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BARKO LOADERS 295 Service Manual

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BARKO
LOADERS
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.
OPERATORS: 800-00030
013112
SERVICE MANUAL
295 Articulated Carrier
Machine
Serial Number
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.
BARKO
HYDRAULICS,
mailing: PO Box 16227, Duluth, MN 55816
phone: 715-392-5641
fax: 715-392-3931
website: www.barko.com
PARTS: 800-00091
shipping: 1 Banks Avenue, Superior, WI 54880
email: barko@barko.com
LLC
SERVICE: 800-00158

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Summary of Contents for BARKO LOADERS 295

  • Page 1 BARKO LOADERS SERVICE MANUAL 295 Articulated Carrier 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.

  • Page 2: Table Of Contents

    General Torque Specifications ......25 TROUBLE SHOOTING ..........80 B. Hydraulic System ..........26 Engine .............. 81 Hydraulic Pressure Settings (295 AC) ....27 Hydraulic System ..........82 Machine Function Speeds ........27 Electrical System ..........83 Hydraulic Pressure Adj (V30D-95/95) ....28 Machine Operations .........
  • Page 3 3 295 AC 800-00158...

  • Page 4: Introduction

    Serial No. NOTE: Information in this manual is current at the time of printing. Barko Hydraulics reserves the right to make changes and improvements to it's products and manuals at any time without notice or obligation. page 4 295 AC 800-00158...

  • Page 5: Abbreviations And Symbols

    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 MACHINE Horn Slower Ignition Key Switch Starter Conditioner Power On (Accessory) Engine Power Off R P M Power On Faster page 5 295 AC 800-00158...

  • Page 6: Hydraulic Pressure Warning Sheet

    Pressures in excess of these settings render each and all Barko warranties null and void and constitute an obvious misuse and abuse of our product. BARKO HYDRAULICS, LLC page 6 295 AC 800-00158...

  • Page 7: Warranty

    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 page 7 295 AC 800-00158...

  • Page 8: Know Your Machine

    10. Replace any safety decals that are faded, torn, missing, illegible, or otherwise damaged. See your machine's Parts Manual for decal kits applicable to your machine and for locations of all decals. Don't stop here - read on. page 8 295 AC 800-00158...

  • Page 9: Safety Summary

    Be extra careful when traveling on a slope, near Never let anyone in or near pivot area of an ditches, congested areas or over rough ground. articulated machine. The danger of tipping is always present. Know your machine's capabilities. page 9 295 AC 800-00158...
  • Page 10 Never move boom or loads over the heads of other persons. When using a Slasher Saw Attachment, be sure to get proper informational manuals from Slasher manufacturer. Read and understand those manuals before using this machine for Slasher purposes. page 10 295 AC 800-00158...
  • Page 11 Transparent material such as safety glass must be replaced when it is cracked or broken, or when Replace any safety decals that are faded, torn, vision is obscured due to scratches. missing, illegible, or otherwise damaged. page 11 295 AC 800-00158...
  • Page 12 If debris is able to bypass the Air Cleaner for any reason, it WARNING can damage the engine. Maintain all components of Muffler Assembly to meet noise and exhaust standards. page 12 295 AC 800-00158...
  • Page 13 J1990. CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. page 13 295 AC 800-00158...

  • Page 14: Fire Prevention

    These starting aids can WARNING explode and injure bystanders. Do not use the machine in areas with explosive dust or gases that can be ignited by arcs, sparks, hot components, or exhaust fumes. page 14 295 AC 800-00158...

  • Page 15: Model Description

    Head Stick Boom Assembly Counterweight Stick Boom Cylinder Main Boom Grapple Cylinder Hanger Turntable Bearing Grapple Grapple Cylinders Rotator Transmission Swing Motor Shift Lever Gearbox Lower (subframe) Stabilizer Grapple Leg and Stabilizer Pad Arms Cylinder page 15 295 AC 800-00158...

  • Page 16: Maintenance

    A. PREVENTIVE MAINTENANCE page 16 295 AC 800-00158...

  • Page 17: Safety While Servicing

    REMEMBER: SAFETY FIRST! page 17 295 AC 800-00158...

  • Page 18: Preventive Maintenance

    3. Change all filter elements. 4. Change hydraulic oil in hydraulic oil reservoir. 5. Change gear fluid in swing motor gearbox. Resume the normal maintenance intervals after this. See the Service Schedule for more information. page 18 295 AC 800-00158...

  • Page 19: Service Schedule

    Check electrolyte level and fill if necessary. Engine Oil Filter - Replace. Hydraulic Oil Cooler and Radiator - Clean. Hydraulic Oil Reservoir Breather - Replace. Hydraulic Collector - Check mounting bolts. Accumulators - Check pressure and maintain at 900 PSI. page 19 295 AC 800-00158...

  • Page 20: Tires

    CAUTION Over or under inflated tires can cause a drastic reduction in tire and rim life. CAUTION Keep the valve caps on to prevent dirt from entering the valves. Dirt will cause valve damage. page 20 295 AC 800-00158...

  • Page 21: Lubrication Points

    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). Transmission: EP 80-90 gear fluid. page 21 295 AC 800-00158...

  • Page 22: Fluid Specifications

    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. page 22 295 AC 800-00158...
  • Page 23 Fluid 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 fluid enters skin or eyes, get immediate medical attention. page 23 295 AC 800-00158...

  • Page 24: Special Torque Specifications

    2. Tighten all nuts in a clockwise pattern to: 3. Tighten all nuts in a clockwise pattern to: Other torques, for the valves, pumps, and motors are found in the service literature for those components. page 24 295 AC 800-00158...

  • Page 25: General Torque Specifications

    (MIN. 8 RADIAL MARKS ON HEAD) GRADE 9 1250 1350 (BOW-MALLOY) 1-1/8 1750 1950 1050 1170 RECOMMENDED 1-1/4 2500 2750 1500 1650 TORQUE FOOT 1-3/8 3250 3700 1950 2220 POUNDS 1-1/2 4350 4850 2600 2900 page 25 295 AC 800-00158...

  • Page 26: Hydraulic System

    B. HYDRAULIC SYSTEM page 26 295 AC 800-00158...

  • Page 27: Hydraulic Pressure Settings (295 Ac)

    HYDRAULIC PRESSURE SETTINGS (295 AC) See the Service Manual for this machine for more specific information. RELIEF VALVES The Relief Valve portion of the control valves in your Barko Loader limit the flow of hydraulic oil, which relieves the excess pressure in the hydraulic system, if for any reason pressure is built up above a predetermined, safe, maximum.

  • Page 28: Hydraulic Pressure Adj (V30D-95/95)

    HYDRAULIC PRESSURE ADJ (V30D-95/95) (FOR MODEL 295 AC) PISTON PUMP ADJUSTMENTS Maximum Displacement Screws (on opposite ends of pumps from Minimum Displacement Screws) (factory set) DO NOT ADJUST! Standby Pressure Load Sense Adjustment Screw Pressure Minimum Displacement (on top) Test Port Screw (factory set).
  • Page 29 HYDRAULIC PRESSURE ADJUSTMENTS CONTINUED... (FOR MODEL 295 AC) PISTON PUMP ADJUSTMENTS CONTINUED... 5. Install a 5000 PSI gauge on the pump UPPER VALVE BANK pressure test port (located at the PX port on the upper valve bank). Pump 6. With engine at full throttle, bottom out the Pressure main boom (up) or the stick boom (in or out).

  • Page 30: K170 Upper Valve Bank Adjustments

    HYDRAULIC PRESSURE ADJUSTMENTS CONTINUED... (FOR MODEL 295 AC) K170 UPPER VALVE BANK ADJUSTMENTS NOTE: The Pilot Filter must be removed and cleaned every 1000 hours. Main Relief - 4000 PSI non-adjustable. Pilot Relief - 450 to 500 PSI non-adjustable. Port Reliefs for all boom and swing functions are non-adjustable.

  • Page 31: K170 Steering/Travel Valve Bank Adjustments

    HYDRAULIC PRESSURE ADJUSTMENTS CONTINUED... (FOR MODEL 295 AC) K170 STEERING/TRAVEL VALVE BANK ADJUSTMENTS Port Reliefs for all steering and travel functions are non-adjustable. For reference: Steering section Port Reliefs = 2320 PSI (160 BAR) Travel section Port Reliefs = 2538 PSI (175 BAR) Steering section is equipped with adjustable feed reducers.

  • Page 32: L90 Stabilizer Valve Bank Adjustments

    HYDRAULIC PRESSURE ADJUSTMENTS CONTINUED... (FOR MODEL 295 AC) L90 STABILIZER VALVE BANK ADJUSTMENTS NOTE: There is no pilot filter on this valve bank. Instead there is a remote filter. To adjust the pressure, install a gauge on the load sense test port located on the tee on pump #1. Adjust the pressure at the load sense adjustment screw on the load sense relief valve.

  • Page 33: L90 Lower Valve Bank Adjustments

    (valve bank 558-01627 used from machine s/n 22942 (11-1-00) & after) On 11-1-00, with machine s/n 22942, the L90 Lower Valve Bank changed from 558-01616 to 558-01627 (NOTE: On 295 AC machines, 558-01616 was never used - it was only used on Truck Mounts). Changes included: - Inlet Cover: still has no main relief, but now has a load sense relief.

  • Page 34: Hydraulic Pressure Adj (Aa11V-095)

    The torque control is factory set and generally will not require adjustment. Turning the screw in (clockwise) will increase the load on the engine by holding the pumps on stroke at a higher pressure. Pump compensator Standby pressure Torque Control page 34 295 AC 800-00158...

  • Page 35: Hydraulic Reservoir Maintenance

    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. page 35 295 AC 800-00158...

  • Page 36: Hydraulic Filter Maintenance

    1. Remove old element by unscrewing it from filter head. 2. Remove used gasket from groove in filter head. Element Bowl 3. Take new gasket from inside new element and install in groove in filter head. 4. Apply oil to new gasket. Figure 3 page 36 295 AC 800-00158...

  • Page 37: Eliminating Air From The System

    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. page 37 295 AC 800-00158...

  • Page 38: Hydraulic Fittings, Hoses & Tubing

    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. page 38 295 AC 800-00158...

  • Page 39: Hydraulic Cylinder Maintenance

    13. Reinstall gland cap, tighten bolts in a cross pattern to torque specified in parts manual. 14. Reinstall on machine and reattach hydraulics lines. NOTE: The more common cylinders use the following tool sizes: Hex head cap screws require 15/16" wrench. Nut requires 3-1/8" wrench. page 39 295 AC 800-00158...
  • Page 40 Depending upon manufacture date item 5 and 7 may be on either side of item 6 ITEM NO. DESCRIPTION QTY. SEAL-PISTON WEAR RING O-RING BACK-UP RING SQUARE RING ROD BUFFER WEAR RING SEAL SEAL ROD DEEP WIPER MODULAR BACKUP RING O-RING page 40 295 AC 800-00158...

  • Page 41: Hydraulic Collector Maintenance

    - 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. page 41 295 AC 800-00158...
  • Page 42 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. page 42 295 AC 800-00158...

  • Page 43: Danfoss Drive Motor Maintenance (Omv800)

    37. BALL 38. SPRING 39. WASHER 40. PLUG 41. SCREW 42. NAME PLATE TORQUES: Item 1:265 - 355 In. Lbs. Item 10: 265 - 530 In. Lbs. Item 41: 1680 - 1860 In. Lbs. 040204 page 43 295 AC 800-00158...
  • Page 44 29. Remove shaft seal (4), use special mandrel (C). 30. Remove shaft including bearings (7, 19, 23), press out the shaft /bearing assembly using a hydraulic press (pressing force max 2500 N [550 lbf]) using the special mandrel (D). 040204 page 44 295 AC 800-00158...
  • Page 45 27. Replace two plugs (42), tighten to 10 - 15 N m [90 - 130 in lbs]. 28. Replace drain plug (10), and washer (11), fill motor with oil before plugging. tighten to 30 - 60 N m [265.5 - 531 in lbs]. 29. Replace two seal plugs (37). 040204 page 45 295 AC 800-00158...

  • Page 46: F12 Swing Motor Maintenance

    BLEEDER PLUG WASHER, seal SHAFT FLAT KEY CYLINDER BARREL NEEDLE BEARING BARREL SUPPORT ASSEMBLY, piston PISTON RING GUIDE PIN RING GEAR TAPERED ROLLER BEARING CYLINDER BEARING WASHER, spacer WASHER, spacer RETAINING RING SHIM SCREW, hex socket page 46 295 AC 800-00158...
  • Page 47 Step 4 Step 8 Turn the bearing housing upside down and loosen the retaining ring holding the seal ring carrier. If it is necessary to remove the bearing races, use a drift or a press. page 47 295 AC 800-00158...
  • Page 48 It is absolutely necessary that these are mating to ensure correct alignment for the pistons in the cylinders. Also, choose correct adjustment shim to ensure correct backlash. page 48 295 AC 800-00158...
  • Page 49 F12 SWING MOTOR MAINTENANCE CONTINUED... page 49 295 AC 800-00158...

  • Page 50: Swing Motor Gearbox Maintenance (G6/08)

    Gearbox mounting bolts should be torqued to 300 Ft. Lbs. of lubed torque. Use anti-seize lubricant 514-00700. Lube Reservoir Filler Cap Lube Reservoir Swing Motor Swing Motor Gearbox Fluid Level inside Gearbox Swing Motor Gearbox Mounting Bolts Drain Plug Figure 1 page 50 295 AC 800-00158...

  • Page 51: Electrical System Maintenance

    C. ELECTRICAL SYSTEM MAINTENANCE page 51 295 AC 800-00158...

  • Page 52: Electrical System Maintenance

    WARNING If welding is to be done on machine: 1) Get factory authorization. 2) Disconnect battery. 3) Disconnect electronic throttle. 4) Disconncet radio. Damage to components will occur if the above procedures are not followed. page 52 295 AC 800-00158...

  • Page 53: Using An Extra Battery To Start Machine

    Do 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 connecting or disconnecting cables at battery. Battery gas can explode and cause serious injury. page 53 295 AC 800-00158...

  • Page 54: Installing A New Battery

    2. Connect a volt meter between the ground and: (See Figure 2.) a) the No. 1 alternator connector. b) the No. 2 alternator connector. the "BAT" connector. Alternator No. 1 terminal No. 2 terminal "BAT" terminal Figure 2 page 54 295 AC 800-00158...
  • Page 55 (Remove both cables from the battery.) extra battery cables (booster cables) are connected wrong. page 55 295 AC 800-00158...

  • Page 56: Trouble Shooting The Electrical System

    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. page 56 295 AC 800-00158...

  • Page 57: Air Conditioner Maintenance

    SEEK MEDICAL ATTENTION IMMEDIATELY. Breathing refrigerant gas can result in respiratory problems, especially for people with cardiovascular disease. Always wear safety goggles or a face shield and allow adequate ventilation when working with refrigerant page 57 295 AC 800-00158...

  • Page 58: Checking/Adding Refrigerant

    Older air conditioning equipment may contain R-12, a substance which harms public health and environment by destroying ozone in the upper atmosphere. To remove R-12 from the air conditioning system, use service equipment certified to meet the requirements of S.A.E. J2209 or J1990. page 58 295 AC 800-00158...

  • Page 59: Running The Unit As Preventive Maintenance

    1) Check if 12V is at air conditioner control. a) If no, check 12V supply. b) If yes, check if power is at terminal B when switch is on. If no, replace switch. If yes, page 59 295 AC 800-00158...
  • Page 60 The binary switch is doing it’s job of shutting system off at high pressure. It also shuts system off if too low pressure (no coolant) is the case. CAUTION DO NOT BYPASS THE BINARY SWITCH WITH JUMPER WIRE OR COMPRESSOR DAMAGE WILL RESULT! page 60 295 AC 800-00158...

  • Page 61: Air Conditioner Charging

    9) Alternately a Recovery/Charging Station similar to RD-5-11087-0P can be used instead of items 6, 7 and 8 above. 10) Thermistor Vacuum Gauge Sensor – similar to RD-5-11115-0P 11) Alternate charging technique- infrared temperature sensor page 61 295 AC 800-00158...
  • Page 62 It is typically ½ to ¾ of the estimated full charge. Close red valve on manifold gauge set. This type of refrigerant charging should be done at an ambient temperature of 32°C (90°F) or greater with machine doors open to provide a load on the evaporator. page 62 295 AC 800-00158...
  • Page 63 5) When (10º to 14° F) (6 to 8°C) of condenser outlet sub-cooling is reached, verify proper a/c operation. 6) Document total refrigerant amount added to system and apply appropriate label near compressor stating refrigerant charge amount. page 63 295 AC 800-00158...
  • Page 64 212.4 193.5 -3.9 22.1 24.6 60.0 227.9 206.6 -1.1 26.1 28.5 62.8 244.3 220.3 30.4 32.6 65.6 261.4 234.6 35.0 37.0 68.3 279.5 249.5 40.0 41.7 71.1 298.4 265.1 10.0 45.3 46.7 73.9 318.3 281.4 page 64 295 AC 800-00158...

  • Page 65: Power Unit Maintenance

    D. POWER UNIT MAINTENANCE page 65 295 AC 800-00158...

  • Page 66: Engine Maintenance

    Complete specifications, operating instructions, and maintenance and lubrication information will be found in the engine manufacturer's manuals which ship with the machine. These manuals may also include information on other, similar, engines. Be sure to use only the information which applies to the engine used on your machine. page 66 295 AC 800-00158...

  • Page 67: Pump Drive Maintenance

    5. Drain the fluid while the unit is still warm, examining for contamination or metal particles. page 67 295 AC 800-00158...
  • Page 68 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. page 68 295 AC 800-00158...
  • Page 69 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: Arrow indicates engine side. page 69 295 AC 800-00158...

  • Page 70: Single Pad Pump Drives

    HAND HOLE PLATE OPERATING LEVER ADJUSTING YOKE ADJUSTING PIN (mounted inside clutch) Pull pin in this direction (it is spring loaded). Figure 5 For cold weather start-up using Disconnect Clutch, see Start-up instructions in Operator's Manual. page 70 295 AC 800-00158...

  • Page 71: Air Cleaner Maintenance

    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. BAFFLE ELEMENT AIR CLEANER DUST CUP ASSEMBLY BODY DUST CUP ARROWS Figure 2 page 71 295 AC 800-00158...
  • Page 72 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. page 72 295 AC 800-00158...
  • Page 73 If air cleaner is equipped with a restriction element was not firmly sealed or that a dust indicator, reset it to the green zone. leak exists. Make certain the cause of that leak is identified and rectified before replacing the element. page 73 295 AC 800-00158...
  • Page 74 If the element is not going to be changed and off using the dirty element until you can get the reassembled immediately, cover the opening. The correct model. only way to be sure nothing got in is to be sure page 74 nothing gets in. 295 AC 800-00158...

  • Page 75: Structural Maintenance

    E. STRUCTURAL MAINTENANCE page 75 295 AC 800-00158...

  • Page 76: Turntable Bearing Maintenance

    Call the factory with any questions. WARNING Do not operate machine with a bearing that is worn out, damaged or has reached maximum permissable clearance measurements. Death, severe injury or property damage will result. page 76 295 AC 800-00158...
  • Page 77 7. Elevate the boom back to the neutral position (dial indicator should return to zero). 8. Rotate the upper works to the next measurement location and take readings the same as above. Measurement Locations Figure 2 page 77 295 AC 800-00158...
  • Page 78 .138 .118 .130 .138 .140 .142 .130 .142 .144 .146 .138 .150 .152 .154 .146 .157 .159 .161 .154 .165 .167 .169 .161 .177 .179 .181 .181 .183 .185 .189 .191 .193 .197 .200 .209 page 78 295 AC 800-00158...
  • Page 79 WARNING Do not allow anyone on or near the machine while rotating the upper structure during the lubrication process. Do not start up machine until all personnel are a safe distance from the machine. page 79 295 AC 800-00158...
  • Page 80 80 295 AC 800-00158...

  • Page 81: Trouble Shooting

    Loose, worn, or broken fan belt. Tighten or replace belt. Radiator plugged. Clean and inspect radiator. Air filter elements plugged. Clean or replace elements. Recharge battery. Engine will not start. Low or discharged battery. page 81 295 AC 800-00158...

  • Page 82: Hydraulic System

    Slow hydraulic functions. Hydraulic oil viscosity too high. should be replaced with proper viscosity. Fill hydraulic reservoir with proper Low hydraulic oil supply. hydraulic oil. Obstruction in line or line Inspect lines. Replace parts if damaged. necessary. page 82 295 AC 800-00158...

  • Page 83: Electrical System

    Defroster switch needs service. Replace switch. Defroster does not work. Defroster fan motor needs Repair or replace motor. service. Disconnected or damaged wiring. Inspect wiring. Connect or replace wiring as necessary. page 83 295 AC 800-00158...

  • Page 84: Machine Operations

    Inspect. Replace if necessary. Solenoid steering select valve needs service. Add oil. Low oil level in reservoir. Repair or replace steering valve Sticky steering valve spool. spool. Repair or replace steering Loose cylinder piston. cylinder. page 84 295 AC 800-00158...

  • Page 85: Decals

    Description/Location Date of Change. 539-00749 DECAL, "Barko" (on each side of main boom) beige w/ orange shadow 539-00965 DECAL, "295" (on each side of main boom) beige w/ orange shadow 539-00925 Striping, 8" orange/brown (wraps around machine) 350" 283-00008 DECAL, Barko Strong Arm (both sides of cab)

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