BARKO LOADERS 295 User manual

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

TABLE OF CONTENTS
INTRODUCTION ........................................................ 3
Introduction ......................................................... 4
Abbreviations and Symbols ................................. 5
Hydraulic Pressure Warning Sheet ...................... 6
Warranty .............................................................. 7
Know Your Machine ............................................. 8
Safety Summary ................................................. 9
Fire Prevention .................................................... 14
Model Description ................................................ 15
MAINTENANCE ......................................................... 16
A. Preventive Maintenance .................................... 16
Safety While Servicing ........................................ 17
Preventive Maintenance ...................................... 18
Special New-Machine Instructions ....................... 18
Service Schedule ................................................ 19
Tires .................................................................... 20
Lubrication Points ................................................ 21
Fluid Specifications ............................................. 22
Special Torque Specifications ............................. 24
General Torque Specifications ............................. 25
B. Hydraulic System .............................................. 26
Hydraulic Pressure Settings (295 AC) .................. 27
Machine Function Speeds ................................... 27
Hydraulic Pressure Adj (V30D-95/95) ................... 28
Piston Pump Adjustments ................................ 28
K170 Upper Valve Bank Adjustments ............... 30
K170 Steering/Travel Valve Bank Adjustments 31
L90 Stabilizer Valve Bank Adjustments ............ 32
L90 Lower Valve Bank Adjustments ................. 33
Hydraulic Pressure Adj (AA11V-095) ................... 34
Hydraulic Reservoir Maintenance ......................... 35
Hydraulic Filter Maintenance................................ 36
Eliminating Air From The System ........................ 37
Hydraulic Fittings, Hoses & Tubing ...................... 38
Hydraulic Cylinder Maintenance ........................... 39
Hydraulic Collector Maintenance .......................... 41
Danfoss Drive Motor Maintenance (OMV800) ...... 43
F12 Swing Motor Maintenance ............................. 46
Swing Motor Gearbox Maintenance (G6/08) ......... 50
C. Electrical System Maintenance ........................ 51
Electrical System Maintenance ........................... 52
Electrical System Description .......................... 52
Electrical System Inspection ............................ 52
Battery Disconnect Switch ............................... 52
Using an Extra Battery to Start Machine .......... 53
Installing a New Battery.................................... 54
Alternator Drive Belt Adjustment ...................... 54
Alternator Maintenance ..................................... 54
Trouble Shooting the Electrical System ............ 56
Air Conditioner Maintenance ................................ 57
Refrigerant ........................................................ 57
Checking/Adding Refrigerant ............................ 58
Running the Unit as Preventive Maintenance ... 59
Fresh-Air Intake Filter ....................................... 59
Receiver/Dryer Installation................................ 59
Condenser Installation ...................................... 59
Air Conditioner Trouble Shooting ...................... 59
Air Conditioner Charging ................................... 61
D. Power Unit Maintenance ................................... 65
Engine Maintenance ............................................ 66
Pump Drive Maintenance ..................................... 67
Two, Three and Four Pad Pump Drives ............ 67
Single Pad Pump Drives .................................. 70
Disconnect Clutch (optional) ............................. 70
Air Cleaner Maintenance ...................................... 71
E. Structural Maintenance ..................................... 75
Turntable Bearing Maintenance ........................... 76
TROUBLE SHOOTING .............................................. 80
Engine .............................................................. 81
Hydraulic System ............................................. 82
Electrical System ............................................. 83
Machine Operations ......................................... 84
DECALS .................................................................... 85

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295 AC
800-00158
Introduction

page 4
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INTRODUCTION
Your Barko Loader has been designed and manufactured with high quality materials and care in workmanship.
This manual is intended as a permanent reference to aid professional operator's in their work, and should be
available for use at any time. If the loader is not equipped with this manual, ask your supervisor to obtain one
for you.
Understand the correct servicing procedures before servicing the loader. It is important to know the correct
operating and servicing procedures of the loader and all safety precautions to prevent the possibility of
property damage and/or personal injury or death.
As a professional, trained operator, you are responsible for safety, both your own and that of your co-workers.
Your knowledge and use of all safety practices and correct servicing procedures in this manual, and your
good judgement, can be a major factor in preventing some of the thousands of injuries and deaths caused by
industrial accidents each year.
A professional operator should also be familiar with the information contained in other applicable sources such
as American National Standards, SAE, OSHA, etc.
ADDITIONAL INFORMATION:
Logging Safety Resource Guide (APA, 95-A-1) is available from the American Pulpwood Association. This
guide lists sources of videotapes, slide programs, movies, and publications on various aspects of logging
safety.
DON'T FORGET - SAFETY FIRST!
Loader
Model No.
Serial No.
Engine
Model No.
Serial No.
The machine serial number plate is located on the
front of the platform near the ladder.
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.
REFERENCEINFORMATION
All requests for information, service or spare parts
should include loader serial number. For more
information contact:
Barko Hydraulics,LLC
P.O. Box 16227
One Banks Avenue
Duluth, MN 55816
Phone: [phone]
Fax: [phone]
Website: www.barko.com
Email: [email protected]

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ABBREVIATIONS AND SYMBOLS
EXPLANATIONS OF OTHER OCCURRENCES IN THIS MANUAL:
- In a parts list, when there are item numbers with empty spaces (no description or part number), these
parts have been previously deleted from that parts list and are not recorded anywhere.
- In a parts list, when there are items with no part number and a dotted line (----) is in the part number
space, this means that the part number is not sold separately or is not available at this time.
- When references to "right hand" or "left hand" are used in this manual, it is done from the operator's seat
in the forward operating position.
SYMBOLS USED ON MACHINE
Ignition
Key Switch
Power On
(Accessory)
Power Off
Power On
Horn
Starter
Engine
RPM
Faster
Slower
Air
Conditioner
a/c = air conditioner
AC = Articulated Carrier (Art. Car.)
adj. = adjust or adjusting
appl. = application
AR = As Required
assy = assembly
BC = Back of Cab
b/m = bill of material
brg. = bearing
CAR = Carrier
coll. = collector
cond. = conditioner
CRL = Crawler
cyl. = cylinder
dia. = diameter
dwg. = drawing
Ft. Lbs. = Foot Pounds
gal. = gallon
HRT = Hydrostatic Rough Terrain carrier
ill. or illus. = illustration
In. Lbs. = Inch Pounds
incl. = includes or including
j.s. = joystick
Lbs. = pounds
LH (lh) = left hand
mtg. = mounting
N/A = Not Applicable
no. = number
NSS = Not Sold Separately
opt. = optional
pg. = page
qt. = quart
RH (rh) = right hand
sec. = secondary
see sep. ill. = see separate illustration (means:
located elsewhere in manual)
SE = Stationary Electric
SER or SR = Stationary Electric Remote
s/n = serial number
str. = straight
swhd = saw head
TM = Truck Mount
w/ = with

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WARNING
BARKO HYDRAULICS, LLC
Raising hydraulic pressure on
this machine above the factory
approved settings may cause
death, severe injury or property
damage and will void the
warranty.
The consequences of increasing hydraulic pressure are
serious. The function of the relief valves is to provide a
fuse action to protect the machine and the operator from
overloading. When overloaded, the machine can
become stressed to a level where parts fracture causing
death, severe injury or property damage. This is an
extremely dangerous practice.
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.
HYDRAULIC PRESSURE WARNING SHEET

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BARKO HYDRAULICS, LLC
WARRANTY
BARKO HYDRAULICS, L.L.C. ("Barko") warrants to the Distributor and/or original Buyer each new hydraulic
knuckle boom loader, feller buncher or other product in BARKO HYDRAULICS Equipment Group including attachments
and accessories thereto, ("Product") sold by BARKO to be free from defects in material and workmanship under normal
use, maintenance and service.
BARKO will cause any major structural component of a BARKO product covered by this warranty which proves to be
defective in material or workmanship under normal use, maintenance and service within three (3) years ) or 6,000
hours, whichever occurs first from first day in service, provided first day in service is not later than one (1) year from
delivery to Distributor and/or original Buyer or other user, to be replaced without charge with a new or repaired part, at
BARKO election. BARKO also will cause the labor to remove any such defective part and to install the new or repaired
part to be provided without charge to the owner of said BARKO product. The parts and labor to meet this warranty will
be furnished by designated BARKO distributor.
BARKO will cause all other parts of product covered by this warranty which proves to be defective in material or
workmanship under normal use, maintenance and service within one (1 ) year or 2,000 hours, whichever occurs first
from first day in service, provided first day in service is not later than one (1) year from delivery to Distributor and/or
original Buyer or other user, to be replaced, without charge, with a new or repaired part, at BARKO election. BARKO
also will cause the labor to remove any such defective part and to install the new or repaired part to be provided without
charge to the owner of said BARKO product. The parts and labor to meet this warranty will be furnished by BARKO
designated distributor.
BARKO warrants all service parts purchased from BARKO and used on a BARKO manufactured unit, to be free
from defects in material and workmanship under normal use, maintenance and service for a period of six (6) months or
1,000 hours, whichever occurs first. BARKO will cause any such part which proves to be defective to be replaced with a
new or repaired part at BARKO election on a parts only basis.
Proof of any defect must be submitted to BARKO within ten (10) days from the date on which the defect was
discovered and any claim submitted within thirty (30) days after repair work is completed.
BARKO warranty does not cover:
1 Defects, damage or deterioration due to normal use, wear, tear, exposure, storage or corrosion.
2. Normal maintenance service, including replacement of filters, oil, seals and the like.
3. Damage due to failure to maintain or use the BARKO product or part according to manuals, schedules or good
practice.
4. Damage caused by abuse of equipment or parts by overloading, misapplication, improper operation or use,
installation of unapproved accessories or unauthorized alterations.
5. Damage resulting from repairs made in an unauthorized manner or installation of components not authorized by
BARKO.
6. The labor to remove and reinstall a defective replacement part after the expiration of the warranty period applicable
to the product in which part is located.
7. Overtime labor premiums.
8. Transportation of the BARKO product to the distributor's service facility or transportation of the distributor's service-
man to the product's location.
9. Vendor components not manufactured by BARKO, such as engines, transmissions and components, Tires, batteries
or other parts normally warrantied and serviced by the manufacturer. The warranty of the respective manufacturers
of these components shall apply.
The Buyer accepts this warranty and the limitations and disclaimers set forth herein as part of the purchase of the
BARKO product or part to which this warranty applies.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED, STATUTORY, WRITTEN OR
ORAL, AND THERE IS NO IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE.
Remedies available to any person claiming under this warranty are exclusive and expressly limited to obtaining the
parts and the labor, where applicable, in accordance with terms of this warranty.
BARKO liability for losses, damages or expenses of any kind arising from the design, manufacture or sale of the
product covered by this warranty, whether based on warranty, negligence, contract, tort or otherwise, is limited to an
amount not exceeding the cost of correcting the defects as herein provided, and, at the expiration of the applicable
warranty period, all such liability shall terminate.
BARKO shall in no event be liable for incidental, consequential or special damages to losses of use of the BARKO
product, a loss or damage to property other than the BARKO product, a loss of profits or other commercial loss, or any
special or consequential damages (except liability for consequential damages which by law may not be disclaimed).
Revised 2/98

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KNOW YOUR MACHINE
The following is a list of ten important safety precautions and warnings you should read through and
understand before operating or servicing your machine.
1. Don't assume that because you know the control functions of other similar machinery, that you
can run and/or service the Barko Loader. All machines differ in some ways, and these
differences must be noted and acknowledged. Read this manual thoroughly and understand all
safety, operating, and servicing procedures before using the loader.
2. Know how to put your machine in a zero energy state for purposes of inspection, maintenance,
or repair.
3. Clear operating area of all obstacles and personnel before operating loader.
4. Never approach power lines with any part of the machine or load! Current in a high voltage
power line may arc some distance to jump from the wire to a nearby "ground". KEEP WELL
CLEAR!
5. Allow only the operator on the machine. Keep riders off. Riders on machine are subject to injury
such as being struck by foreign objects and being thrown off the machine. Riders also obstruct
the operator's view, resulting in the machine being operated in an unsafe manner.
6. Never use a boom or attachment for a work platform or personnel carrier. Serious injury or death
may result.
7. When machine is not operating or when leaving cab, boom and attachment must be lowered to
the ground. Failure to do so may allow boom or attachment to move, causing property damage,
injury, or death.
8. Do not tamper with any hydraulic line when it is pressurized. Escaping fluid under pressure can
penetrate the skin, causing serious injury. Relieve pressure before unhooking hydraulic or other
lines. Tighten all connections before applying pressure. Keep hands and body away from
pinholes and nozzles which eject fluids under high pressure. Use a piece of cardboard to search
for leaks.
If any fluid is injected into the skin, it must be surgically removed within a few hours by a doctor
familiar with this type of injury or gangrene may result.
9. Under no circumstances should any modifications be made to Barko machinery without factory
authorization. Any modifications may void the warranty. This machine was designed to do a
specific job and alterations could result in property damage, injury or death.
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.

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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 - Indicates an immediate hazard which WILL result in severe personal injury or death.
WARNING - Indicates a hazard or unsafe practice which COULD result in severe personal injury or death.
CAUTION - Indicates a hazard or unsafe practice which could result in minor personal injury or property
damage.
DANGER
Never let anyone in or near pivot area of an
articulated machine.
WARNING
Combustible and flammable fluids can cause
death or severe injury. Do not smoke or permit
open flames near fuels or hydraulic fluids. Do not
fill the tanks to capacity - allow room for fluid
expansion. Do not remove the fuel cap or refuel
while engine is hot, running or without proper
ventilation. Never use fuel for cleaning purposes.
Clean up any fluid spills immediately.
WARNING
An unstable machine can cause death, severe
injury, or property damage. Do not operate
machine without lowering stabilizers on firm,
level ground.
WARNING
Be extra careful when traveling on a slope, near
ditches, congested areas or over rough ground.
The danger of tipping is always present. Know
your machine's capabilities.
WARNING
Always lower boom to ground and shut down
engine before leaving cab. If necessary to work
on machine with lifted boom, securely support
machine and attachment.
DANGER
Never approach power lines with any part of the
machine. Current in a high voltage line may arc
some distance to jump from the wire to a nearby
"ground". KEEP WELL CLEAR!
DANGER
Do not operate machine during electrical storms.

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WARNING
Do not operate or work on machine until you:
- Read and understand machine manuals, safety
decals, employer work rules, and applicable
government regulations.
- Are trained and qualified in safe machine
operation and maintenance.
- Consult supervisor to explain any unclear
instructions and warnings.
- Contact Barko to replace lost manuals.
DANGER
Moving stabilizers will cause death or severe
injury. Stand clear. Operate stabilizers only
when personnel are clear.
SAFETY SUMMARY CONTINUED...
WARNING
If machine malfunctions during operation, stop
machine motion as quickly as possible, lower
boom to the ground and shut down the machine.
Service or repair the machine as needed before
running or operating again.
WARNING
Allow only the operator on the machine. Keep
riders off. Riders on machine are subject to death
or injury from being struck by foreign objects and
being thrown from machine. Riders also obstruct
the operator's view, resulting in machine being
operated in an unsafe manner.
Never use a boom attachment for a work platform
or personnel carrier.
WARNING
Ensure that tire pressure is within rated limits to
prevent personal injury or damage to machine.
DANGER
Falling boom or load will cause death or severe
injury. Stay clear if boom or load are not
grounded.
Clear all persons from area of operation and
machine movement. Never move boom or loads
over the heads of other persons.
WARNING
Wear required personal protective equipment at
all times to help prevent personal injury. Do not
wear loose fitting clothing or personal articles,
loose or uncovered long hair, or jewelry.
WARNING
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.

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WARNING
Improper load handling and/or hydraulic pressure
loss can cause load to impact cab guard,
resulting in death or severe injury.
- Do not rely on guard alone for personal
protection. Use safe and proper load
handling techniques.
- Do not operate machine with damaged or
unsecured guard or cab.
- Do not repair damaged guard. Replace with
factory-authorized guard.
- Do not modify guard without factory
authorization.
- Do not operate before conducting Pre-Start
Maintenance Inspection. Check hydraulic
components for leaks, loose fittings or
damage.
WARNING
High pressure hydraulic fluid can penetrate skin
causing death, gangrene or other severe injury.
Seek immediate medical help to remove fluid.
- Keep hands and body away from areas
ejecting fluid. Use piece of cardboard to
check for leaks. Wear proper hand and eye
protection.
- Relieve hydraulic pressure before loosening
any hydraulic connections.
- Tighten all hydraulic connections before
applying hydraulic pressure.
WARNING
Always maintain 3-point contact with handles and
steps when mounting or dismounting. Never
jump on or off machine. Do not rush. Walk, do
not run.
WARNING
Mechanically connected controls will cause
movement of components at all times - even if
pump or engine is not operating. Always be
certain that boom and attachment are properly
supported or resting on firm ground before
stopping engine to minimize chance of
accidental movements of components causing
death, severe injury or property damage.
WARNING
Grease all boom, cylinder, and turntable bearing/
pinion points daily.
WARNING
Transparent material such as safety glass must be
replaced when it is cracked or broken, or when
vision is obscured due to scratches.
WARNING
Loose or overtorqued bolts can cause death,
severe injury, or property damage. Maintain
proper bolt torque. Visually check bolts daily.
Check torque every 50 hours.
WARNING
Remove or secure all personal or maintenance
items such as lunch buckets, chains, shovels,
tools, etc., before moving or operating machine.
WARNING
Replace any safety decals that are faded, torn,
missing, illegible, or otherwise damaged.
SAFETY SUMMARY CONTINUED...
WARNING
Make sure that all walking and climbing surfaces
of machine are free of dirt, debris, water, grease,
oil, and snow. Do not leave loose tools or rags
on machine. Replace all non-skid material that is
torn, missing or damaged.

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WARNING
Any unauthorized welding, alterations, additions
or modifications made to Barko machinery will
void warranty. 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, first
disconnect battery, electronic throttle, and radio,
or electrical and structural damage may occur.
WARNING
Hot and pressurized fluid can cause severe burns.
Let system cool before removing any caps. Then
remove caps slowly.
WARNING
If this machine is equipped with electric motor
driven Auxiliary Oil Cooler, be sure battery is
disconnected before going near cooler fan. If
battery is not disconnected, fan may come on at
any time causing severe injury.
WARNING
Hot exhaust pipe can cause severe burns. Do not
touch exhaust pipe when hot, or when engine is
running.
CAUTION
Use only hydraulic fluid in hydraulic oil reservoir.
Use only diesel fuel in fuel reservoir.
Other fluids will cause machine damage.
SAFETY SUMMARY CONTINUED...
DANGER
Improper electrical connections will cause battery
explosion, combustion or electrical component
damage, and may result in death or severe injury.
This is a 12 volt negative ground electrical
system.
WARNING
Always wear seat belt when operating or running
machine.
CAUTION
Check the Air Cleaner Assembly daily for cracks,
loose clamps, or any other damage. If debris is
able to bypass the Air Cleaner for any reason, it
can damage the engine.
WARNING
Maintain all components of Muffler Assembly to
meet noise and exhaust standards.
WARNING
Improper machine transport can cause death,
severe injury or property damage.
Before transporting:
- Lower and secure boom/attachment.
- Raise stabilizers.
- Shut down machine to a zero energy state.

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WARNING
Use caution when checking items beyond your
reach. Use an approved safety ladder.
SAFETY SUMMARY CONTINUED...
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.
WARNING
Do not exceed 15 PSI nozzle pressure when
drying parts with compressed air. Do not direct
compressed air against human skin. Serious
injury could result.
WARNING
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.
WARNING
On machines equipped with an accumulator,
release all pressure before working on the
system. After service work is done, repressurize
the accumulator(s) to the proper specification.

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FIRE PREVENTION
This machine may have several components which are at high temperatures under normal operating conditions, such
as the engine, exhaust system, brake system and transmission.
Clean the machine often. High pressure washing of the machine is suggested every 1000 hours (or 6 months) and
always after a spill.
The following list of hazards provides information which will help to prevent fires:
WARNING
Always keep a fire extinguisher
and first aid kit where they can be
easily reached in case of fire and
keep these items properly
maintained.
Operating personnel should be
instructed on what to do in case
of fire and be required to
demonstrate how to use fire
extinguisher and fire suppression
equipment.
Any portable fire extinguisher or
fire suppression system carried
on the machine that has been
used, should be recharged or
replaced before the machine
resumes operating. Fire
extinguisher manufacturers
recommended service intervals
should be followed.
WARNING
Allow machine to cool down by
idling the engine for a while
before shut-down. Many engine
and transmission fires start after
shut-down.
WARNING
Before adding fuel, shut down
the engine and allow it to cool.
Never smoke while handling fuel
or working on either the fuel or
the hydraulic system.
WARNING
Do not use the machine in areas
with explosive dust or gases that
can be ignited by arcs, sparks,
hot components, or exhaust
fumes.
WARNING
Daily inspect the machine for
flammable debris, removing any
twigs, leaves, straw, rags, fluid
spills or leaks, dirt or grime. Pay
special attention to areas such as
the engine, engine cooling
system, exhaust system, battery,
electrical connections, brake
systems, transmission/drivetrain,
fuel system and hydraulic system.
Clean as often as necessary to
help prevent overheating and
combustion.
WARNING
The electrical system (battery,
electrical connections, etc.) can
be a source of arcs or sparks if
damaged or incorrectly
maintained. Daily inspect all
electrical wiring and connections
for damage. Keep the battery
terminals clean and tight. Replace
or repair any damaged part. Use
proper battery connection and
disconnection procedures.
WARNING
Daily inspect all fuel and
hydraulic oil tubes, hoses, and
fittings for damage and leakage.
Tighten or replace as necessary.
Always clean fluid spills.
WARNING
Do not use ether or starting fluids
on diesel engines with glow
plugs. These starting aids can
explode and injure bystanders.
WARNING
Before doing welding of any kind,
clean machine and disconnect
battery cables. Cover rubber
hoses, battery, and other
flammable parts. Never ground
an arc welder or electrical
accessories through turntable or
boom bearings as arcing may
occur causing bearing damage.
Do not weld on any structural
member unless specifically
authorized by Barko
Hydraulics. Any unauthorized
welding or welding procedures
will void the warranty, and may
cause structural damage.
WARNING
Read the Engine Manual that
comes with every machine for
complete engine operating and
engine safety instructions.

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Stick Boom
Cylinder
Main
Boom
Platform/Control Deck
Hydraulic Oil Reservoir,
Shrouding, Power Unit
& Pumps
Main Boom
Cylinder
Turntable Bearing
Lower
(subframe)
Swing Motor
Gearbox
Stabilizer
Leg and
Cylinder
Stabilizer Pad
Grapple
Rotator
Grapple
Arms
Grapple
Cylinders
Counterweight
Cab
Head
Assembly
MODEL DESCRIPTION
Stick Boom
Grapple
Hanger
Operator's Seat
with Seatbelt
Heater/Air Conditioner
(located under and behind the seat
with attached ducting)
Heater/Air
Conditioner Ducting
(not shown attached
to unit)
Instrument Panel
(seat mounted)
Instrument Panel (wall
mounted)
Cup and
Thermos Holder
Door Handle
Swing Pedal
Servo Lever
(lifts entire armrest,
shutting off servo)
Heater/Air
Conditioner Ducting
(not shown attached
to unit)
Ladder
Handrails
LEFT SIDE VIEW
Transmission
Shift Lever

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Maintenance
A. PREVENTIVE MAINTENANCE
Maintenance

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The following maintenance section gives suggested guidelines for operational maintenance on your machine. It is
not intended for use as a service manual.
In severe conditions (extreme dust, heat, cold, humidity, etc.) you will need to service your machine more often.
Your experience will dictate a more severe servicing program.
Safety while servicing your machine is your responsibility. Only qualified and authorized personnel should be
permitted to maintain, repair, adjust and inspect machine.
Read and understand warnings and safety precautions in Safety Summary and elsewhere in this manual before
doing any service on machine. The following precautions should be used as a reminder to safe servicing.
SAFETY WHILE SERVICING
REMEMBER: SAFETY FIRST!
WARNING
Always shut down the machine and lower the boom
and attachment to the ground before working on the
machine. If necessary to work on a lifted boom or
attachment, securely support the boom and
attachment so that they cannot move or fall in any
way.
WARNING
Don't leave loose tools and rags on the
machine. Ensure that all walking and climbing
surfaces are clean.
WARNING
Handle fuel carefully. Do not smoke while filling
fuel tank or working near fuel.
Refer to Fluid Specifications whenever
replacing oils, fluids, or filling fuel tank.
WARNING
Do not weld on any structural member unless
specifically authorized by Barko Hydraulics. Any
unauthorized welding or welding procedures will
void the warranty, and may cause death, severe
injury, property damage or structural damage to the
machine.
WARNING
Do not support the machine on cinder blocks,
hollow tiles, or props that may crumble under a
load. Do not work under a machine that is
supported solely by a jack.
CAUTION
Check the Hour Meter regularly to determine when
the machine needs periodic maintenance. Use the
intervals on the Service Schedule except when
operating in extreme conditions; then shorter
intervals must be used.
WARNING
Under no circumstances should any modifications
be made to Barko machinery without factory
authorization. Any modifications may void the
warranty. This machine was designed to do a
specific job and alterations could result in death,
severe injury or property damage.
WARNING
Relieve all hydraulic pressure before breaking any
hydraulic connection, opening the reservoir access
cover, or performing any maintenance on the
machine.
- Lower boom to ground.
- Shut down machine to a zero energy state.
- Remove key from ignition.
- Disengage servo lever.
- Allow machine to cool.
- Relieve all hydraulic pressure.
- Disconnect battery using battery disconnect switch.
- Remove, block or guard against body contact with all
other sources of hazardous pressure, temperature,
electricity, or machine motion.
- Ensure machine, boom or attachment are not
supported on props that may collapse. Ensure boom
and attachment are grounded.
BEFORE INSPECTION OR MAINTENANCE:

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Preventive maintenance is really just a simple matter of common sense. If you keep any piece of mechanical
equipment clean and properly lubricated, and promptly replace any worn or damaged parts, you are going to "prevent"
deterioration and promote long life and safe, productive service. The only other requisite to such a program is the
regular scheduling of such maintenance.
Obviously, when you are operating under severe job conditions, such as a dusty job site, in extreme heat or cold, a long
operating day, or extremely heavy loads, the recommended intervals in the schedule should be shortened.
The suggested schedule on the following page is designed to be just a reminder of what should be done. For detailed
instructions on each item, consult the Table of Contents for where each is located in this manual.
AFTER THE FIRST 50 HOURS OF OPERATION OF A NEW MACHINE
A new machine needs a special maintenance procedure after the first 50 hours of operation.
1. Do a complete inspection of the loader. Rectify any problems, replace any damaged parts.
2. Check torque (retorque if necessary):
- Turntable Bearing Mounting Bolts
- Mounting Bolts/Nuts on major machine components (gearboxes, motors, pumps, booms,
attachment, turntable bearing, lower assembly, tires, etc.)
3. 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.
SPECIAL NEW-MACHINE INSTRUCTIONS
PREVENTIVE MAINTENANCE
WARNING
Instructions are necessary before doing service on loader. See
warnings and instructions both at the beginning and
throughout this manual. After doing service or making repairs
or adjustments always check function of loader.
Safety glasses or goggles are always needed for eye protection
from electric arcs, from shorts or welding, battery acid,
compressed springs, fluids under pressure, and flying debris
or loose material when engines are running or tools are used.
Use eye protection approved for type of welding. Failure to
obey warnings can cause death, severe injury or property
damage.

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8 hours
Daily
SERVICE REQUIRED
Fan and Drivebelts - Check for looseness
and wear. Tighten or replace as needed.
Operator's Platform - Clean area of debris,
tools, rags, water, ice, and snow.
Fuel Tank - Check level and fill if necessary.
Engine Crankcase Oil - Check level.
Engine Radiator - Check coolant level and
fill if necessary. Inspect exterior for dirt and
debris and clean if necessary.
Hoses, Connections, Cylinders - Inspect for
leaks and damage. Tighten, repair, or
replace parts if necessary.
Pump Drive - Check fluid level.
Swing Motor Gearbox - Check fluid level.
Engine Air Cleaner - Inspect & replace
element,if needed.
Hydraulic Reservoir - check level and quality
of oil.
Hydraulic Oil Reservoir - On new machines
the oil must be changed after the first 50 hours,
and then every 1000 hours after that.
Hydraulic Oil Filter - On new machines the
filter element should be replaced first at 50
hrs. and then at 400 hrs. thereafter.
Engine Shrouding - Clean and inspect.
SERVICE SCHEDULE
Fittings - Lubricate as shown on Lubrication
Points. Use a multi-purpose grease.
Bolts/Nuts - Visually inspect for wear or
damage.
Control Lever Linkage - Lubricate.
Bolts/Nuts - Check for proper
torque every 50 hours. Retorque if necessary.
Battery - Clean and coat posts with grease.
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.
50 hours
Weekly
100 hours
Monthly
400 hours
2 Months
1000 hours
6 Months Yearly
Swing Motor Gearbox - On new machines
the fluid should be changed first at 50
hrs. and then every 400 hours thereafter.

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Hydraulic Reservoir - Replace oil and clean
suction screens.
Entire Loader - Steam clean, inspect for
stress, wear, cracks, damage, and loose parts.
SERVICE REQUIRED
NOTE: Use the intervals on Service Schedule when operating in normal conditions. Service the
machine at shorter intervals when operating in very hot, cold, dusty, or humid conditions.
SERVICE SCHEDULE CONTINUED...
Pilot Filters in Valve Banks - Remove, inspect
and clean.
Air Conditioner Air Intake Filter - Replace.
8 hours
Daily
50 hours
Weekly
100 hours
Monthly
400 hours
2 Months
1000 hours
6 Months Yearly
Swing Motor Gearbox - Replace fluid. On new
machines the fluid should be changed first at 50
hrs. and then every 400 hours thereafter.
Tires - Check for correct pressure.
Axle Cradle Center Pivots - Lubricate.
Articulating Pivot Points - Lubricate.
Pump Drive - Replace fluid.
Planetary Axle - Drain and fill with lubricant.
Replace seals. Refer to Service Manual.
Drive Shaft Universal Joint - Lubricate.
Brakes - Adjust if necessary.
Wheel Bearings - Clean and inspect. Replace
if necessary. Pack with grease.
Hydraulic Oil Filter - Replace elements every
400 hours, after initial change at 50 hours on a
new machine.
Transmission - Check fluid. Add if necessary.
Transmission - Change fluid (80-90 gear fluid).
Visually inspect the tires for proper inflation, and for cuts, gouges, blisters or tread separation.
Check the tire pressure. Make sure all tires are properly inflated.
WARNING
Improperly inflated tires can cause excessive heat buildup resulting in blowouts. Always
keep tires inflated to the proper pressure. Unexpected blowouts may cause severe injury or
death.
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.
TIRES