Allied 495 Product manual

OperatOr and parts Manual
122011 P3690
Loader
Models 495, S495

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Table of Contents - 495 & S495 Loader
Table of Contents
Introduction .................................................................................................................................4
• Terminology .....................................................................................................................4
• Hydraulic (Hose Kit).........................................................................................................5
Specifications...............................................................................................................................6
Safety............................................................................................................................................8
• Safety ................................................................................................................................8
• General Safety..................................................................................................................9
• Installation........................................................................................................................9
• Safety Decals..................................................................................................................10
• Important Precautions ................................................................................................... 11
Operation ...................................................................................................................................12
• Operation........................................................................................................................12
• Operating Suggestions for Loading .............................................................................13
• Operating Suggestions for Backfilling .........................................................................14
• Attaching the Loader toYourTractor.............................................................................15
• Removing the Loader fromYourTractor.......................................................................17
General Instructions ..................................................................................................................19
TSL General Note and Instructions..........................................................................................20
Troubleshooting.........................................................................................................................22
Maintenance ..............................................................................................................................21
Lubrication .................................................................................................................................21
Bolt Torque .................................................................................................................................25
• Checking BoltTorque .....................................................................................................25
Parts............................................................................................................................................26
• Sub Frame Assembly and Parts List.............................................................................26
• Main Frame Assembly and Parts List ...........................................................................28
• Hydraulic Plumbing Assembly and Parts List..............................................................30
Assembly....................................................................................................................................32
• Hydraulic Cylinder Assembly........................................................................................32
Pre-delivery Check List..............................................................................................................33
Warranty.....................................................................................................................................34
Manufacturer’s statement: for technical reasons Buhler Industries Inc. reserves the right to modify
machinery design and specifications provided herein without any preliminary notice.
Information provided herein is of descriptive nature. Performance quality may depend on soil fertility,
applied agricultural techniques, weather conditions and other factors.

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Introduction - 495 & S495 Loader
Introduction
Allied by Farm King front-end loaders are backed by years of extensive research. Factory testing
simulates specific operations to evaluate durability; days of continuous cycling in raising, twisting
and dropping loads using a programmed hydraulic power unit represents years of extreme use.
With one of the largest mounting kit application lists in the industry, there is an Allied front-end
loader available for nearly every tractor, large or small, new or old. Custom colors are available to
match all tractor brands which adds resale value and visual appeal.
Keep this manual handy for frequent reference. All new operators or owners must review the
manual before using the equipment and at least annually thereafter. Contact your Allied by Farm
King Dealer if you need assistance, information, or additional copies of the manual. Visit our
website at www.buhlerindustries.com for a complete list of dealers in your area.
The directions left, right, front and rear, as mentioned throughout this manual, are as seen facing
in the direction of travel of the implement.
Terminology
Basic terminology used throughout this manual has been identified below. For part numbers and
further details refer to the Parts section.

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Safety - 495 & S495 Loader
Hydraulic (Hose Kit)
Hose Kit “A”
Loader powered by the tractor remotes.
Consists of four hoses leading from loader
tubing to tractor remote couplers
Hose Kit “B”
Loader operated by an external OC or CC valve
that is powered from the tractor remotes.
Hose Kit “C”
Loader operated by an external valve that is
plumbed into the tractor hydraulic system.
Consists of 4 hoses leading from loader tubing
to external mounted valve plus the necessary
fittings, hoses and adapter blocks (if necessary)
to tap into tractor hydraulic system. Use valve
type shown with hose kit “C”

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Specifications - 495 & S495 Loader
Specifications

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Specifications - 495 & S495 Loader
Model number: 495
Mounting height: 36" (nominal)
Typical range: 33" - 39"
Description Bucket Lift
Bore 2.50" 2.50"
Rod 1.50" 1.50"
Stroke 20.63" 20.63"
A - Maximum lift height to pivot point (full height): 130" (11.0')
B - Clearance with bucket dumped: 100.4" (8.4')
C - Reach at maximum height: 28.2"
D - Maximum dump angle: 38°
F - Bucket rollback angle: 23.4°
G - Digging depth: 5.5"
H - Overall height in carry position: 70.7" (5.9')
R - Rollback angle at full height: 102.1°
Calculated breakout force: 2500 lbs with 2.5" lift cylinders
Calculated lift capacity: 2075 lbs with 2.5" lift cylinders
Notes:
1 - Calculated values assume 2500 psi lift cylinder pressure
2 - Breakout force estimated as per ASAE S301.2 - 4.1.2 (net payloud applied at cutting edge)
3 - Lift capacity estimated a per ASAE S301.2 - 4.1.1 (net payload applied at bucket midpoint)
4 - Average bucket weight (72"): 450 lbs
5 - Optional 3" lift cylinders available
6 - Short models breakout approx. 10% more than corresponding reg. models

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Safety - 495 & S495 Loader
Safety
Safety Instructions
Remember,YOU are the key to safety. Good safety practices not only protect you, but also the
people around you. Make these practices a working part of your safety program. Be certain that
everyone operating this equipment is familiar with the recommended operating and maintenance
procedures and follows all the safety precautions. Most accidents can be prevented. Do not risk
injury or death by ignoring good safety practices.
The alert symbol is used throughout this manual. It indicates attention is required and identifies
hazards. Follow the recommended precautions.
The safety alert symbol means…
ATTENTION! BECOME ALERT!YOUR SAFETY IS INVOLVED!
CAUTION
The caution symbol indicates a potentially hazardous situation
that, if not avoided, may result in minor or moderate injury. It
may also be used to alert against unsafe practices.
WARNING
The Warning Symbol indicates a potentially hazardous situation
that, if not avoided, could result in death or serious injury, and
includes hazards that are exposed when guards are removed. It
may also be used to alert against unsafe practices.
DANGER
The Danger Symbol indicates an imminently hazardous situation
that, if not avoided will result in death or serious injury. This
signal word is to be limited to the most extreme situations,
typically for machine components that, for functional purposes,
cannot be guarded.

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Safety - 495 & S495 Loader
General Safety Instructions
• Have a first-aid kit available for use and know how to use it.
• Have a fire extinguisher available, stored in a highly visible location, and know how to use it.
• Wear appropriate protective gear.This list may include but is not limited to:
- hard hat
- protective shoes with slip resistant soles
- protective glasses or goggles
- heavy gloves
- wet weather gear
- hearing protection
- respirator or filter mask
• Read and understand the Operator’s Manual and all safety signs before operating, servicing,
adjusting, repairing, or unplugging the equipment.
• Never work beneath raised loader unless it is securely supported.The following are
instructions for the lift lock supports.
• Do not pivot or turn tractor with bucket raised, except at a minimum speed. Always make
allowance for length of loader when making turns.
• Never leave tractor unattended while the bucket is raised. Always lower bucket to the ground
and shut off before leaving the tractor seat.
• Do not walk under raised bucket.
• Never operate loader while operator is not seated in the driver's seat on the tractor.
• Keep tractor on solid ground. Loose fill, rocks and holes can be dangerous for loader
operation or movement.
• Never operate a loader with frayed or damaged hoses or leaking fittings.
• Add ballast as required to ensure 25% of gross vehicle weight is transferred to the rear axle.
• Space rear tires as recommended by tractor manufacturer. Maximize width for high lift
applications.
• Do not raise bucket to extreme heights while tractor is on an incline. Carry loader low for
safety. Load center when bucket is raised on a slope. Be alert for terrain changes and adjust
bucket accordingly. Keep bucket low, no more than one foot high, as long as possible.
• Note: A pivoting front axle acts like a three-wheeled tractor until the stops hit the axle.
• If the cylinders are used to raise front wheels of tractor for service, place blocks under tractor
before working around front end.
Installation
• To install safety signs, ensure the installation area is clean and dry. Decide on the exact
position before you remove the backing paper. Remove the smallest portion of the split
backing paper and align over the specified area. Carefully press in place.
• Slowly peel back the remaining paper and smooth the remaining portion in place. Small air
pockets can be pierced with a pin and smoothed out.

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Safety - 495 & S495 Loader
Safety Decals

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Safety - 495 & S495 Loader
Important Precautions

12
Operation - 495 & S495 Loader
Operation
Operation
General Operating Notes:
Refer to tractor Operator's Manual for Operating information on the tractor's hydraulic system.
Hydraulic systems using auxiliary valves should have them located for easy reach from the tractor
seat. Hoses should be connected in such a manner that pushing forward on valve handles lowers
the boom or dumps the bucket
WARNING Always connect boom hoses to float section.
Weight added to rear of tractor provides better
traction and an easier, more efficient loader
operation. Extra weight along with the rear wheels,
reduces the risk of roll-over.
The smaller the tractor is, the easier it will roll. We
recommend that weight be added to rear tires with
liquid or by the installation of rear wheel weights.
Where additional weight is required, a counterweight
box can be fabricated for tractors with three-point
hitches.
Extra weight can also be added by the use of a heavy
implement mounted to the three-point hitch.
A roll-over protective structure is also recommended.
In cold weather, operate the tractor's engine at idle
speed until the hydraulic fluid is warmed up. High
engine speed when the hydraulic fluid is cold will
cause the pump to wear prematurely.
Under normal conditions, operate the tractor's engine
at 1/2 throttle. Shift the tractor into a low gear before
entering a pile of material to minimize strain on
loader arms.

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Operating Suggestions for Loading
When handling heavy loads, be sure to lower lift arms slowly.This is known as feathering the
hydraulic lever. If load is lowered too fast and stopped suddenly, excessive shock loads are created
which can damage loader or tractor.
When loading bucket, drive straight into material. Attempting to turn tractor while loading bucket
can cause damage to both the loader and tractor.
Operation - 495 & S495 Loader
Note: Bottom surface of bucket is parallel to
line on motion.
Work both levers back to direct pressure to
both cylinders.
Combined action of lift and bucket cylinders
increases loading efficiency.
A straight bottom offers more resistance to lift.
To increase loading efficiency. Minimize angle
of turn and length to run between pile and
spreader.
Leave material, which drifts over the bucket sides
for final cleanup.

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Operation - 495 & S495 Loader
Do not use bucket in dumped position for
bulldozing.This will only impose severe shock
loading on the bucket cylinders and make it
more difficult to maintain a level grade.
When backfilling approach pile with a flat
bucket. Leave dirt in bucket. Dumping on each
pass wastes time.
Backgrade work surface with a loaded bucket.
Release all pressure on lift cylinders so full
weight of bucket is scraping ground. Use heel
of bucket
DOTHIS
WARNING Do not use loader as battering ram!
Operating Suggestions for Backfilling

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Operation - 495 & S495 Loader
Attaching the Loader toYourTractor
1. Postions the tractor as centrally as possible and drive, using lowest gear possible, into the
loader frame until hoses can be connected.
2. Couple up the hydraulic hose lines to the loader or tractor valve ensuring proper function (see
operator and maintenance section)
NOTE: When mounting the loader for the first time, slowly work the cylinders back and forth,
so that most of the air is removed Loosen the bolts on the hooks so that they can be moved.
Also, check that the nuts in the rear of the subframe are in line with the holes.
3. On some tractors, the lift cylinders may have to be extended slightly, so that the subframes can
clear the front axle. Do not extend the cylinders more than is required.
On self leveling loaders, the bucket will dump
at the same time the loader is raised.Therefore,
Operate both hydraulic levers together.
4. Drive the tractor ahead until the subframe is past the front axle and the front hook is close to
mounting boss.
Check front grille clearance during installation to
avoid tractor damage.
5. Retract or extend the lift cylinders to line up the front hook with the mounting boss.
On self leveling loaders, the bucket will roll back
at the same time the loader is lowered.Therefore,
operate both hydraulic levers together.
6. When the hook is lined up, dump or roll back the bucket to lower or raise the subframe upright
to align with the mounting boot.

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Operation - 495 & S495 Loader
7. Continue to drive the tractor forward until the subframe uprights are seated in the boot.
8. Secure the subframe uprights with the bolts and washers.Torque 500 ft-lb.
When mounting for the first time, the front hook
bolts will have to be tightened after positioning
the hook directly over the mounting boss (most
rearward position)
9. Raise the loader and lock the support stand tubes in the up position.
When mounting for the first time, raise the loader
slowly and check to make sure that the hoses do
not bind or become pinched in all positions. Work
the loader and bucket up and down to work out
all the air in the hydraulics. Check and refill the
tractor's hydraulic system.

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Operation - 495 & S495 Loader
Removing the Loader fromYourTractor
WARNING
When removing the loader, it must be fitted with a bucket or other
suitable attachment to give the frame stability after removal. If
this is not done, the frame will not remain standing.
WARNING
Always remove the loader on firm, level ground (away from
children's play area and high traffic areas).This makes attaching
and removing much faster and easier. It also makes the free
standing loader more stable.
1. Raise the loader, lower support stand tubes and lock into position.
2. Lower the loader until the stand tubes are firmly on the ground and then dump the bucket so
that it is also firmly on the ground. there should be slight downward pressure.
3. Loosen the bolts from the rear of the subframe boots and swing bolt up into lock position.

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Operation - 495 & S495 Loader
4. Roll back the bucket slightly and simultaneously extend or retract the lift cylinders to free hooks
from spools.Then slowly back up the tractor.
5. Once the subframe is clear of the boot and the hook is clear of the mounting boss, roll back the
bucket all the way.This raises the rear uprights of the loader.
On some mountings, the lift cylinders must be
extended more while the tractor is backing up,
so that the subframes clear the front axle.
6. Continue backing up until the loader is clear.
Be sure the hoses do not get pinched or catch on
any frame members while backing up.
7. After the loader is clear, retract the lift cylinders to protect the shafts and disconnect the
hydraulic lines at quick couplers.

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General Instructions
As with any piece of equipment, the care with which your loader is operated and maintained
will greatly affect it’s life and the safety of the people using it.
1. Keep all pivots well lubricated for longer bushing life. Inspect every 500 hours of operationfor
wear.
2. Periodically check all bolts for tightness. If any bolt is damaged, replace it with a bolt
ofequivalent grade or strength.
3. Follow the recommendations of the tractor manufacturer in regards to the quantity of oil used.
4. Check oil level frequently to ensure the system is full.
5. When making an oil check, be sure lift cylinders are retracted.
6. Before operating the loader, particularly if the loader is left standing for any length of time,
check the hydraulic system and oil level.
7. When installing hydraulics, follow the circuit carefully. See hydraulic hook-up section and make
sure the hoses do not contact any hot manifolds or sharp edges on tractor. After assembly,
raise the loader slowly and check to make sure that the hoses do not bind in all positions.
8. The pressure of the relief and open center valves is set at the factory. Do not tamper with the
setting, serious injury to the operator or damage to the loader or tractor hydraulics may occur.
Warranty will be void if the loader is operated above recommended pressure.
9. When servicing any hydraulic components, care must be taken to prevent any foreign matter
from entering the system.
10. Do not neglect oil leaks. Leaks affect loader operation, are dangerous and can result in
personal injury or damage to the hydraulic system.
11. Never leave the cylinder shafts exposed when loader is not in use.
12. Worn or damaged components should be replace as soon as possible with only the
manufacturer’s recommended component or equivalent.
General Instructions - 495 & S495 Loader