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Barko 6025 Service Manual

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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 Specialty Equipment to make changes
and improvements in it's product at any time without notice or obligation.
082014
Service Manual
Service Manual
Service Manual
Service Manual
Service Manual
6025 Chipper
6025 Chipper
6025 Chipper
6025 Chipper
6025 Chipper
Machine
Serial Number

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Summary of Contents for Barko 6025

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

  • Page 2: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS TABLE OF CONTENTS TABLE OF CONTENTS TABLE OF CONTENTS INTRODUCTION INTRODUCTION INTRODUCTION INTRODUCTION INTRODUCTION ....................................................3 3 3 3 3 Introduction ............4 Abbreviations and Symbols........ 5 Hydraulic Pressure Warning Sheet ..... 6 Warranty .............
  • Page 3 Marker Marker Marker Marker Marker page 3 page 3 240 Harvester Feller/ page 3 page 3 page 3 Buncher...

  • Page 4: Introduction

    N O T E : N O T E : 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 5: Abbreviations And Symbols

    ABBREVIATIONS AND SYMBOLS ABBREVIATIONS AND SYMBOLS ABBREVIATIONS AND SYMBOLS ABBREVIATIONS AND SYMBOLS ABBREVIATIONS AND SYMBOLS air conditioner j.s. joystick Articulated Carrier (Art. Car.) Lbs. pounds adj. adjust or adjusting LH (lh) left hand appl. application mtg. mounting As Required Not Applicable assy assembly number...

  • Page 6: Hydraulic Pressure Warning Sheet

    Accordingly, you are advised that the pressure settings of this machine are limited to the factory approved settings. 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 7: Warranty

    BARKO's option. 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.

  • Page 8: Know Your Machine

    KNOW YOUR MACHINE KNOW YOUR MACHINE KNOW YOUR MACHINE KNOW YOUR MACHINE KNOW YOUR MACHINE page 8 page 8 page 8 page 8 page 8 240 Harvester Feller/ Buncher...

  • Page 9: Safety Summary

    SAFETY SUMMARY SAFETY SUMMARY SAFETY SUMMARY SAFETY SUMMARY SAFETY 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. DANGER DANGER DANGER...
  • Page 10 - - - - - Contact Barko to replace lost manuals. Contact Barko to replace lost manuals. Contact Barko to replace lost manuals. Contact Barko to replace lost manuals.
  • Page 11 SAFETY SUMMARY CONTINUED... WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING WARNING High pressure hydraulic fluid can penetrate skin High pressure hydraulic fluid can penetrate skin High pressure hydraulic fluid can penetrate skin High pressure hydraulic fluid can penetrate skin High pressure hydraulic fluid can penetrate skin Improper hydraulic pressure loss can cause Improper hydraulic pressure loss can cause...
  • Page 12 WARNING WARNING WARNING WARNING WARNING or modifications made to Barko machinery will or modifications made to Barko machinery will or modifications made to Barko machinery will or modifications made to Barko machinery will or modifications made to Barko machinery will void warranty.
  • Page 13 SAFETY SUMMARY CONTINUED... CALIFORNIA CALIFORNIA CALIFORNIA CALIFORNIA CALIFORNIA Proposition 65 Warning Proposition 65 Warning Proposition 65 Warning Proposition 65 Warning Proposition 65 Warning Diesel engine exhaust and some of its constituents are Diesel engine exhaust and some of its constituents are Diesel engine exhaust and some of its constituents are Diesel engine exhaust and some of its constituents are Diesel engine exhaust and some of its constituents are...

  • Page 14: Fire Prevention

    Barko unless specifically authorized by Barko unless specifically authorized by Barko unless specifically authorized by Barko...

  • Page 15: Fire Prevention

    FIRE PREVENTION FIRE PREVENTION FIRE PREVENTION FIRE PREVENTION FIRE PREVENTION Fire Extinguisher Fire Extinguisher Fire Extinguisher Fire Extinguisher Fire Extinguisher Make sure you have the proper fire extinguisher that is labeled A (wood, trash), B (gas, grease, oil, paint) and C (electrical). In case of Fire 1.

  • Page 16: Model Description

    MODEL DESCRIPTION MODEL DESCRIPTION MODEL DESCRIPTION MODEL DESCRIPTION MODEL DESCRIPTION page 16 page 16 page 16 page 16 page 16 240 Harvester Feller/ Buncher...

  • Page 17: Maintenance Maintenance

    A. PREVENTIVE A. PREVENTIVE A. PREVENTIVE A. PREVENTIVE A. PREVENTIVE MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE page 17 page 17 240 Harvester Feller/ page 17 page 17 page 17 Buncher...

  • Page 18: Safety While Servicing

    Under no circumstances should any Under no circumstances should any Under no circumstances should any Under no circumstances should any modifications be made to Barko machinery modifications be made to Barko machinery modifications be made to Barko machinery modifications be made to Barko machinery modifications be made to Barko machinery Handle fuel carefully.

  • Page 19: Preventive Maintenance

    PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE PREVENTIVE MAINTENANCE Preventive maintenance is really just a simple matter of common sense. If you keep any piece of mechanical equipment clean and properly lubricated, and promptly replace any worn or damaged parts, you are going to "prevent"...

  • Page 20: Common Replacement Parts

    COMMON REPLACEMENT PARTS COMMON REPLACEMENT PARTS COMMON REPLACEMENT PARTS COMMON REPLACEMENT PARTS COMMON REPLACEMENT PARTS Routine component replacement part numbers - Engine: Oil Filter - 535-04320 Air Filter (Primary) - 535-02437 Air Filter (Safety Element) - 535-02438 Fuel Filter - 535-02439 Fuel Water Separator Filter - 535-04321 Hydraulics: Main Return Filter - 565-01724...

  • Page 21: Lubrication Points

    LUBRICATION POINTS LUBRICATION POINTS LUBRICATION POINTS LUBRICATION POINTS LUBRICATION POINTS (PERFORM DAILY) (PERFORM DAILY) (PERFORM DAILY) (PERFORM DAILY) (PERFORM DAILY) Grease Points Grease Points Grease Points Grease Points Grease Points page 21 page 21 page 21 page 21 page 21 240 Harvester Feller/ Buncher...
  • Page 22 LUBRICATION POINTS LUBRICATION POINTS LUBRICATION POINTS LUBRICATION POINTS LUBRICATION POINTS (PERFORM DAILY) (PERFORM DAILY) (PERFORM DAILY) (PERFORM DAILY) (PERFORM DAILY) Grease Points Continued Grease Points Continued Grease Points Continued Grease Points Continued Grease Points Continued page 22 page 22 page 22 page 22 page 22 240 Harvester Feller/...

  • Page 23: Fluid Specifications

    FLUID SPECIFICATIONS FLUID SPECIFICATIONS FLUID SPECIFICATIONS FLUID SPECIFICATIONS FLUID SPECIFICATIONS GREASE GREASE GREASE GREASE GREASE Use grease shown on chart below, depending on the expected air temperature range. AIR TEMPERATURE RANGE AIR TEMPERATURE RANGE AIR TEMPERATURE RANGE AIR TEMPERATURE RANGE AIR TEMPERATURE RANGE Fahrenheit (F) Fahrenheit (F)
  • Page 24 FLUID SPECIFICATIONS CONTINUED... FUEL STORAGE FUEL STORAGE FUEL STORAGE FUEL STORAGE FUEL 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.

  • Page 25: Special Torque Specifications

    SPECIAL TORQUE SPECIFICATIONS SPECIAL TORQUE SPECIFICATIONS SPECIAL TORQUE SPECIFICATIONS SPECIAL TORQUE SPECIFICATIONS SPECIAL TORQUE SPECIFICATIONS 6025 CHIPPER 6025 CHIPPER 6025 CHIPPER 6025 CHIPPER 6025 CHIPPER WARNING WARNING WARNING WARNING WARNING Loose or overtorqued bolts can cause death, severe injury, or property...

  • Page 26: General Torque Specifications

    GENERAL TORQUE SPECIFICATIONS GENERAL TORQUE SPECIFICATIONS GENERAL TORQUE SPECIFICATIONS GENERAL TORQUE SPECIFICATIONS GENERAL TORQUE SPECIFICATIONS See Special Torque Specifications that pertain specifically to this machine. D R Y D R Y D R Y *LUBRICATED *LUBRICATED *LUBRICATED D R Y D R Y *LUBRICATED *LUBRICATED...

  • Page 27: Hydraulic System

    B. HYDRAULIC SYSTEM B. HYDRAULIC SYSTEM B. HYDRAULIC SYSTEM B. HYDRAULIC SYSTEM B. HYDRAULIC SYSTEM page 27 page 27 240 Harvester Feller/ page 27 page 27 page 27 Buncher...

  • Page 28: Hydraulic Pressure Settings

    RELIEF VALVES The Relief Valve portion of the control valves in your Barko Chipper 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 29: Hydraulic Fittings, Hoses & Tubing

    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.

  • Page 30: Electrical System Maintenance

    ELECTRICAL SYSTEM MAINTENANCE ELECTRICAL SYSTEM MAINTENANCE ELECTRICAL SYSTEM MAINTENANCE ELECTRICAL SYSTEM MAINTENANCE ELECTRICAL SYSTEM MAINTENANCE ELECTRICAL SYSTEM DESCRIPTION ELECTRICAL SYSTEM DESCRIPTION ELECTRICAL SYSTEM DESCRIPTION ELECTRICAL SYSTEM DESCRIPTION ELECTRICAL SYSTEM DESCRIPTION This machine has 24 Volt electrical system with alternator, negative ground, and 24 Volt battery. This machine has 24 Volt electrical system with alternator, negative ground, and 24 Volt battery.

  • Page 31: Using An Extra Battery To Start Machine

    ELECTRICAL SYSTEM MAINTENANCE CONTINUED... USING AN EXTRA BATTERY TO START MACHINE USING AN EXTRA BATTERY TO START MACHINE USING AN EXTRA BATTERY TO START MACHINE USING AN EXTRA BATTERY TO START MACHINE USING AN EXTRA BATTERY TO START MACHINE If necessary to use an extra battery and "jumper" cables to start engine, be careful. This is a two-person operation. There must be one person in operator's seat and one person to connect and disconnect battery cables.

  • Page 32: Installing A New Battery

    ELECTRICAL SYSTEM MAINTENANCE CONTINUED... INSTALLING A NEW BATTERY INSTALLING A NEW BATTERY INSTALLING A NEW BATTERY INSTALLING A NEW BATTERY INSTALLING A NEW BATTERY Remove battery cables. Remember position of positive terminal and negative terminal so you can connect them again correctly.

  • Page 33: Trouble Shooting The Electrical System

    ELECTRICAL SYSTEM MAINTENANCE CONTINUED... CHECKING ALTERNATOR OUTPUT CHECKING ALTERNATOR OUTPUT CHECKING ALTERNATOR OUTPUT CHECKING ALTERNATOR OUTPUT CHECKING ALTERNATOR OUTPUT Disconnect negative battery cable. Remove wire from "BAT" connector on alternator and fasten it to one connector of an ammeter. Fasten other connector of ammeter to "BAT"...

  • Page 34: Iqan Xa2

    IQAN XA2 IQAN XA2 IQAN XA2 IQAN XA2 IQAN XA2 BLINK CODES BLINK CODES BLINK CODES BLINK CODES BLINK CODES If one of the following error is detected, a message will be presented on the display together with an error code on the module.

  • Page 35: Failure Mode

    IQAN XA2 IQAN XA2 IQAN XA2 IQAN XA2 IQAN XA2 FAILURE MODE FAILURE MODE FAILURE MODE FAILURE MODE FAILURE MODE The following tables contain information about the different possible failures that could occur for each module subsystem. In most cases when an error is detected, a message will be presented on the master display together with an error code on the module.
  • Page 36 IQAN XA2 IQAN XA2 IQAN XA2 IQAN XA2 IQAN XA2 FAILURE MODE Failure modes for VIN Failure modes for VIN Failure modes for VIN Failure modes for VIN Failure modes for VIN Failure mode Failure mode Failure mode Effect Effect Effect Failure mode Failure mode...
  • Page 37 IQAN XA2 IQAN XA2 IQAN XA2 IQAN XA2 IQAN XA2 FAILURE MODE Failure modes in Current Mode Failure modes in Current Mode Failure modes in Current Mode Failure modes in Current Mode Failure modes in Current Mode The table below presents failure modes and effects on I/O. Failure mode Failure mode Failure mode...
  • Page 38 IQAN XA2 IQAN XA2 IQAN XA2 IQAN XA2 IQAN XA2 FAILURE MODE Failure modes in PWM Mode Failure modes in PWM Mode Failure modes in PWM Mode Failure modes in PWM Mode Failure modes in PWM Mode The table below presents failure modes and effects on I/O. Failure mode Failure mode Failure mode...

  • Page 39: Iqan Xs2

    IQAN XS2 IQAN XS2 IQAN XS2 IQAN XS2 IQAN XS2 BLINK CODES BLINK CODES BLINK CODES BLINK CODES BLINK CODES If one of the following error is detected, a message will be presented on the display together with an error code on the module.

  • Page 40: Failure Mode

    IQAN XS2 IQAN XS2 IQAN XS2 IQAN XS2 IQAN XS2 FAILURE MODE FAILURE MODE FAILURE MODE FAILURE MODE FAILURE MODE The following tables contain information about the different possible failures that could occur for each module subsystem. In most cases when an error is detected, a message will be presented on the master display together with an error code on the module.
  • Page 41 IQAN XS2 IQAN XS2 IQAN XS2 IQAN XS2 IQAN XS2 FAILURE MODE Failure modes for VIN Failure modes for VIN Failure modes for VIN Failure modes for VIN Failure modes for VIN Failure mode Failure mode Failure mode Effect Effect Effect Failure mode Failure mode...

  • Page 42: Power Unit Maintenance

    D. POWER UNIT MAINTENANCE D. POWER UNIT MAINTENANCE D. POWER UNIT MAINTENANCE D. POWER UNIT MAINTENANCE D. POWER UNIT MAINTENANCE page 42 page 42 240 Harvester Feller/ page 42 page 42 page 42 Buncher...

  • Page 43: Engine Maintenance

    ENGINE MAINTENANCE ENGINE MAINTENANCE ENGINE MAINTENANCE ENGINE MAINTENANCE ENGINE MAINTENANCE The standard source of power for the hydraulic system in this machine is a Cummins or John Deere diesel engine. Complete specifications, operating instructions, and maintenance and lubrication information will be found in the engine manufacturer's manuals which ship with the machine.
  • Page 44 page 44 page 44 page 44 page 44 page 44 240 Harvester Feller/ Buncher...
  • Page 45 page 45 page 45 page 45 page 45 page 45 240 Harvester Feller/ Buncher...
  • Page 46 page 46 page 46 page 46 page 46 page 46 240 Harvester Feller/ Buncher...
  • Page 47 page 47 page 47 page 47 page 47 page 47 240 Harvester Feller/ Buncher...
  • Page 48 page 48 page 48 page 48 page 48 page 48 240 Harvester Feller/ Buncher...

  • Page 49: Air Cleaner Maintenance

    AIR CLEANER MAINTENANCE AIR CLEANER MAINTENANCE AIR CLEANER MAINTENANCE AIR CLEANER MAINTENANCE AIR CLEANER MAINTENANCE Proper air cleaner servicing will result in maximum engine protection against the ravages of dust. Proper servicing can also save you time and money by increasing filter life and dust cleaning efficiency. Two of the most common servicing problems are: 1.
  • Page 50 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.
  • Page 51 AIR CLEANER MAINTENANCE CONTINUED... IMPORTANT STEPS TO FOLLOW EVERY TIME AN AIR IMPORTANT STEPS TO FOLLOW EVERY TIME AN AIR IMPORTANT STEPS TO FOLLOW EVERY TIME AN AIR IMPORTANT STEPS TO FOLLOW EVERY TIME AN AIR IMPORTANT STEPS TO FOLLOW EVERY TIME AN AIR CLEANER ELEMENT IS REPLACED: CLEANER ELEMENT IS REPLACED: CLEANER ELEMENT IS REPLACED:...
  • Page 52 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'T DON'T DON'T DON'T DON'T DON'T DON'T DON'T DON'T...

  • Page 53: Structural Maintenance

    E. STRUCTURAL MAINTENANCE E. STRUCTURAL MAINTENANCE E. STRUCTURAL MAINTENANCE E. STRUCTURAL MAINTENANCE E. STRUCTURAL MAINTENANCE page 53 page 53 240 Harvester Feller/ page 53 page 53 page 53 Buncher...

  • Page 54: Trouble Shooting Trouble Shooting

    Marker Marker Marker Marker Marker Marker Marker Marker Marker Marker Marker Marker Marker Marker Marker page 54 page 54 240 Harvester Feller/ page 54 page 54 page 54 Buncher...

  • Page 55: Trouble Shooting

    TROUBLE SHOOTING TROUBLE SHOOTING TROUBLE SHOOTING TROUBLE SHOOTING TROUBLE SHOOTING Use this section only as a general guide to finding solutions for machine problems. If the machine should malfunction, find the problem in the headings listed then refer to the possible causes and remedies listed with the problem.

  • Page 56: Hydraulic System

    TROUBLE SHOOTING CONTINUED... HYDRAULIC SYSTEM HYDRAULIC SYSTEM HYDRAULIC SYSTEM HYDRAULIC SYSTEM HYDRAULIC SYSTEM PROBLEM PROBLEM PROBLEM CAUSE CAUSE CAUSE R E M E D Y R E M E D Y R E M E D Y PROBLEM PROBLEM CAUSE CAUSE R E M E D Y R E M E D Y...

  • Page 57: Electrical System

    TROUBLE SHOOTING CONTINUED... HYDRAULIC SYSTEM HYDRAULIC SYSTEM HYDRAULIC SYSTEM HYDRAULIC SYSTEM HYDRAULIC SYSTEM CONTINUED... CONTINUED... CONTINUED... CONTINUED... CONTINUED... PROBLEM PROBLEM CAUSE CAUSE R E M E D Y R E M E D Y PROBLEM PROBLEM PROBLEM CAUSE CAUSE CAUSE R E M E D Y R E M E D Y R E M E D Y...

  • Page 58: Decals Decals

    page 58 page 58 240 Harvester Feller/ page 58 page 58 page 58 Buncher...

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