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Barko 830B Service Manual

Wheeled feller buncher (wfb)
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®
MANUAL P/N
SERVICE MANUAL
800-00479
REVISION
0
DATE
WHEELED FELLER BUNCHER (WFB)
06/07/2019
830B
Serial Number Range:
11983025001 thru
Machine Serial Number:
NOTE:
This Service Manual does not include safety, operation, or parts information. Seperate Oprator's and Parts Manuals are
available for this machine and can be purchased through your Barko dealer. The Operator's Manual include safety instructions
which must be read and understood before operating or servicing this machine. Keep the machine's Operator's Manual with
the machine at all times.
The information and illustrations in this manual have been approved as accurate at the time of printing. However, this 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 its product at any time without notice or obligation.
Grapple and attachment information is not included in this manual. See separate Grapple and Attachment Owner's,
Installation, Parts and Service Manual(s) which accompanies all grapples from the factory.
®
1 Banks Avenue • Superior • WI • 54880
Phone: 800-544-6532 • 715-395-6700
Fax: 800-772-2448 • 715-392-9348
Web: www.barko.com Email: Support@barko.com

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Summary of Contents for Barko 830B

  • Page 1 The information and illustrations in this manual have been approved as accurate at the time of printing. However, this 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 its product at any time without notice or obligation.

  • Page 2: Table Of Contents

    22-2 12V ELECTRICAL SYSTEM 22-3 E3 SCHEMATIC INSTRUCTIONS 22-4 ELECTRIC SCHEMATICS- WFB 830B 903-00332 22-25 ELEC AY- HARNESS CONNECTIONS 955-00249 CH-26 HVAC 26-1 26-3 GENERAL HVAC SYSTEM 26-9 GENERAL WFB HVAC LAYOUT ® SUPERIOR • WI • USA • www.barko.com...
  • Page 3 65-9 2-SPEED 360 GEARBOX / TRANSMISSION 65-13 IWT HYDRAULIC DRIVE MOTOR 65-20 HYDRAULIC BRAKE 65-24 WHEELS & TIRES CH-70 RESERVOIR HYD & FUEL 70-1 70-3 IWT HYDRAULIC RESERVOIR 70-6 IWT FUEL RESERVOIR ® SUPERIOR • WI • USA • www.barko.com...
  • Page 4 THIS PAGE INTENTIONALLY BLANK ® SUPERIOR • WI • USA • www.barko.com...
  • Page 5 WELDING SAFETY 10-12 FIRE PREVENTION 10-14 BARKO DEALER NET 10-14 PARTS TAB 10-14 MANUALS TAB 10-15 SERVICE TAB 10-16 ABBREVIATIONS SERVICE ® 800-10003 1 BANKS AVE • SUPERIOR • WI • USA • www.barko.com (P) 800-544-6532 • (F) 800-772-2448 • Support@barko.com...
  • Page 6 Remember, use only... * GENUINE BARKO PARTS * NOTE This Service Manual has limited parts information. A BARKO Parts Manual will have detailed parts lists and illustrations that may assist in performing service work. A BARKO Operator’s Manual will have safe operating procedures which may assist servicing your BARKO loader or attachment.
  • Page 7 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.

  • Page 8: Introduction

    All parts for your BARKO machine or attachment may be ordered from your nearest BARKO Dealer. If you are not certain of the dealer's location check our website or contact BARKO Customer Service for assistance: WEB: www.barko.com/dealer-locator...

  • Page 9: Know Your Barko

    Don't assume that because you know the control functions of other similar machinery, that you can run and/or service the BARKO machine. All machines differ in some ways, and these differences must be noted and acknowledged. Read this manual thoroughly and understand all safety, operating, and servicing procedures before using the machine.

  • Page 10: Safety Summary

    Consult supervisor to explain any unclear instructions Ÿ and warnings. Always maintain 3-point contact with handles and Contact Barko to replace lost manuals. Ÿ steps when mounting or dismounting. Never jump on or off machine. Do not rush. Walk, do not run.
  • Page 11 SAFETY SUMMARY Updated (continued...) 06/19/2018 WARNING WARNING Combustible and flammable fluids can cause Improper machine transport can cause death, severe death or severe injury. injury or property damage. Do not smoke or permit open flames near fuels or Ÿ hydraulic fluids. Before transporting: Do not fill the tanks to capacity, allow room for fluid Lower and secure boom/attachment to truck/trailer bed.
  • Page 12 SAFETY SUMMARY Updated (continued...) 06/19/2018 CAUTION WARNING Transparent material such as safety glass must Hot and pressurized fluid can cause severe burns. be replaced when it is cracked or broken, or Let system cool before removing any caps, then remove when vision is obscured due to scratches.
  • Page 13 SAFETY SUMMARY Updated (continued...) 06/19/2018 DANGER WARNING Falling arms or load will cause death or severe injury. Set parking brake before servicing machine. Stay clear if arms or load are not grounded. Clear all persons from area of operation and machine movement. WARNING Never raise lifting arms or loads over the heads of other persons.
  • Page 14 WARNING Any unauthorized welding, alterations, additions or Older air conditioning equipment may contain R-12, a modifications made to Barko machinery will void substance which harms public health and warranty. This machine was designed to do a specific job environment by destroying ozone in the upper and alterations could result in death, severe injury or atmosphere.

  • Page 15: Welding Safety

    This machine was designed to do a specific job and alterations could result in death, severe injury or property damage. If BARKO-Authorized welding must be done, refer to service manual for welding procedure. If procedure is not followed electrical and structural damage may occur.

  • Page 16: Fire Prevention

    Do not weld on any structural member unless specifically WARNING authorized by Barko Hydraulics. Any unauthorized welding or welding procedures will void the warranty, and may Inspect the machine daily for flammable debris, cause structural damage.
  • Page 17 Updated FIRE PREVENTION (continued...) 06/19/2018 FIRE EXTINGUISHER Make sure you have the proper fire extinguisher that is labeled A (wood, trash), B (gas, grease, oil, paint) and C (electrical). FIRE EXTINGUISHER P-A-S-S IN CASE OF A FIRE REMEMBER Ÿ PULL the pin Ÿ...

  • Page 18: Barko Dealer Net

    Contact BARKO Machine Sales or your Barko Sales Representative for more information and to access BARKO Dealer Net. PARTS View Barko’s Parts Policy and Barko Dealer Net parts ordering instructions • Download the latest Clearance Parts List and machine Recommenced Stocking Lists •...
  • Page 19 BARKO DEALER NET (continued...) 06/19/2018 SERVICE Access the latest Service Advisories and Bulletins • Process and track Warranty Claims • *The screen shots showing BARKO Dealer Net may change over time. 10-15 SERVICE SUPERIOR • WI • USA • www.barko.com...

  • Page 20: Abbreviations

    Updated ABBREVIATIONS 06/19/2018 The following table is a list of BARKO Engineering Standard Abbreviations. These abbreviations are used throughout BARKO Operator’s, Parts and Service Manuals as well as BARKO Advisories and Bulletins. Air Conditioning Female O-Ring Face Seal Lower Reference...

  • Page 21: Model Description- Wheeled Feller Buncher

    13-17 UNF (FINE) 13-18 METRIC HHCS (COARSE) 13-19 UNC SHCS 13-19 METRIC SHCS 13-20 MACHINE TRANSPORTING 13-21 MACHINE STORAGE SERVICE ® 800-13020 1 BANKS AVE • SUPERIOR • WI • USA • www.barko.com (P) 800-544-6532 • (F) 800-772-2448 • Support@barko.com...
  • Page 22 Updated MODEL DESCRIPTION- WFB 05/28/2019 1 WHEELED FELLER BUNCHER (WFB) MODEL & SPECIFICATION 830B (shown w/o attachment) 830B Specs: w/std 28L-26 20-ply Tire Package Ÿ w/o Attachment Ÿ Weight (w/o ATT): 33,250 lbs (15,080 kg) Ÿ Wheel Base: 9’ (274 cm) Ÿ...
  • Page 23 Updated MODEL DESCRIPTION- WFB 05/28/2019 FUEL OPERATOR’S CAB 830B RESERVOIR (chapter 40) (chapter 70) LIFTING ARMS (chapter 30) ATTACHMENT (chapter 35) POWER PACKAGE (chapter 60) SHROUDING (chapter 50) DRIVETRAIN (chapter 65) COOLER AY FRAME AY (chapter 60) HYDRAULIC RESERVOIR (chapter 47) (chapter 70) ®...

  • Page 24: Safety While Servicing

    Handle fuel carefully. Do not smoke while filling fuel tank Under no circumstances should any modifications be or working near fuel. Refer to Fluid Specifications made to Barko machinery without factory whenever replacing oils, fluids, or filling fuel tank. authorization. Any modification may void the warranty.

  • Page 25: Preventive Maintenance

    Resume the normal maintenance intervals after this. See the Service Schedule for more info. Ÿ NOTICE This manual does not contain specific service or maintenance information for attachments or diesel engines if applicable. Please refer to separate attachment or engine manuals supplied with your BARKO loader. ® 13-5 SERVICE...

  • Page 26: Hydraulic

    The following maintenance schedule must be followed to ensure safe operation and long service life of your BARKO machine or attachment. The listed maintenance intervals are for normal use applications. Maintenance intervals may need to be shortened to account for extreme operating conditions.

  • Page 27: Hvac

    MAINTENANCE SCHEDULE Updated (continued...) 05/28/2019 INTERVAL LOCATION INSPECTION & NOTES / / SYSTEM SERVICE REQUIRED INSTRUCTIONS Air Conditioner- run Manifold Gauge Check- performed only by qualified check a/c refrigerant HVAC service personnel HVAC Under Seat A/C Pleated Filter- replace Under Seat A/C Mesh Filter- replace Grease Bushings, Pins and Shims-...
  • Page 28 A/C Condenser- clean Radiator & Hydraulic Oil check for leaks, clean if Cooler- inspect necessary see Section 4 in Cummins manual, BARKO Engine- perform "100 hour or recommends performing the 1 month" maintenance Cummins 250 hour procedures maintenance at 100 hours for...
  • Page 29 MAINTENANCE SCHEDULE Updated (continued...) 05/28/2019 INTERVAL LOCATION INSPECTION & NOTES / / SYSTEM SERVICE REQUIRED INSTRUCTIONS Axle Wheel Retainer Cap check torque after both initial Screws- check torque 8 & 50 hours of service Wheel Lug Nuts- check check torque after initial 8 hrs torque and every 100 hrs thereafter Transmission- check fluid...
  • Page 30 Updated LUBRICATION & FLUID SPECIFICATIONS 05/28/2019 HYDRAULIC 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. Ÿ Anti-foaming agents to break up air bubbles and prevent "foaming" that may cause Ÿ...
  • Page 31 Contact your BARKO dealer or BARKO Customer Service. LUBRICANT STORAGE Your BARKO machine or attachment 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.
  • Page 32 Updated LUBRICATION & FLUID SPECS (continued...) 05/28/2019 DEF (DIESEL EXHAUST FLUID) DEF is a critical element of the Tier 4 Final aftertreatment system. DEF is used as a consumable in selective catalytic reduction (SCR) in order to lower NOx concentration in the diesel exhaust emissions from diesel engines.
  • Page 33 Follow the Test step of this procedure. NOTICE To assist in preventing Diesel Exhaust Fluid from deteriorating when stored in your BARKO machine DEF tank, locate and plug the tanks venting to seal the tank exposure to the atmosphere. DEF HANDLING DEF is not harmful to handle.
  • Page 34 FLUID & LUBRICATION POINTS- WFB Updated 05/28/2019 1. ENGINE COMPARTMENT 3. LIFTING ARMS A) Engine Oil (chapter 60) (see next page & B) DEF Fluid (chapter 60) chapter 30) C) Engine Coolant (chapter 60) D) Pump & Drive Ay (chapter 60) 8.
  • Page 35 All grease points need to be greased daily. Not all grease points are shown on these illustrations. Other grease and lubrication locations are discussed and illustrated within chapters throughout BARKO Operator’s, Parts and Service Manuals as well as component manufacturer manuals supplied with your BARKO machine or attachment. 1. Engine Compartment (A-C) See separate Cummins Operation and Service Manual for diesel engine service.
  • Page 36 Updated GENERAL TORQUE SPECIFICATIONS 05/28/2019 This BARKO technical standard lists torque specifications for commonly used threaded fasteners. This standard is to be followed by all business functions of BARKO Hydraulics, LLC unless otherwise noted. ACRONYMS / DEFINITIONS Unified Thread Standard Ÿ...
  • Page 37 Updated GENERAL TORQUE SPECS (continued...) 05/28/2019 NOTICE DRY & LUBRICATED A dry condition bolt or nut is considered a fastener that is free of rust or other Ÿ debris and doesn't have any external lubrication added by the end user. A lubricated bolt or nut is considered a fastener that is free of rust or other Ÿ...
  • Page 38 Updated GENERAL TORQUE SPECS (continued...) 05/28/2019 ISO METRIC HHCS BOLT TORQUE (COARSE THREAD) Class 8.8 Class 10.9 Class 12.9 Dia (mm) Pitch Lubricated Lubricated Lubricated ft-lb ft-lb ft-lb ft-lb ft-lb ft-lb 0.70 0.80 1.00 1.00 1.25 1.50 1.75 2.00 2.00 2.50 2.50 2.50...
  • Page 39 2.00 1071 1315 NOTICE Some components on your loader or attachment may require different torques than what is listed from these tables. Special torque specifications are listed throughout the chapters of BARKO Operation, Service and Parts Manuals. ® 13-19 SERVICE...
  • Page 40 1 KNOW YOUR LAWS AND LIMITS 2 PREPARE FOR TRANSPORTING Learn Your Route, know... Follow these steps to prepare your BARKO WFB overhead clearances for over the road transportation. Ÿ road and bridge weight limits Carefully drive the machine up on the trailer.
  • Page 41 MACHINE STORAGE Updated 05/28/2019 BARKO recommends the following storage steps for all machines not being used for more than 2 MONTHS under normal conditions, either at the dealer's location or the customer's site. NOTICE Machines stored in extreme conditions (cold, wet, humid, and/or salty coastal environments) may require these steps even if stored for shorter periods of time.
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  • Page 43 560-02944 20-24 HYD FITTINGS, HOSES & TUBING 20-25 HYD FLANGE PORTS 20-25 FLANGE PORT ASSEMBLY 20-26 GENERAL CYLINDER MAINTENACE SERVICE ® 800-20018 1 BANKS AVE • SUPERIOR • WI • USA • www.barko.com (P) 800-544-6532 • (F) 800-772-2448 • Support@barko.com...
  • Page 44 Part No. Updated HYD AY- WFB 830B 605-01591 05/30/2019 20-2 SERVICE SUPERIOR • WI • USA • www.barko.com...
  • Page 45 Updated Part No. HYD AY- WFB 830B 05/30/2019 605-01591 20-3 SERVICE SUPERIOR • WI • USA • www.barko.com...
  • Page 46 Part No. Updated SCHEM- HYD IWT FB 607-00229 05/30/2019 PX PS PL LS 20-4 SERVICE SUPERIOR • WI • USA • www.barko.com...
  • Page 47 Updated Part No. SCHEM- HYD IWT FB 05/30/2019 607-00229 PX PS PL LS 20-5 SERVICE SUPERIOR • WI • USA • www.barko.com...
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  • Page 49 Raising hydraulic pressure on this machine above the factory approved settings may cause death, severe injury or property damage. 1 PRESSURE SETTINGS The following table lists pressure settings used on your Barko 830 WFB machines. Consult your BARKO Dealer for any questions. 830B TEST PORT /...
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  • Page 51 HYD VALVES & MANIFOLDS- WFB 05/30/2019 1 BARKO 830B WFB VALVE AND MANIFOLD LOCATIONS See illustrations below for locations of valves and manifolds used on BARKO 830B WFB machines. Also, see chapter references for more information on these components. NOTICE All valve and manifold locations are NOT shown in these illustrations.
  • Page 52 Updated HYD VALVE- WFB FRONT (558-02174) 05/30/2019 1 FRONT VALVE ASSEMBLY (Fig-1) BUTT END PORTS INLET SECTION SECTION SOLENOID VALVES ROD END PORTS Fig-1 1.1 Solenoid Valves (Fig-2) Bleeding Solenoid Valves: BLEEDER Start system and leave idling. SCREW Unscrew the Bleeder Screw one full turn. Actuate the Solenoid ON - OFF (10) times.
  • Page 53 Updated HYD VALVE- WFB STEERING (558-02175) 05/30/2019 1 STEERING VALVE ASSEMBLY (Fig-1) STEERING CYLS ( R & L ) INLET MANIFOLD SECTION L CYL BUTT R CYL ROD L CYL ROD R CYL BUTT Fig-1 ® 20-11 SERVICE...
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  • Page 55 Updated PILOT DRIVE MANIFOLD 05/30/2019 BARKO Machine Applications for PILOT DRIVE MANIFOLD: BARKO P/N Barko Application 563-01196 830B, 930B, 937B Ÿ The Pilot Drive Manifold diverts hydraulic fluid/presures to various functions on this machine. Proper settings of this manifold are vital to machine performance.
  • Page 56 Updated PILOT DRIVE MANIFOLD (continued...) 05/30/2019 1.1 Brake Pressure Setting Procedure (Brake Sequence Valve): Install pressure transducer or 5000 PSI gauge IAdjust Brake Squence Valve pressure to 2800 on GB port. PSI (193.1 bar). Note: If you can not install transducer, you Tighten jam nut on the Brake Sequence Valve may need to relieve pressure by pumping the brake pedal or opening the Brake...
  • Page 57 Updated PILOT DRIVE MANIFOLD (continued...) 05/30/2019 1.3 Pilot/Differential Pressure Setting Procedure: Install pressure transducer or 5000 PSI gauge Tighten jam nut on the Pilot Pressure Reducing on PRGP port. Valve. Note: Verify the pilot pressure does not Start machine. change after you have tightened the jam nut.
  • Page 58 Updated MANIFOLD BOOST FLUSHING- IWT 05/30/2019 BARKO Machine Applications for BOOST FLUSHING MANIFOLD: BARKO P/N Barko Application 563-01203 930B, 937B Ÿ The Boost Flushing Manifold is used to flush the attachment closed loop circuit when excess heat is generated. Setting the relief valve ensures hydraulic oil is being sent back through the oil cooler.
  • Page 59 Updated RETURN BYPASS / RELIEF MANIFOLD 05/30/2019 BARKO Machine Applications for RETURN BYPASS/ RELIEF MANIFOLD: BARKO P/N Barko Application 653-00940 930B, 937B Ÿ Provides make-up oil to the attachment pump. When the low side Ÿ pressure drops below 250 PSI, oil is directed back to the attachment pump.
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  • Page 61 HYD PUMPS- WFB 05/30/2019 1 BARKO 830B WFB HYDRAULIC PUMP LOCATIONS See illustrations below for locations of hydraulic pumps used on BARKO 830B WFB machines. Also, see chapter references for more information on these components. NOTICE All pumps may NOT shown in these illustrations. Refer to BARKO Parts Manuals for locations and parts illustrations for all components.
  • Page 62 Updated PRES SETTING- IWT & WFB DRIVE PUMP 05/30/2019 BARKO Machine Applications for DRIVE PUMP: BARKO P/N Pump Barko Application 560-02701 100cc 830B, 930B, 937B Replenishes fluid lost from the closed loop due to volumetric Ÿ inefficiency of the pump and motor.
  • Page 63 Updated IMPLEMENT PUMP SETTING- WFB 05/30/2019 BARKO Machine Applications for IMPLEMENT PUMP: BARKO P/N Barko Application 560-02943 830B Ÿ Setting the standby pressure ensures there is enough pilot oil to shift the control valve(s). Setting the system pressure ensures lifting capacities can be reached and maintained.
  • Page 64 Updated SAW PUMP SETTING- WFB 05/30/2019 BARKO Machine Applications for HYD SAW PUMP: BARKO P/N Barko Application 560-02944 830B Ÿ Setting the standby pressure ensures there is enough pilot oil to shift the control valve(s). Setting the system pressure ensures function pressure requirements can be reached and maintained.
  • Page 65 Updated SAW PUMP SETTING- WFB (continued...) 05/30/2019 2 Saw Pump Pressure Setting Procedure (refer to Fig-2): NOTICE To set Saw Pump pressure, the pressure line needs to be plugged or the attachment stalled. Install pressure transducer or 5000 PSI gauge Turn on saw pump.
  • Page 66 PIPE THREAD SEALER BARKO recommends the use of pipe thread sealer on all exterior pipe plug threads and pipe fittings. The main causes of air being introduced into a hydraulic system are loose connections and fittings.
  • Page 67 Updated HYDRAULIC FLANGE PORTS 05/30/2019 Large threaded port connections, such as SAE straight thread, require very high torque to assemble. This makes assembly very difficult, especially where wrench clearance is limited. Split flange connections solve this problem by dividing the hydraulic load among four bolts each requiring much less torque, smaller wrenches and smaller wrench clearance.
  • Page 68 Updated HYDRAULIC CYLINDER MAINTENANCE 05/30/2019 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. See Fig-1 for a typical high pressure cylinder breakdown and gland bolts torque pattern.
  • Page 69 Updated HYDRAULIC CYLINDER MAINTENANCE 05/30/2019 CYLINDER SERVICING & RE-SEAILING (continued...) NOTICE 11.Tighten nut to torque listed in parts manual. 12.Oil new cylinder seals lightly before installing rod Follow order and orientation of seals shown in Fig- assembly in cylinder barrel, oil barrel if 2.
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  • Page 71 22-29 HARNESS AY- BOC RT REAR FRAME 954-01563 22-30 AFTERTREATMENT CONNECTIONS 22-31 BATTERY / STARTER / ALTERNATOR CABLE 951-00737 SERVICE ® 800-22012 1 BANKS AVE • SUPERIOR • WI • USA • www.barko.com (P) 800-544-6532 • (F) 800-772-2448 • Support@barko.com...
  • Page 72 Turn switch to OFF to disconnect battery circuit. Turn switch to ON to connect battery circuit. The Master Electrical Disconnect Switch (Fig-1) can vary in appearance and is Fig-1 generally located close to the battery(s) on BARKO Machines. WARNING BEFORE WELDING... SEE WELDING SAFETY IN CHAPTER 10 Ÿ...
  • Page 73 Updated E3 SCHEMATIC INSTRUCTIONS 05/31/2019 This guide will assist you on how to use and navigate the electrical schematics used in this chapter. These schematics are designed to be used together, showing the relations of the sheets as well as where wires and connections lead to. See Fig-1 for style of schematic to which this applies. Fig-1 The schematics use a combination of mapping coordinates and “sheet”...
  • Page 74 +RTC 18AWG-RED /4.B7 973-00860 R1:2 954-01542 P1:1 +12V HOT 14AWG-RED /4.A7 DIAG PWR 18AWG-RED /7.A1 +12V HOT 14AWG-RED +12V HOT 973-00860 P8:B 548-04545 973-00860 W61:R1 954-01542 J9:8 /3.A8 /7.A1 SECTION 3 & 4 GND 12AWG-BLK SECTION 3 & 4 GND 973-00860+ST2 T26:1 HVAC PWR 12AWG-R/W...
  • Page 75 12V KEYED PWR LINKED 973-00860+K9 T18:1 973-00860 F21:2 +12V KEYED PWR 10AWG-R/W MC43 PWR 12AWG-R/W /4.C5 /4.D9 973-00860+K9 T18:1 973-00860 F10:1 +12V KEYED PWR 10AWG-R/W +12V KEYED PWR 14AWG-R/W /4.C5 /1.E8 973-00860 F22:1 REAR LIGHTS PWR 10AWG-ORG +12V KEYED PWR 10AWG-R/W /4.D6 973-00860 F22:1...
  • Page 76 SP10 973-00860 C2:49 973-00860 C2:14 C2:49 (HS) AWG18-R/W-TXL HIGH SHIFT (LS) AWG18-WHT-TXL /4.E7 /4.E5 C2:49 (HS) 18AWG-R/W 973-00860 P3:51 HIGH SHIFT (LS) 18AWG-WHT /1.C5 973-00860 C2:29 REAR DIF LOCK (LS) AWG18-VIO-TXL /4.E6 C2:49 (HS) 18AWG-R/W 973-00860 P3:50 REAR DIF LOCK (LS) 18AWG-VIO /1.C4 973-00860 C2:30...
  • Page 77 CAN-A-L J1939-15 G AWG 18 CAN-B-L J1939-15 G AWG 18 CAN-C-L J1939-15 G AWG 18 #1T TAG ADD1 548-03165 973-00860 W7:L1 +VREF-A AWG18-R/B-TXL /2.E2 973-00860 W8:5 HYD TEMP AWG18-GRN-TXL /2.E3 973-00860 SP8:1 FUEL LEVEL AWG18-GRY-TXL /2.F4 973-00860 W15:3 EGRESS DOOR SW AWG18-WHT-TXL /2.E5 973-00860 W16:5...
  • Page 78 954-01541 SP1:1 /6.B2 REAR LIGHTS PWR 12AWG-ORG REAR LIGHTS PWR 12AWG-ORG 954-01541 SP1:1 /6.B2 REAR LIGHTS PWR 12AWG-ORG REAR LIGHTS PWR 12AWG-ORG 954-01541 SP2:1 /6.B2 GND (LGTS) 12AWG-BLK GND (LGTS) 12AWG-BLK RADIO PIGTAIL 954-01541 SP2:1 /6.B2 GND (LGTS) 12AWG-BLK GND (LGTS) 12AWG-BLK 548-02932 548-02931...
  • Page 79 22-9...
  • Page 80 J2 A R-JS PWR 18AWG-RED R-JS TRIG 18AWG-GRY R-JS BTN 1 18AWG-WHT R-JS BTN 2 18AWG-GRN R-JS BTN 4 18AWG-PNK R-JS BTN 3 18AWG-BRN 548-02409 J3 A L-JS PWR 18AWG-RED L-JS TRIG 18AWG-GRY L-JS BTN 1 18AWG-WHT L-JS BTN 2 18AWG-GRN L-JS BTN 4 18AWG-PNK...
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  • Page 85 120OHM 22-15...
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  • Page 89 96 PIN ECM CONNECTOR 22-19...
  • Page 90 SECTION 4 (A) = ACCUM CLOSE SECTION 4 (B) = ACCUM OPEN SECTION 3 (A) = CLAMP CLOSE SECTION 3 (B) = CLAMP OPEN 22-20...
  • Page 91 BATT SUPPLY (-) 2/0AWG-BLK 548-01136 BATT SUPPLY (-) 2/0AWG-BLK 548-01136 BATT SUPPLY (-) 1/0AWG-BLK 548-01136 548-01111 548-04928 548-01136 BATT SUPPLY (+) 3/0AWG-RED 548-02984 BATT SUPPLY (+) 2/0AWG-RED 548-01136 200A BATT SUPPLY (+) 2/0AWG-RED 548-04607 548-01136 250A 548-03272 548-04794 6AWG-BLK +12V UNKEYED PWR 6AWG-RED 22-21...
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  • Page 95 TO 954-01541 TO 954-01540 548-02379 548-02382 TO 954-01541 TO 954-01540 548-02932 548-02931 22-25...
  • Page 96 548-02981 RELAYS/ 548-02617 FUSES 548-02617 548-02781 INPUT GROUND OUTPUT POWER 548-02617 548-02617 548-02781 548-01456 548-02982 548-02409 548-02982 548-02932 548-02981 22-26...
  • Page 97 22-27...
  • Page 98 TO 954-01528: P1 548-03206 WINCH AIR VLV (NOT USED) LOW BRK PRESS SW 548-02908 548-05137 PARKING BRAKE TRANS HIGH SHIFT 548-02908 548-02908 LOW LOCK TRANS LOW SHIFT 548-02908 FRONT DIF LOCK 548-02908 548-02908 REAR DIF LOCK HORN (+) 548-02908 548-04622 SERVO PWR ENGINE AIR FILT SW HORN (-)
  • Page 99 TO 954-01529: J18 548-02617 548-03207 548-05145 548-05146 548-02908 CAB HEAT WATER VLV 548-02908 548-02907 548-02981 548-01111 548-02908 RTMR MODULE IGN INPUT FUSE 548-03275 548-03557 548-03532 24 PIN ECM CONN 548-04537 GRID HTR COIL (-) 548-04477 548-01031 GRID HTR COIL (+) A/C COMP CLUTCH 548-01031 96 PIN ECM CONN...
  • Page 100 SECTION 4 (A) = ACCUM CLOSE SECTION 4 (B) = ACCUM OPEN SECTION 3 (A) = CLAMP CLOSE SECTION 3 (B) = CLAMP OPEN 22-30...
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  • Page 103 GENERAL WFB HVAC LAYOUT 26-10 UNDER-SEAT HEATER-A/C UNIT 26-10 HEATER-A/C UNIT PARTS ILLUSTRATION 548-04558 26-11 HEATER-A/C UNIT ELEC SCHEMATIC 548-04558 SERVICE 800-26005 ® 1 BANKS AVE • SUPERIOR • WI • USA • www.barko.com (P) 800-544-6532 • (F) 800-772-2448 • Support@barko.com...
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  • Page 105 Figs 1 & 2 show the components and flows of a typical A/C system. There - 3 0 are two basic system configurations: systems that use expansion valves and systems that use orifice tubes. BARKO machines use the expansion valve t a t system. i d e t a t °...
  • Page 106 SERVICE- HVAC SYSTEM Updated (continued...) 05/31/2019 1.1 SERVICE SCHEDULE: Use the following HVAC service schedule as a general guideline to maintain an efficient HVAC system. This is recommended for “normal” operating conditions, adjust accordingly to extreme conditions. INTERVAL COMPONENT / INSPECTION &...
  • Page 107 Updated (continued...) 05/31/2019 NOTICE UNLESS OTHERWISE NOTED, ALWAYS USE R134a REFRIGERANT IN BARKO A/C SYSTEMS 1.2 A/C SYSTEM SERVICING: 1.2.1 Service Safety Servicing of an air conditioning system should be conducted by a qualified A/C technician. Ÿ In servicing HVAC systems you will be exposed to high pressures, temperatures and several Ÿ...
  • Page 108 SERVICE- HVAC SYSTEM Updated (continued...) 05/31/2019 1.2.3 A/C Charging Procedure (refer to figures and table on next page for more information) 1) Insure all fittings are tight and components 14) Zero charging scale measurement. installed correctly. Use mineral oil on o-rings and fitting threads.
  • Page 109 (10º to 14° F) (6 to 8°C) below the saturation temperature (sub-cooled region). Generally for most Barko machines, 3 pounds of refrigerant is required for the system to operate properly. Use the chart below to determine the exact amount. PRESSURE TEMPERATURE CHART...
  • Page 110 SERVICE- HVAC SYSTEM Updated (continued...) 05/31/2019 1.2.5 Diagnosing an Expansion Valve System Refrigerant Pressure Diagnosis- Use the chart below to help diagnose air conditioning problems in an expansion valve system. System Operating Normally – Fully Charged Low Side High Side Sight Glass Evaporator Outlet Duct Temp...
  • Page 111 SERVICE- HEATER/AC UNIT WFB Updated 05/31/2019 1 WFB AIR CONDITIONER SYSTEM LAYOUT CAUTION Charge the WFB Air Conditioner system with R134a refrigerant. An overcharged system may cause damage to the compressor and other A/C system components. The following pages in this sub-section are machine specific for 830 WFB HVAC Systems 1.1 Fig-1 General Layout of HVAC on 830 WFB Compressor A/C - Heater Unit...
  • Page 112 SERVICE- HEATER/AC UNIT WFB Updated (continued...) 05/31/2019 1.2 548-04558 A/C-HEATER UNIT used on BARKO WFB machines with s/n starting with 116930 or 116937 and after Ÿ 1.2.1 Fig-2 548-04558 Parts Illustration see parts manual for part numbers and descriptions Ÿ...
  • Page 113 SERVICE- HEATER/AC UNIT WFB Updated (continued...) 05/31/2019 1.2.2 Fig-3 548-04558 Schematic Fig-3 ® 26-11 SERVICE...
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  • Page 115 Table of Contents- CHAPTER 35 CHAPTER 35-2 WFB ATTACHMENTS 35-2 REPLACEMENT PARTS 35-2 SERVICE & REPAIRS 35-3 HYDRAULIC HOOK-UP SERVICE ® 800-35007 1 BANKS AVE • SUPERIOR • WI • USA • www.barko.com (P) 800-544-6532 • (F) 800-772-2448 • Support@barko.com...
  • Page 116 Updated WFB ATTACHMENTS 06/07/2019 NOTICE This BARKO manual DOES NOT contain operators or service information for this attachment. Separate manuals from the attachment manufacturer are provided with your BARKO machine. REPLACEMENT PARTS Your BARKO Parts manual may contain replacement parts for your attachment.
  • Page 117 Updated HYDRAULIC HOOK-UP- WFB TO ATT 06/07/2019 The illustration below shows a standard front frame port layout on BARKO Wheeled Feller Buncher for attachment hook-up. (Fig-1) WARNING Refer to hydraulic schematics specific to your BARKO WFB. Machine configurations may vary from the illustration below. Incorrect hydraulic hose hook ups may cause damage to machine and/or attachment as well as injury to operator or bystanders.
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  • Page 119 47-10 MANUAL OVERRIDE 47-11 L90LS HYD VALVE 47-12 INLET SECTION 47-12 END SECTION 47-13 WORKING SECTION 47-14 MANUAL OVERRIDE SERVICE ® 800-47004 1 BANKS AVE • SUPERIOR • WI • USA • www.barko.com (P) 800-544-6532 • (F) 800-772-2448 • Support@barko.com...

  • Page 120: Wfb Front & Rear Frame Overview

    The Front & Rear Lower Frame of your BARKO WFB contains many components that require routine inspection and maintenance from the operator to ensure safe operation and long life your BARKO machine. This chapter will go over the basics an operator or technician should be familiar with. NOTICE Refer to BARKO Parts Manuals for complete service parts information for components in this assembly.

  • Page 121: Special Torques

    Updated FRAME PIVOT- WFB 06/04/2019 1 SPECIAL TORQUE SPECS FOR WFB FRAME PIVOT On the Frame Pivot (center section) of machine there are cap screws that must be tightened to specified torques. See Fig-1. DETAIL A Fig-1 Torque to 100 ft-lbs (use Blue Loctite #242) ®...
  • Page 122 Updated WFB FRONT VALVE 06/04/2019 558-02174 WFB FRONT VALVE the BARKO WFB Front Valve is a K220LS Ÿ Mobile Directional Control Valve NOTICE For general service information for this valve, see the K220LS Valve section later in this chapter. For service parts information, search for part number 558-02174 in your BARKO parts manual if service parts are available.
  • Page 123 Updated WFB STEERING VALVE 06/04/2019 558-02175 WFB STEERING & WINCH VALVE the BARKO WFB Steering & Winch Valve is Ÿ a L90LS Mobile Directional Control Valve NOTICE For general service information for this valve, see the L90LS Valve section later in this chapter.
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  • Page 125: K220Ls Hyd Valve

    240B / 260B energy efficiency. 558-02165 7-SEC 240B / 260B 558-02174 FRONT 830B ***not all BARKO K220LS valve configurations listed above*** 1 K220LS HYDRAULIC VALVE OVERVIEW 1.1 Typical Valve Layout & Technical Data (see Fig-1) Work Work Work Work Section 2...

  • Page 126: End Section

    SERVICE- K220LS HYD VALVE Updated (continued...) 06/04/2019 1.1 Typical Valve Layout & Technical Data (continues...) Filtration Hydraulic Fluids Filtration must be arranged so that ISO 4406 Target Best performance is obtained using mineral base Contamination Class 20/18/14 is not exceeded. For oil of high quality and cleanness in the hydraulic the pilot circuit, ISO 4406 Target Contamination system.
  • Page 127 Spool Spool Actuator Pressure Compensator Fig-4 NOTICE Refer to BARKO machine specific Parts Manual(s) for detailed parts breakdowns for your K220LS Control Valve. Figures 1-4 are general K220LS valve cutaways to show common configurations and major components. ® 47-9 SERVICE...
  • Page 128 When using the manual override be certain that all operations of the application, regardless of speed, Ÿ will not endanger persons or property nearby. Consult BARKO Operator’s & Parts manual for all specifications and functions of the valve. If there are Ÿ questions contact BARKO Service.
  • Page 129 930B, 937B 558-02175 STEERING 830B ***not all BARKO L90LS valve configurations listed above*** The L90LS is a stackable, multi-section, load-sensing, pressure-compensated directional valve for mobile machines. It is designed for working pressures of up to 320 bar and a maximum pump flow of 200 l/min. The valve can...
  • Page 130 Updated SERVICE- L90LS HYD VALVE (continued...) 06/04/2019 1.1.1 Inlet Section (Fig-2) Tank connection T1 [25] Pump connection P1 [26] Pressure relief valve PS [16] Gauge port:: Copied load signal LS Pump pressure Load signal PL Pump unloading function BEN [22] Fig-2 1.1.2 End Section (Fig-3) Counter pressure valve,...
  • Page 131 Lever bracket LM [51] Load-hold check valve [66] Fig-4 NOTICE Refer to BARKO machine specific Parts Manual(s) for detailed parts breakdowns for your L90LS Control Valve. Figures 1-4 are general L90LS valve cutaways to show common configurations and major components. ®...

  • Page 132: Manual Override

    When using the manual override be certain that all operations of the application, regardless of speed, Ÿ will not endanger persons or property nearby. Consult BARKO Operator’s & Parts manual for all specifications and functions of the valve. If there are Ÿ questions contact BARKO Service.
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  • Page 135 60-35 LOW FLOW 60-36 NO PRESSURE 60-36 LOW PRESSURE 60-36 UNCOMMON NOISE 60-37 UNUSUAL HEAT 60-37 SHAFT SEAL LEAK SERVICE ® 800-60013 1 BANKS AVE • SUPERIOR • WI • USA • www.barko.com (P) 800-544-6532 • (F) 800-772-2448 • Support@barko.com...
  • Page 136 60-39 WFB IMPLEMENT PUMP 560-02943 60-39 WFB SAW PUMP 560-02944 60-40 SERIES 45 HYDRAULIC PUMP DESCRIPTION 60-40 PUMP SETTINGS (see chapter 20) 60-41 REPLACEMENT PARTS 60-41 MINOR REPAIR 60-41 SHAFT SEAL REPLACEMENT 60-42 AUXILIARY PADS 60-43 LS & PC CONTROLS 60-44 ELECTRIC CONTROLS...
  • Page 137 Updated WFB POWER PACKAGE OVERVIEW 06/05/2019 NOTICE See Fig-1 for major components of the WFB Power Package. See your Cummins manual for more detailed components of the diesel engine. AFTERTREATMENT ENGINE COOLER ASSEMBLY INTAKE DEF SUPPLY MODULE DEF TANK PUMP DRIVE DIESEL ENGINE DRIVE &...
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  • Page 139 Radiator Pressure Cap - Inspect for Reuse Ÿ 2 ROUTINE SERVICE PARTS- ENGINE MODULES, FILTERS & BELTS See BARKO Parts manual and/or the BARKO Quick Reference Parts List in this manual for common Ÿ service parts for this machine. DESCRIPTION...
  • Page 140 Follow steps in Section 5 of your Cummins manual for changing the Lubricating Oil and Filters. This BARKO machine is equipped with a Drain Valve, and a Drain Line to Ÿ the Drain Plug to ease in the engine oil change process.
  • Page 141 CUMMINS TIER 4 DIESEL ENGINE Updated (continued...) 06/05/2019 3.2 Fuel Filter Replacement DANGER The filter must be changed when the engine is cold to avoid the risk of fire from spilled fuel on hot surfaces. NOTICE Do not fill the new fuel filter with fuel before assembly. There is a risk that contamination could get into the system and cause malfunctions or damage.
  • Page 142 CUMMINS TIER 4 DIESEL ENGINE Updated (continued...) 06/05/2019 3.4 Air Intake System NOTICE Engine wear is largely affected by the cleanliness of the intake air. Therefore it is important to check the air cleaner regularly and to service it properly. Pre-Cleaner The Cummins Precleaner utilized in precleaning the intake air is beneficial in reducing component Ÿ...
  • Page 143 1. GENERAL PUMP DRIVE INSTALLATION NOTICE There are 3 types of standard inputs that are available with the Durst pump drive models. Check with BARKO Service for which is applicable for your BARKO machine. 1.1 Drive Plate Driven This unit mounts directly to the engine flywheel. Use extreme care when mounting the drive plate to the engine flywheel to avoid pre-loading the crankshaft bearings.
  • Page 144 2. Align the splines of the hydraulic pump to the spline adapter. DO NOT use the hydraulic pump mounting bolts to seat the hydraulic pump onto the pump pad. Refer to your BARKO Parts Manual for correct mounting mounting bolts.
  • Page 145 Updated SERVICE- 2PD PUMP DRIVES (continued...) 06/05/2019 3. REPAIR & REBUILDING INSTRUCTIONS 3.1 Disassembly Instructions 1. Make certain that the power supply is disconnected before attempting to service or remove any components. Lockout the power supply and tag it to prevent unexpected application of power. Drain oil while the unit is still warm.
  • Page 146 Updated SERVICE- 2PD PUMP DRIVES (continued...) 06/05/2019 7. Evenly lift the output housing half, being careful not to lift any of the gears. Inspect the gears and bearings for any defects, wear, or contamination before removal. To remove the gears and bearings, swiftly and evenly lift from the housing.
  • Page 147 Updated SERVICE- 2PD PUMP DRIVES (continued...) 06/05/2019 3.2 Reassembly Instructions Before reassembling the pump drive gear box, make sure that both housings have been cleaned and inspected. Because of the modular design of the Durst pump drives, the adapter groups can be either installed after the gear box has been assembled or left on during assembly.
  • Page 148 Updated SERVICE- 2PD PUMP DRIVES (continued...) 06/05/2019 Place the output housing half together with the input housing. Both housings must be orientated in the same direction for the dowel pin holes to line up properly (see Fig-7). Press in the two (2) dowel pins to insure proper alignment. Evenly install and tighten the cap screws.
  • Page 149 It is recommended to change oil after the first 500 hours or 3 months of service, which ever occurs first. Thereafter, and under normal operating conditions BARKO recommends that the oil be changed every 1000 hours or 6 months of service.
  • Page 150 5. 2PD PUMP DRIVE CUT-AWAY ILLUSTRATION DIPSTICK & PLUG VENT DOWEL FITTING WASHER CAP SCREW PLUG INPUT GEAR SEAL BEARING OUTPUT GEAR INPUT HOUSING MAGNETIC DRAIN PLUG OUTPUT HOUSING NOTICE Refer to machine specific BARKO Parts Manuals for pump drive replacement parts. ® 60-16 SERVICE...
  • Page 151 Ÿ ***not all BARKO pumps are shown above CAUTION WARRANTY Before beginning repairs on manufacturer components on your BARKO machine, consult BARKO Service. Unauthorized repairs may void any warranties associated with your BARKO machine or attachment. 1. INTRODUCTION For repair, place the unit in a stable position with the shaft pointing downward. It will be necessary to secure the pump while removing and torquing end covers, controls, and valves.
  • Page 152 Updated SERVICE- SERIES 90 HYD PUMP (continued...) 06/05/2019 1.3 Cross Section Illustration (Fig-1) The Basic Closed Circuit Hydraulic lines connect the main ports of the pump to the main ports of the motor. Fluid flows in either direction from the pump to the motor then back to the pump in this closed circuit. Either of the hydraulic lines can be under high pressure.
  • Page 153 Updated SERVICE- SERIES 90 HYD PUMP (continued...) 06/05/2019 3. MINOR REPAIR 3.1 Removing the Pump Before working on the pump, clean the outside of the pump. If the pump has an auxiliary pump attached, remove both pumps as a single unit. Tag and cap all hydraulic lines as they are disconnected and plug all open ports to ensure that contamination does not enter the system.
  • Page 154 Updated SERVICE- SERIES 90 HYD PUMP (continued...) 06/05/2019 3.2.1 Shaft Removal (continued...) Remove the O-ring (L50) from the seal carrier and discard. Place seal carrier and seal in an arbor press and press out the seal (L40). Remove shaft (L100) and roller bearing assembly (L10) from pump.
  • Page 155 Updated SERVICE- SERIES 90 HYD PUMP (continued...) 06/05/2019 3.3 Multi-Function Valve Cartridges (see Fig-3 & 4) ***only applies to pumps manufactured from 1988 and later*** P2B1 P2A1 Fig-3 3.3.1 Removal Remove multi-function valves (P2A1 and P2B1) Remove and discard O-rings (P13 and P06). Relieve spring pressure by removing bypass actuator (P03), using a 1-1/16 wrench.
  • Page 156 Updated SERVICE- SERIES 90 HYD PUMP (continued...) 06/05/2019 3.3.2 Reassembly Clean and inspect all disassembled parts. Lubricate and install internal components (P07, P08, P17, P16, P15, P14, P09, P11, and P12). Place the cartridge in a vise and press on the poppet seat (P12). Lubricate and install new O-rings (P02, P06, P13).
  • Page 157 Updated SERVICE- SERIES 90 HYD PUMP (continued...) 06/05/2019 3.4 Charge Pressure Relief Valve (see Fig-5) The charge pressure relief valve is shim adjustable (early models) or screw adjustable (late models). Screw adjustable charge relief valve is shown. 3.4.1 Removal 1. Remove the shim adjustable charge relief valve plug with a 1” hex wrench. NOTICE Before removing the screw adjustable relief valve plug, mark the plug (K90), lock nut (K10), and housing to approximately maintain the original...
  • Page 158 Updated SERVICE- SERIES 90 HYD PUMP (continued...) 06/05/2019 3.5 Integral Charge Pressure Filter Replacement (see Fig-6) 3.5.1 Removal Remove the filter canister (N40) from the filter head (N10) as described on the canister. Hold the filter head in place and loosen the lock nut (N20) using the wrench size corresponding to pump frame size.
  • Page 159 Ÿ ***not all BARKO pumps are shown above CAUTION WARRANTY Before beginning repairs on manufacturer components on your BARKO machine, consult BARKO Service. Unauthorized repairs may void any warranties associated with your BARKO machine or attachment. 1. VANE PUMP DESCRIPTIONS T6 and T7 style Vane Pumps come in either Single (Fig-1), Double (Fig-2) or Triple Unit assemblies.
  • Page 160 Updated SERVICE- HYD PUMP T6, T7 VANE (continued...) 06/05/2019 General Cartridge Assembly (see Fig-3) Seals Back-Up Ring Port Plate- Pressure Vane Rotor Cam Ring Port Plate- Rear Bolt Dowel Pins Fig-3 2. PUMP SERVICE & REPAIR 2.1 Pump Disassembly (Double Vane Pump steps shown, see Fig-2 for reference) After pump is removed from machine, The seal place on a stable work surface.
  • Page 161 Updated SERVICE- HYD PUMP T6, T7 VANE (continued...) 06/05/2019 2.1 Pump Disassembly (Double Vane Pump steps shown, see Fig-2 for reference) 4. Disassemble the P2 cartridge / end cap with a wheel/bearing puller. (Fig-5) Fig-5 5. Put two screws in the housing and flip the pump (housing + P1 assembly).
  • Page 162 Ÿ seal damage. If you don't, change the shaft seal. If not new, the shaft seal should be Ÿ replaced. If the shaft Ø is bigger than the shaft Ÿ seal Ø, please contact BARKO Service. Fig-10 ® 60-28 SERVICE...
  • Page 163 Updated SERVICE- HYD PUMP T6, T7 VANE (continued...) 06/05/2019 2.1 Pump Disassembly (Double Vane Pump steps shown, see Fig-2 for reference) 9. Shaft seal out. (Fig-11) Housing End cap Cartridge P2 Cartridge P1 Retaining ring Shaft assembly Front cap Shaft seal Fig-11 ®...
  • Page 164 A : Protective cone on the shaft assembly If the shaft Ø is bigger than the shaft Ÿ seal Ø, please contact BARKO Service. B : Shaft assembly + protective cone into the front cap. Slightly rotate the shaft to avoid the shaft seal lip(s) to be deteriorated.
  • Page 165 Updated SERVICE- HYD PUMP T6, T7 VANE (continued...) 06/05/2019 2.2 Pump Reassembly Assemble the front cap assy on the housing & cartridge assy. (see Fig-14) Position the shaft / front cap assy Ÿ only if the cartridge is well positioned, dowel pin in the housing dowel pin hole.
  • Page 166 Updated SERVICE- HYD PUMP T6, T7 VANE (continued...) 06/05/2019 2.2 Pump Reassembly Fit the cartridge (P2) into the housing. (see- Fig-16) Fig-16 (see Fig-17 for 5 & 6) Check if the dowel pin is in its position in the housing by trying to rotate the cartridge. If the cartridge does rotate, the dowel Ÿ...
  • Page 167 Updated SERVICE- HYD PUMP T6, T7 VANE (continued...) 06/05/2019 2.2 Pump Reassembly Final assembly (see Fig-18). Fig-18 Always check if the shaft rotates. (a slight torque due to the spring loaded resistance force). Otherwise, please go back to the previous step. Check the porting configuration.
  • Page 168 Updated SERVICE- HYD PUMP T6, T7 VANE (continued...) 06/05/2019 3. TROUBLESHOOTING No flow, no pressure a) Is the pump rotating? a-1) Check if the coupling is rotating. If not, check the rotation of the electric motor. a-2) Check the keys of the pump and E motor shaft. a-3) Check if the shaft is not broken.
  • Page 169 Updated SERVICE- HYD PUMP T6, T7 VANE (continued...) 06/05/2019 3. TROUBLESHOOTING Not enough flow (or not a) Are the components a-1) Check the displacement of the pump. the flow required) a-2) Check if the speed of the pump is not too low or too high (E motor or thermic engine sized too small so dropping the speed too low...).
  • Page 170 Updated SERVICE- HYD PUMP T6, T7 VANE (continued...) 06/05/2019 3. TROUBLESHOOTING No pressure a) Is the hydraulic circuit a-1) Check the hydraulic circuit schematic. correctly designed? b) Is the circuit correctly b-1) Compare the schematic to the piped circuit. piped? c) Are the components c-1) Check the main sequences.
  • Page 171 Updated SERVICE- HYD PUMP T6, T7 VANE (continued...) 06/05/2019 3. TROUBLESHOOTING Unusual heat level a) Does the heat appear a-1) Check the oil level and the suction pipe. Is the oil when the pump is running coming to the pump (check the length of the pipe, its without pressure? internal diameter, all that could influence the inlet pressure)?
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  • Page 173 Ÿ 560-02944 90cc 830B SAW Ÿ ***not all BARKO Series 45 pumps are shown above CAUTION WARRANTY Before beginning repairs on manufacturer components on your BARKO machine, consult BARKO Service. Unauthorized repairs may void any warranties associated with your BARKO machine or attachment.
  • Page 174 Updated SERVICE- SERIES 45 HYD PUMP (continued...) 06/05/2019 1.3 Cross Section Illustration (Fig-1) Open Circuit Axial Piston Pump The pump receives fluid directly from the reservoir through the inlet line. The pump outlet feeds a PVG- 32 multi-section, load sensing, directional control valve. The PVG valve directs pump flow to the cylinder and gear motor.
  • Page 175 SERVICE- SERIES 45 HYD PUMP (continued...) 06/05/2019 NOTICE REPLACEMENT PARTS- Refer to your BARKO Parts Manual for service and replacement parts for these pumps and other components. 3. MINOR REPAIR NOTICE Before working on the pump, clean the outside of the pump. If the pump has an auxiliary pump attached, remove both pumps as a single unit.
  • Page 176 Updated SERVICE- SERIES 45 HYD PUMP (continued...) 06/05/2019 3.2 Auxiliary Pads (Fig-3) 3.2.1 Removal Remove the screws (J130), retaining the cover plate (J110) or auxiliary pump (not shown). Remove the shipping cover or auxiliary pump and its seal (J120). Remove the drive coupling (J140) if present. 3.
  • Page 177 Updated SERVICE- SERIES 45 HYD PUMP (continued...) 06/05/2019 3.3 LS and PC Controls (Fig-4) LS control shown; parts C104 through C106 and C112 through C118 are not used on PC control Ÿ 3.3.1 Disassembly Remove the 4 screws (C300) holding the control housing onto the endcap.
  • Page 178 Updated SERVICE- SERIES 45 HYD PUMP (continued...) 06/05/2019 3.3.3 Reassembly Install the PC spool (C132), spherical end first, into the PC bore. Using a new O-ring (C103A), install the plug (C103). Torque the plug (C103) to 12 N•m [9 lbf•ft]. Place the two PC springs (C134, C135) onto the spring guide (C133) and install into the PC bore.
  • Page 179 Updated SERVICE- SERIES 45 HYD PUMP (continued...) 06/05/2019 Remove four screws (C151). Remove the manifold (C152) and discard the two interface O-rings (C154). 9. For electric proportional controls only: Remove the electric control manifold drain orifice (C149). Remove plug (C153). Remove the cartridge valve nut (C125), electric solenoid (C155), and cartridge valve (C150) from the electric control manifold.
  • Page 180 Updated SERVICE- SERIES 45 HYD PUMP (continued...) 06/05/2019 Using petroleum jelly to retain them, install the two interface O-rings (C154) in the recesses on the electric control manifold. Install the manifold assembly onto the control housing using four screws (C151). Torque the screws to 6.4 N•m [4.7 lbf•ft].
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  • Page 183 65-21 DISASSEMBLY 65-22 ASSEMBLY 65-23 CROSS-SECTION VIEW 65-24 WHEELS & TIRES 65-24 INSPECTION & SERVICE 65-24 WHEEL LUG TORQUE SERVICE ® 800-65002 1 BANKS AVE • SUPERIOR • WI • USA • www.barko.com (P) 800-544-6532 • (F) 800-772-2448 • Support@barko.com...
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  • Page 185 The Drivetrain of your BARKO IWT / WFB contains many components that require routine inspection and maintenance from the operator to ensure safe operation and long life your BARKO machine. This chapter will go over the basics an operator or technician should be familiar with.
  • Page 186 Updated DRIVETRAIN TORQUES- IWT / WFB 06/05/2019 1 SPECIAL TORQUE SPECS FOR IWT / WFB DRIVETRAIN COMPONENTS See Fig-1 torque specifications for IWT / WFB drivetrain components. REAR FRONT Fig-1 Torque Front Axle Bolts to 400 ft-lbs (use anti-seize) Torque Rear Axle Bolts to 252 ft-lbs (use anti-seize) Torque Driveshaft Bolts to 75 ft-lbs (use anti-seize) Torque Transmission Mounting Bolts to 212 ft-lbs (use anti-seize) WARNING...
  • Page 187 Updated SERVICE- 1200 & 1400 PLANETARY AXLES 06/05/2019 BARKO Machine Applications for 1200 & 1400 AXLES: BARKO P/N Series BARKO Application 535-04014 1200 930B / 937B REAR Ÿ 535-04225 1200 OSC 160B AC Ÿ 535-04226 1200 FIXED 160B AC Ÿ...
  • Page 188 Updated SERVICE- 1200 & 1400 AXLES (continued...) 06/05/2019 2. GENERAL REPAIRS NOTICE Before beginning repairs, review the following guidelines. These are to provided to emphasize the need for attention to detail and care when servicing the axle assembly. 2.1 Inspection Before Disassembly 2.4 Bearings (continued...) Inspect the planet pinion carrier, axle shaft, the When installing bearings cups and cones,...
  • Page 189 Updated SERVICE- 1200 & 1400 AXLES (continued...) 06/05/2019 3. SEALING INSTRUCTIONS 3.1 Disassembly 3.3 Application & Assembly Guidlines On disassembly, the dowel pins should Final Drive Ring Gear-to-Case and Axle Ÿ remain pressed into the differential case Housing: cover. On earlier versions, the dowel pins Do not use an excessive amount of sealant.
  • Page 190 Updated SERVICE- 1200 & 1400 AXLES (continued...) 06/05/2019 F° C° 4. AXLE ASSEMBLY LUBRICATION 4.1 Specifications Use oil viscosity based on the expected air temperature range during the period between oil changes. Preferred Oils: JD HY-GARD Ÿ JD LOW VISCOSITY HY-GARD Ÿ...
  • Page 191 Updated SERVICE- 2-SPEED 360 GEARBOX 06/05/2019 BARKO Machine Applications for 2-SPD 360 GEARBOX: BARKO P/N Gearbox BARKO Application 535-06330 5.46 / 2.14 Ÿ 535-06351 4.85 / 1.59 830B / 930B / 937B Ÿ 1. MAINTENANCE 1.1 Fluid Fill and Drain Locations (Fig-1) Fig-1 OIL FILL &...
  • Page 192 Updated SERVICE- 2-SPEED 360 GEARBOX (continued...) 06/05/2019 1.2 Service & Inspection Schedule 1st INSPECTION TASK LOCATION FREQUENCY LUBRICANTS REMARKS or SERVICE Oil Level Clean carefully oil 10 whs Monthly see below Check plug magnet Central body standard bevel gears - UTTO (API GL4), or gear: If with limited slip J20/C, MF M1143, or...
  • Page 193 Updated SERVICE- 2-SPEED 360 GEARBOX (continued...) 06/05/2019 2. EXPLODED VIEW (Fig-2) NOTICE See your BARKO Parts Manual for service part numbers and parts ordering information. Fig-2 ® 65-11 SERVICE...
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  • Page 195 filter and when removing hoses or plumbing. CAUTION WARRANTY Before beginning repairs on manufacturer components on your BARKO machine, consult BARKO Service. Unauthorized repairs may void any warranties associated with your BARKO machine or attachment.
  • Page 196 Updated SERVICE- H1B HYD MOTOR (continued...) 06/05/2019 Keep It Clean Cleanliness is a primary means of assuring satisfactory motor life, on either new or repaired units. Clean the outside of the motor thoroughly before disassembly. Take care to avoid contamination of the system ports. Cleaning parts with a clean solvent wash and air drying is usually adequate.
  • Page 197 Updated SERVICE- H1B HYD MOTOR (continued...) 06/05/2019 1.3 H1 Hydraulic Motor Parts Illustration (continued...) Cross-section of H1 motor with electric two-position control (Fig-2) Fig-2 1. Differential Servo Piston 6. Loop Flushing Shuttle Spool 2. Valve Segment 7. Electric Two-Position Control 3.
  • Page 198 Updated SERVICE- H1B HYD MOTOR (continued...) 06/05/2019 1.5 H1 Hydraulic Motor Port Locations / Descriptions Port locations proportional control (Fig-4) (M4 on reverse side) (MB on reverse side) System System Port A Port B (Port XA on reverse side) Axial Ported Endcap (M4 on reverse side) System Port A (System Port B...
  • Page 199 Updated SERVICE- H1B HYD MOTOR (continued...) 06/05/2019 2. ADJUSTMENTS 2.1 Threshold Adjustment (while on machine) (Fig-6) Install 600 bar [10,000 psi] gauges to ports M5 and M4. Connect a variable pressure supply to X1 port (0-50 bar). 2. Raise wheels off ground, or disconnect the work function. WARNING Unintended movement of the machine or mechanism may cause injury to the technician or bystanders.
  • Page 200 Updated SERVICE- H1B HYD MOTOR (continued...) 06/05/2019 3. MINOR REPAIRS 3.1 Shaft Seal (Fig-7) 3.1.1 Removal Using snap ring pliers, remove retaining ring (1). 2. Use a slide-hammer style puller to remove seal (2). Be careful not to damage the shaft or seal bore when removing.
  • Page 201 Updated SERVICE- H1B HYD MOTOR (continued...) 06/05/2019 3.2 Hydraulic Proportional Control Module (Fig-8) 3.2.1 Removal Remove four cap screws (5). Refer to table for wrench sizes. 5 (4X) 6 mm Remove control (1) from motor. Remove and discard gasket (4). 37 Nm [27 lbf•ft] Proportional...
  • Page 202 See Fig-1 for typical exploded view for this style of Hydraulic Spring-loaded Brake. Fig-1 NOTICE Refer to your BARKO Parts Manual for part numbers and ordering instructions for hydraulic brake service parts. ® 65-20...
  • Page 203 Updated SERVICE- HYDRAULIC BRAKE (continued...) 06/05/2019 2. INSTALLATION Remove nut and washer from the shaft. Install yoke, washer and nut. Torque nut to 275-325 ft-lbs (373-441 Nm). Move brake into position and align mounting bolt holes and yokes. Insert four unlubricated 16 mm or four lubricated 5/8 inch bolts through holes in each mounting foot.
  • Page 204 0-RING KIT: Includes o-rings and internal gasket. See your BARKO Parts Manual or BARKO Service for replacement part availability. Use the reverse of the disassembly procedure with the following notes and additions: Worn and damaged o·rings must be replaced prior to assembly.
  • Page 205 Updated SERVICE- HYDRAULIC BRAKE 06/05/2019 4. CUTAWAY VIEW (Fig-2) Fig-1 PRESSURE RELIEF VALVE STATIONARY DISC TAPERED ROLLER BEARING (CONE) ROTATING DISC TAPERED ROLLER BEARING (CUP) GASKET SPACER POWER PLATE RETAINING RING BOLT- HEX SHIM SPINED SHAFT SHIM COMPRESSION SPRING PLUG- PROTECTIVE COMPRESSION SPRING OIL SEAL SPRING RETAINER...
  • Page 206 Updated SERVICE- IWT / WFB WHEEL & TIRE 06/05/2019 BARKO Machine Applications for IWT / WFB TIRES: BARKO P/N Model Barko Application 535-00002 67x34-26 830, 930, 937 Ÿ 537-00704 28L-26 830, 930, 937 Ÿ WARNING Improperly inflated tires can cause excessive heat build-up resulting in blowouts.
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  • Page 209 CHAPTER 70-3 IWT HYDRAULIC RESERVOIR 70-4 RETURN FILTER ASSEMBLY 70-5 FILTER ELEMENT SERVICE & REPLACEMENT 70-6 IWT FUEL RESERVOIR SERVICE ® 800-70008 1 BANKS AVE • SUPERIOR • WI • USA • www.barko.com (P) 800-544-6532 • (F) 800-772-2448 • Support@barko.com...
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  • Page 211 Updated HYDRAULIC RESERVOIR- IWT / WFB 06/06/2019 The Hyd Reservoir Ay on the BARKO IWT / WFB is located on the REAR RIGHT of the machine. See Fig-1 for component of the Hyd Reservoir. CHECK TOP VIEW VALVE SENDING UNIT...
  • Page 212 Updated HYD RESERVOIR- IWT / WFB (continued...) 06/06/2019 RETURN FILTER AY (Fig-2) Keep Hydraulic Fluids Clean! 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.
  • Page 213 06/06/2019 SERVICING & REPLACING ELEMENTS (Fig-3) NOTICE Refer to your BARKO Parts Manual for service parts and parts ordering information. See INSPECTION & SERVICE SCHEDULE in Chapter 13 in this manual for filter replacement intervals. Shut down system and relieve all pressure Replace element on diverter/bypass valve in filter line.
  • Page 214 Updated FUEL RESERVOIR- IWT / WFB 06/06/2019 The Fuel Reservoir Ay on the BARKO IWT / WFB is located on the REAR LEFT of the machine. See Fig-1 for component of the Fuel Reservoir. FUEL SENDING BACK-UP ALARM UNIT BREATHER...
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  • Page 218 ® 1 Banks Avenue • Superior • WI • 54880 Phone: 800-544-6532 • 715-395-6700 Fax: 800-772-2448 • 715-392-9348 Web: www.barko.com Email: Support@barko.com...

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