY TIME AN AIR CLEANER ELEMENT IS REPLACED:CLEANER ELEMENT IS REPLACED:

CLEANER ELEMENT IS REPLACED:

CLEANER ELEMENT IS REPLACED:CLEANER ELEMENT IS REPLACED:

REMOVE THEREMOVE THE

REMOVE THE

REMOVE THEREMOVE THE

OLD ELEMENTOLD ELEMENT

OLD ELEMENT

OLD ELEMENTOLD ELEMENT AS GENTLYAS GENTLY

AS GENTLY

AS GENTLYAS GENTLY AS POSSIBLEAS POSSIBLE

AS POSSIBLE

AS POSSIBLEAS POSSIBLE

Loosen wing nut and remove old element. Baby that dirty element until you get it clear out of the housing. Accidentally bumping it while still inside means dropped dirt and dust that may contaminate the clean side of your filter housing, before the new filter element has a chance to do its job.

ALWAYS CLEANALWAYS CLEAN

ALWAYS CLEAN

ALWAYS CLEANALWAYS CLEAN THE INSIDE OFTHE INSIDE OF

THE INSIDE OF

THE INSIDE OFTHE INSIDE OF THE HOUSINGTHE HOUSING

THE HOUSING

THE HOUSINGTHE HOUSING CAREFULLYCAREFULLY

CAREFULLY

CAREFULLYCAREFULLY

Dirt left in the air cleaner housing spells death for your engine. Use a clean, damp cloth to wipe every surface clean. Check it visually to make sure it's clean before putting in a new element.

ALWAYS CLEANALWAYS CLEAN

ALWAYS CLEAN

ALWAYS CLEANALWAYS CLEAN THE GASKETTHE GASKET

THE GASKET

THE GASKETTHE GASKET SEALINGSEALING

SEALING

SEALINGSEALING SURFACES OFSURFACES OF

SURFACES OF

SURFACES OFSURFACES OF THE HOUSINGTHE HOUSING

THE HOUSING

THE HOUSINGTHE HOUSING

An improper gasket seal is one of the most common causes of engine contamination. Make sure that all hardenend dirt ridges are completely removed, both on the bottom and top of the cleaner.

CHECK FORCHECK FOR

CHECK FOR

CHECK FORCHECK FOR UNEVEN DIRTUNEVEN DIRT

UNEVEN DIRT

UNEVEN DIRTUNEVEN DIRT PATTERNS ONPATTERNS ON

PATTERNS ON

PATTERNS ONPATTERNS ON YOUR ELEMENTYOUR ELEMENT

YOUR ELEMENT

YOUR ELEMENTYOUR ELEMENT

Your old element is a valuable clue to dust leakage or gasket sealing problems. A pattern on the element clean side is a sign that the old element was not firmly sealed or that a dust leak exists. Make certain the cause of that leak is identified and rectified before replacing the element.

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PRESS YOURPRESS YOUR

PRESS YOUR

PRESS YOURPRESS YOUR FRESH GASKETFRESH GASKET

FRESH GASKET

FRESH GASKETFRESH GASKET TO SEE IF ITTO SEE IF IT

TO SEE IF IT

TO SEE IF ITTO SEE IF IT SPRINGS BACKSPRINGS BACK

SPRINGS BACK

SPRINGS BACKSPRINGS BACK

Make sure your new element is made with a highly compressible gasket that springs right back when your finger pressure is released. A quality gasket is one of the most important parts of the element.

MAKE SURE THEMAKE SURE THE

MAKE SURE THE

MAKE SURE THEMAKE SURE THE GASKET ISGASKET IS

GASKET IS

GASKET ISGASKET IS SEATING EVENLYSEATING EVENLY

SEATING EVENLY

SEATING EVENLYSEATING EVENLY

If you don't feel the gasket is seating evenly for a perfect seal, you don't have protection. Recheck to see if the sealing surface in the housing is clean, or if the element is the correct model number. It may be too short for the housing.

REINSTALL DUSTREINSTALL DUST

REINSTALL DUST

REINSTALL DUSTREINSTALL DUST CUPCUP

CUP

CUPCUP

Be sure the dust cup seals 360 degrees around the air cleaner body and the directional arrows are pointing up.

CHECKCHECK

CHECK

CHECKCHECK CONNECTIONSCONNECTIONS

CONNECTIONS

CONNECTIONSCONNECTIONS & DUCTS FOR& DUCTS FOR

& DUCTS FOR

& DUCTS FOR& DUCTS FOR AIR TIGHT FITAIR TIGHT FIT

AIR TIGHT FIT

AIR TIGHT FITAIR TIGHT FIT

Check that all clamps and flange joints are tight, as well as cleaner mounting bolts. Seal any leaks immediately - they mean dirt is directly entering your engine. All duct joints, from air cleaner to engine, must be tight.

RESET THERESET THE

RESET THE

RESET THERESET THE RESTRICTIONRESTRICTION

RESTRICTION

RESTRICTIONRESTRICTION INDICATORINDICATOR

INDICATOR

INDICATORINDICATOR

If air cleaner is equipped with a restriction indicator, reset it to the green zone.

AIR CLEANER MAINTENANCE CONTINUED...

THE IMPORTANT "DON'TS" TO ALWAYS REMEMBER:THE IMPORTANT "DON'TS" TO ALWAYS REMEMBER:

THE IMPORTANT "DON'TS" TO ALWAYS REMEMBER:

THE IMPORTANT "DON'TS" TO ALWAYS REMEMBER:THE IMPORTANT "DON'TS" TO ALWAYS REMEMBER:

DON'TDON'T

DON'T

DON'TDON'T

ELEMENT FORELEMENT FOR

ELEMENT FOR

ELEMENT FORELEMENT FOR INPECTIONINPECTION

INPECTION

INPECTIONINPECTION

Such a check will always do more harm to your engine than good. Ridges of dirt on the gasket sealing surface can drop on the clean filter side when the gasket is released. Stick with the schedule. If you are on restriction maintenance, follow your reading or get a new indicator if you don't trust it.

NEVERNEVER

NEVER

NEVERNEVER

ELEMENT TO CLEANELEMENT TO CLEAN

ELEMENT TO CLEAN

ELEMENT TO CLEANELEMENT TO CLEAN IT. THIS WILL ONLYIT. THIS WILL ONLY

IT. THIS WILL ONLY

IT. THIS WILL ONLYIT. THIS WILL ONLY DESTROY IT.DESTROY IT.

DESTROY IT.

DESTROY IT.DESTROY IT.

Rapping hard enough to knock off dust often damages the element and destroys your engine protection. Deeply embedded dirt is never released by tapping. It's always safer to keep operating until you can change to a fresh filter.

NEVER NEVER

NEVER

NEVER NEVER

YOUR ELEMENT'SYOUR ELEMENT'S

YOUR ELEMENT'S

YOUR ELEMENT'SYOUR ELEMENT'S LIFE BY LOOKINGLIFE BY LOOKING

LIFE BY LOOKING

LIFE BY LOOKINGLIFE BY LOOKING AT IT.AT IT.

AT IT.

AT IT.AT IT.

A dirty filter may still have plenty of life left, while carbon contamination is not visible to the eye. And you can't see the dirt that is embedded deep within the filter paper. Your best bet for lowest filter maintenance costs and best engine performance is to follow a restriction gauge. It's a smart, low-cost investment.

REMOVE REMOVE

REMOVE

REMOVE REMOVE

RAP AN RAP AN

RAP AN

RAP AN RAP AN

JUDGEJUDGE

JUDGE

JUDGEJUDGE

DON'TDON'T

DON'T

DON'TDON'T

OVERLOOK AOVERLOOK A

OVERLOOK A

OVERLOOK AOVERLOOK A WORN ORWORN OR

WORN OR

WORN ORWORN OR DAMAGED GASKETDAMAGED GASKET

DAMAGED GASKET

DAMAGED GASKETDAMAGED GASKET IN THE HOUSINGIN THE HOUSING

IN THE HOUSING

IN THE HOUSINGIN THE HOUSING

If your cleaner has a cover gasket, replace it with a new one. Always check to be sure no piece of the old gasket remains in the housing and that the gasket is not worn. If your filter model calls for a new gasket with each use, never reuse the old one.

DON'TDON'T

DON'T

DON'TDON'T

DENTED ORDENTED OR

DENTED OR

DENTED ORDENTED OR BUNCHED FILTERBUNCHED FILTER

BUNCHED FILTER

BUNCHED FILTERBUNCHED FILTER ELEMENT.ELEMENT.

ELEMENT.

ELEMENT.ELEMENT.

Never install a dented or punctured element, because it cannot protect properly against contamination. A dent can make a firm seal impossible or can indicate damaged media. An element with bunched pleats saps engine power and fuel dollars right from the start.

NEVERNEVER

NEVER

NEVERNEVER

WARPED COVERWARPED COVER

WARPED COVER

WARPED COVERWARPED COVER ON A HOUSINGON A HOUSING

ON A HOUSING

ON A HOUSINGON A HOUSING

Replace with a new cover as soon as possible. A warped or damaged cover cannot make a proper seal. Also check to make sure there is no damage to the air cleaner housing that could cause a leak.

USE A USE A

USE A

USE A USE A

USE A

USE A USE A

NEVERNEVER

NEVER

NEVERNEVER

AIR CLEANER OPENAIR CLEANER OPEN

AIR CLEANER OPEN

AIR CLEANER OPENAIR CLEANER OPEN LONGER THANLONGER THAN

LONGER THAN

LONGER THANLONGER THAN NECESSARY.NECESSARY.

NECESSARY.

NECESSARY.NECESSARY.

Your open air cleaner is a direct entry to your engine. 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.

LEAVE AN LEAVE AN

LEAVE AN

LEAVE AN LEAVE AN

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NEVERNEVER

NEVER

NEVERNEVER

SUBSTITIUTE ANSUBSTITIUTE AN

SUBSTITIUTE AN

SUBSTITIUTE ANSUBSTITIUTE AN INCORRECTINCORRECT

INCORRECT

INCORRECTINCORRECT ELEMENT MODELELEMENT MODEL

ELEMENT MODEL

ELEMENT MODELELEMENT MODEL NUMBERNUMBER

NUMBER

NUMBERNUMBER

Elements may look almost identical but can differ by a fraction of an inch in length - a difference that makes a firm seal impossible. You're always better off using the dirty element until you can get the correct model.

E. CAT 330 CRAWLER LOWERE. CAT 330 CRAWLER LOWER

E. CAT 330 CRAWLER LOWER

E. CAT 330 CRAWLER LOWERE. CAT 330 CRAWLER LOWER

MAINTENANCEMAINTENANCE

MAINTENANCE

MAINTENANCEMAINTENANCE

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MaintenanceMaintenance

Maintenance

CAT 330 CRAWLER LOWER MAINTENANCECAT 330 CRAWLER LOWER MAINTENANCE

CAT 330 CRAWLER LOWER MAINTENANCE

CAT 330 CRAWLER LOWER MAINTENANCECAT 330 CRAWLER LOWER MAINTENANCE

TRACK ADJUSTMENT PROCEDURETRACK ADJUSTMENT PROCEDURE

TRACK ADJUSTMENT PROCEDURE

TRACK ADJUSTMENT PROCEDURETRACK ADJUSTMENT PROCEDURE

1. Drive the machine forward in the direction of the idlers.

2. Stop when one track pin is directly over the front carrier roller.

3. The correct adjustment is 25 to 40 mm (1.0 to 1.5 in.) of sag halfway between the front carrier roller and the idler.

WARNING WARNING

WARNING

WARNING WARNING

To prevent possible personal injury, never visually inspect the relief valveTo prevent possible personal injury, never visually inspect the relief valve

To prevent possible personal injury, never visually inspect the relief valve

To prevent possible personal injury, never visually inspect the relief valveTo prevent possible personal injury, never visually inspect the relief valve to see if grease is coming out. Always look at the track to see if it hasto see if grease is coming out. Always look at the track to see if it has

to see if grease is coming out. Always look at the track to see if it has

to see if grease is coming out. Always look at the track to see if it hasto see if grease is coming out. Always look at the track to see if it has become loose or tight.become loose or tight.

become loose or tight.

become loose or tight.become loose or tight.

Open the relief valve one turn only.

CAUTION CAUTION

CAUTION

CAUTION CAUTION

If the dimension between the end of the track roller frame and the flangeIf the dimension between the end of the track roller frame and the flange

If the dimension between the end of the track roller frame and the flange

If the dimension between the end of the track roller frame and the flangeIf the dimension between the end of the track roller frame and the flange on the idler hub (as shown in Figure 2) is less than 25 mm (1 in.), do not adjust theon the idler hub (as shown in Figure 2) is less than 25 mm (1 in.), do not adjust the

on the idler hub (as shown in Figure 2) is less than 25 mm (1 in.), do not adjust the

on the idler hub (as shown in Figure 2) is less than 25 mm (1 in.), do not adjust theon the idler hub (as shown in Figure 2) is less than 25 mm (1 in.), do not adjust the track.track.

track.

track.track.

4. Remove the plate covering the fill and relief valves on the track roller frame.

5. If the track is too loose, add grease in the fill valve until the track sag is correct.

6. If the track is too tight, turn the relief valve counterclockwise one turn and let grease come out until the adjustment is correct.

NOTENOTE

NOTE: It will be necessary to move the machine back and forth to get the pressure equal.

NOTENOTE

7. Check the adjustment again.

8. If the adjustment is correct, tighten the relief valve and replace the cover plate.

Figure 1 - Measuring Track LoosenessFigure 1 - Measuring Track Looseness

Figure 1 - Measuring Track Looseness

Figure 1 - Measuring Track LoosenessFigure 1 - Measuring Track Looseness

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Figure 2 - Measuring Track LoosenessFigure 2 - Measuring Track Looseness

Figure 2 - Measuring Track Looseness

Figure 2 - Measuring Track LoosenessFigure 2 - Measuring Track Looseness

CAT 330 CRAWLER LOWER MAINTENANCE CONTINUED...

FINAL DRIVES - CHECKING THEFINAL DRIVES - CHECKING THE

FINAL DRIVES - CHECKING THE

FINAL DRIVES - CHECKING THEFINAL DRIVES - CHECKING THE OIL LEVELOIL LEVEL

OIL LEVEL

OIL LEVELOIL LEVEL

See Figure 1.

1. Position one final drive with oil drain plug at the bottom.

2. Remove oil level plug.

Oil Level PlugOil Level Plug

Oil Level Plug

Oil Level PlugOil Level Plug

Oil Drain PlugOil Drain Plug

Oil Drain Plug

Oil Drain PlugOil Drain Plug

Figure 1Figure 1

Figure 1

Figure 1Figure 1

3. Oil should be to the bottom of the oil level plug opening.

FINAL DRIVES - CHANGING THEFINAL DRIVES - CHANGING THE

FINAL DRIVES - CHANGING THE

FINAL DRIVES - CHANGING THEFINAL DRIVES - CHANGING THE OILOIL

OIL

OILOIL

See Figure 1.

1. Position one final drive with oil drain plug at the bottom.

2. Remove oil drain plug and level plug. Allow the oil to drain into a container.

3. Clean the plugs and inspect the o-ring seal. Replace them if they are worn or damaged.

4. Install drain plug.

5. Fill the final drive to bottom of oil level plug opening.

Fill with SAE 30 CD/TO-2 engine oil. Capacity: 2.1 U.S. gallons (8 liters) per final drive.

6. Install oil level plug.

7. Perform step 1-6 on other final drive.

8. Completely remove oil spilled onto surfaces.

4. Add oil through the opening of the oil level plug, if necessary.

5. Clean oil level plug. Inspect the O-RING seal. Replace it if it is worn or damaged.

6. Install the oil level plug.

7. Repeat procedure on the other final drive.

CRAWLER LOWER LUBRICATION POINTSCRAWLER LOWER LUBRICATION POINTS

CRAWLER LOWER LUBRICATION POINTS

CRAWLER LOWER LUBRICATION POINTSCRAWLER LOWER LUBRICATION POINTS

See Lubrication Points section in this manual for the fluid and grease points of the crawler lower.

CRAWLER LOWER TORQUE SPECIFICATIONSCRAWLER LOWER TORQUE SPECIFICATIONS

CRAWLER LOWER TORQUE SPECIFICATIONS

CRAWLER LOWER TORQUE SPECIFICATIONSCRAWLER LOWER TORQUE SPECIFICATIONS

See Special Torque Specifications section in this manual for crawler lower bolt torques.

9. Start engine and allow the final drives to run through several cycles.

10. Stop engine. Check the oil level.

11. Check the drained oil for metal chips or particles. If there are any, contact your dealer.

12. Dispose of drained material according to local regulation.

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BARKO LOADERS Crawler 475A Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Introduction

INTRODUCTION

ABBREVIATIONS AND SYMBOLS

HYDRAULIC PRESSURE WARNING SHEET

WARRANTY

KNOW YOUR MACHINE

SAFETY SUMMARY

FIRE PREVENTION

MODEL DESCRIPTION

A. PREVENTIVE MAINTENANCE

Maintenance

SAFETY WHILE SERVICING

PREVENTIVE MAINTENANCE

SPECIAL NEW-MACHINE INSTRUCTIONS

SERVICE SCHEDULE

LUBRICATION POINTS

FLUID SPECIFICATIONS

SPECIAL TORQUE SPECIFICATIONS

GENERAL TORQUE SPECIFICATIONS

HYDRAULIC SCHEMATIC

HYDRAULIC PRESSURE SETTINGS

HYDRAULIC RESERVOIR MAINTENANCE

HYDRAULIC OIL FILTER MAINTENANCE

ELIMINATING AIR FROM THE SYSTEM

HYDRAULIC FITTINGS, HOSES AND TUBING

HYDRAULIC CYLINDER MAINTENANCE

COLLECTOR MAINTENANCE

VALVE MAINTENANCE (A20/A35 CONTROL VALVES)

PUMP MAINTENANCE (SWING)

PUMP MAINTENANCE (BOOM & TRAVEL)

PUMP MAINTENANCE (SERVO)

MOTOR MAINTENANCE (DRIVE)

SWING MOTOR GEARBOX MAINTENANCE (S10A)

SWING BRAKE MAINTENANCE

ELECTRICAL SYSTEM DESCRIPTION

ELECTRICAL SYSTEM INSPECTION

USING AN EXTRA BATTERY TO START MACHINE

ALTERNATOR DRIVE BELT ADJUSTMENT

ALTERNATOR MAINTENANCE

ELECTRICAL SYSTEM TROUBLE SHOOTING

D. POWER UNIT MAINTENANCE

ENGINE MAINTENANCE

PUMP DRIVE MAINTENANCE

A. TWO, THREE AND FOUR PAD PUMP DRIVES

B. SINGLE PAD PUMP DRIVES

C. OPTIONAL DISCONNECT CLUTCH

AIR CLEANER MAINTENANCE

TRACK ADJUSTMENT PROCEDURE

FINAL DRIVES - CHECKING THEFINAL DRIVES - CHECKING THE OIL LEVELOIL LEVEL

FINAL DRIVES - CHANGING THEFINAL DRIVES - CHANGING THE OILOIL

CRAWLER LOWER LUBRICATION POINTS

CRAWLER LOWER TORQUE SPECIFICATIONS