BARKO LOADERS 295 Service Manual Download

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page 15

295 AC

800-00158

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

Summary of Contents for 295

Page 1: ...ligation 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 Ser...

Page 2: ...8 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 Sy...

Page 3: ...page3 295AC 800 00158 Introduction...

Page 4: ...s 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 S...

Page 5: ...r 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...

Page 6: ...tion 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...

Page 7: ...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 Nor...

Page 8: ...d 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 attachme...

Page 9: ...ds 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...

Page 10: ...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 mann...

Page 11: ...ver 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...

Page 12: ...pe 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 w...

Page 13: ...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 a...

Page 14: ...aust 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 cool...

Page 15: ...ght Cab Head Assembly MODEL DESCRIPTION Stick Boom Grapple Hanger Operator sSeat withSeatbelt Heater AirConditioner located under and behind the seat with attached ducting Heater Air ConditionerDuctin...

Page 16: ...page16 295AC 800 00158 Maintenance A PREVENTIVE MAINTENANCE Maintenance...

Page 17: ...tural 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 da...

Page 18: ...eration 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 machi...

Page 19: ...he 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...

Page 20: ...ts 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...

Page 21: ...Gearbox EP 80 90 gear fluid fill until oil is as high as top of cluster bearings see service manual for more information if lube reservoir is used maintain at half full Transmission EP 80 90 gear flui...

Page 22: ...dation and prevent varnish formation and deposits that foul systems Anti wear properties to prevent scuffing and exccesive wear at high speeds and high pressures Good viscosity index for easy flow at...

Page 23: ...ns in certain geographical areas may require special lubricants and lubrication practices which do not appear in this manual LUBRICANT STORAGE The machine can operate at top efficiency only if clean l...

Page 24: ...n to K170Upper Valve Bank Ft Lbs 11 30 44 L90Lower Valve Bank Ft Lbs 7 21 33 Other torques for the valves pumps and motors are found in the service literature for those components WARNING Loose or ove...

Page 25: ...7 8 606 668 364 400 1 909 995 545 597 1 1 8 1288 1444 773 866 1 1 4 1817 2012 1090 1207 1 3 8 2382 2712 1430 1627 1 1 2 3161 3557 1897 2134 GRADE8 SAE GRADE 8 RECOMMENDED TORQUEFOOT POUNDS GRADE5 SAE...

Page 26: ...page26 295AC 800 00158 Maintenance B HYDRAULIC SYSTEM...

Page 27: ...cylinder 4000 PSI at the Port Relief Main Boom down rod end of main boom cylinder 1800 PSI at the Port Relief Stick Boom up butt end of secondary boom cylinder 4000 PSI at the Port Relief Stick Boom d...

Page 28: ...n pump 1 in clockwise until pressure on the load sense gauge starts to increase Then turn the pressure back down so that it matches the standby pressure on pump 2 and tighten the lock nut PISTON PUMPS...

Page 29: ...kwise to decrease using a13mm wrench Tighten the lock nut 9 Turn the pressure compensator adjustment screw on pump 1 in clockwise until pressure starts to increase Then turn the pressure back down so...

Page 30: ...he tee on pump 1 Remove the acorn nut and loosen the jam nut 13 mm wrench Using a 4 mm Allen wrench turn the adjustment screw out counterclockwise to lower the pressure or in clockwise to raise pressu...

Page 31: ...d on the tee on pump 1 Remove the acorn nut and loosen the jam nut 13 mm wrench Using a 4 mm Allen wrench turn the adjustment screw out counterclockwise to lower the pressure or in clockwise to raise...

Page 32: ...re at the load sense adjustment screw on the load sense relief valve Pressure should be 2500 PSI L90 STABILIZER VALVE BANK Stab Stab Stab Stab Solenoids qty8 Remote Pilot Oil Filter Inlet Cover Outlet...

Page 33: ...the pressure remove the plastic caps on the feed reducers loosen the lock nut with a 10 mm wrench and turn the adjustment screw out counterclockwise with a 3 mm Allen wrench Sections without Feed Redu...

Page 34: ...econnect hoses Repeat for other pump Standby pressure Pump compensator Torque Control 1 Install an electronic digital gauge on the system pressure test port which is located on the main control valve...

Page 35: ...nnels oil filling equipment the oil filler opening and above all the hydraulic oil itself must be kept absolutely clean Dirt in the hydraulic system can cause serious damage to pumps valves and cylind...

Page 36: ...keep dirt out of tubelines and openings THE RETURN FILTER See Figure 1 The Return Filters 565 00116 are welded into the top of the hydraulic oil reservoir The filter heads must be unbolted twisted an...

Page 37: ...air may be drawn in where fluid will not necessarily leak out 5 Fluid level too low This can cause vortexing at pump inlet in reservoir thus drawing in air 6 Air trapped in filter with no means of bl...

Page 38: ...ion in the fluid but also provides the risk of contamination entering the fluid and components with the air The easiest way to effectively reduce and possibly eliminate this problem is to use an adequ...

Page 39: ...ecial pliers part number 412 00409 can be used to aid in assembly see photo on next page Install item 10 before item 8 Heating item 10 7 and the stiff portion of 1 in a 200 oven for 5 minutes will mak...

Page 40: ...2 7 8 10 9 11 5 4 2 6 NOTE Follow order and orientation of seals shown in drawing Expansion ring on item 8 must point towards pressurized end of cylinder with item 10 behind it Depending upon manufac...

Page 41: ...amage seal lands or polished inside diameter of barrel Remove seals from spool by cutting with sharp knife being careful not to damage spool lands If teflon rings are used they must be cut off also an...

Page 42: ...teflon rings are heated beyond 400 degrees Fahrenheit they will give off harmful toxic fumes When the right temperature is reached the teflon ring will act like a rubber band when shaken Using heat r...

Page 43: ...to airblast all parts and wipe them with a clean lintless cloth before assembly USECAUTIONINGRIPPINGALLPARTS IN A VISE TO AVOID DAMAGING MACHINEDSURFACES TORQUES Item 1 265 355 In Lbs Item 10 265 530...

Page 44: ...moveO ring 24 10 Remove channel plate 28 11 Remove stop ring 29 12 Remove disc valve 30 13 Removespacer 35 14 Remove balance plate 31 Fill the spacer hole with oil and use the 18 4 mm mandrel as a pis...

Page 45: ...the tip of a spline tooth is opposite the bottom of a tooth in the external rotor teeth see drawing 11 Replace valve drive 27 mark the bottom of a spline tooth on the valve drive Line up mark on rotor...

Page 46: ...YLINDER BARREL 1 17 NEEDLE BEARING 2 18 BARREL SUPPORT 1 19 ASSEMBLY piston 7 20 PISTON RING 21 21 GUIDE PIN 1 22 RING GEAR 1 23 TAPERED ROLLER BEARING 1 24 CYLINDER BEARING 1 25 WASHER spacer 1 26 WA...

Page 47: ...a press or a plastic mallet Step 8 If it is necessary to remove the bearing races use a drift or a press Step 1 Put the unit in a bench with a hole or place it on a fixture for assembly Loosen the fo...

Page 48: ...the retinaing ring on the shaft to enter into its groove Step 2 Install pistons cylinder barrel support and cylinder barrel NOTE The shaft has got one tooth marked with a punchmark and the barrel has...

Page 49: ...page49 295AC 800 00158 F12 SWING MOTOR MAINTENANCE CONTINUED...

Page 50: ...cap has a built in breather which allows air to escape as needed FLUID CAPACITIES Fluid capacity of gearbox 10 78 quarts Fluid capacity of lube reservoir 2 quarts keep at half full once gearbox is fi...

Page 51: ...page51 295AC 800 00158 Maintenance C ELECTRICAL SYSTEM MAINTENANCE...

Page 52: ...R DRIVE BELT ADJUSTMENT information Loose wire connections Be sure all wires are tightly connected Broken or open wires Replace any wires that are damaged or worn Proper electrolyte level in battery A...

Page 53: ...o positive terminal of extra battery Connect other end of same jumper cable to positive terminal of machine battery 6 Connect end of second jumper cable to negative terminal of extra battery Connect o...

Page 54: ...BELT ADJUSTMENT 1 Loosen alternator adjusting bolt and mounting bolt See Figure 1 2 Move alternator along adjustment bar to adjust tension of belt to have 1 2 movement at 10 pounds of pressure at cen...

Page 55: ...d amperage marked on alternator case 7 If reading is correct alternator is good If reading is more or less than 10 percent of rated amperage check regulator CHECKING THE REGULATOR 1 Use steps 1 throug...

Page 56: ...ery connections are dirty of loose 3 Battery is damaged 4 The ground connection is not making a good contact 5 The alternator is damaged 6 The engine is locked 7 The starter has damage 8 The wiring or...

Page 57: ...ust be certified as proof of their training Organizations such as the Mobile Air Conditioning Society MACS and the National Institute for Automotive Service Excellence ASE are approved by the Environm...

Page 58: ...de the coil and not the coil surfaces Add to temperature for coil air off temperatures 8 10f CONDENSER temperatures are not ambient temperatures Add to ambient 35 40 F for proper heat transfer then re...

Page 59: ...y CONDENSER INSTALLATION The condenser must be installed with the ports at the top Installing the condenser with the ports at the bottom will flood the compressor with coolant and ruin it AIR CONDITIO...

Page 60: ...ge CAUTION If no pressure air conditioning system must be checked for leaks before refilling Trouble shooting tip If air conditioner works in the morning and after shutdown for a while system is getti...

Page 61: ...e compressed air to leak test or pressure test an R134a system Under certain conditions pressurized mixtures of R134a and air can be combustible In addition shop air injects moisture into the system 7...

Page 62: ...ssure in a c system rises above 1000 microns the system has a leak and needs to be repaired prior to charging system 11 After verifying the system has no leaks remove thermistor vacuum gauge Vacuum ga...

Page 63: ...m and apply appropriate label near compressorstatingrefrigerantchargeamount Alternate Charging Technique 1 Perform steps 1 20 above 2 With an infrared thermometer measure condenser tube temperatures f...

Page 64: ...8 25 31 7 6 9 2 3 90 32 2 103 9 99 8 20 28 9 3 7 0 6 95 35 0 113 5 108 3 15 26 1 0 0 2 4 100 37 8 123 6 117 2 10 23 3 1 9 4 5 105 40 6 134 3 126 6 5 20 6 4 1 6 7 110 43 3 145 6 136 4 0 17 8 6 5 9 2 1...

Page 65: ...page65 295AC 800 00158 Maintenance D POWER UNIT MAINTENANCE...

Page 66: ...diesel engine Complete specifications operating instructions and maintenance and lubrication information will be found in the engine manufacturer s manuals which ship with the machine These manuals m...

Page 67: ...time checking for fluid leaks Because the lubricant system is the heart of the unit it is especially important that the fluid be kept clean The following procedures should be followed 1 Stop engine be...

Page 68: ...gears and their bearings have been removed position gear box so that the engine adaptor is facing up Remove place bolts and lift engine adaptor up from gear box Lift pinion gear and bearings from pump...

Page 69: ...heel housings involving more than 4 bolt holes be sure cord gasket lap joint falls behind one hole location which will be used for a bolt or stud fastener Do not lap ends behind an unused bolt hole Re...

Page 70: ...uires several adjustments until friction discs are worn in See Figure 5 For cold weather start up using Disconnect Clutch see Start up instructions in Operator s Manual Example of a Pump Drive with a...

Page 71: ...steps shown below and on the next few pages you can avoid unnecessary dust contamination to the engine The following steps should be taken on a daily basis or more often in severe conditions 1 Check t...

Page 72: ...riction of the Air Cleaner with a service gauge or a water manometer at the restriction tap provided in the Air Cleaner the transfer pipe or the blower intake Replace the element only when the restric...

Page 73: ...or that a dust leak exists Make certain the cause of that leak is identified and rectified before replacing the element 5 PRESSYOUR FRESH GASKET TO SEE IF IT SPRINGS BACK Make sure your new element i...

Page 74: ...ement is not going to be changed and reassembled immediately cover the opening The only way to be sure nothing got in is to be sure nothing gets in THE IMPORTANT DON TS TO ALWAYS REMEMBER DON T OVERLO...

Page 75: ...page75 295AC 800 00158 Structural E STRUCTURAL MAINTENANCE...

Page 76: ...ance which accelerates towards the end of the bearing life The last item bearing clearance can be measured and is a good means of determining the bearing condition MEASURING BEARING CLEARANCE Permissa...

Page 77: ...icator 4 Balance the machine so as to have zero moment load on the bearing This is done by adjusting the boom angle Zero moment is when the upper race is at its lowest position at both front and rear...

Page 78: ...2 90 079 091 098 114 118 122 126 100 079 091 102 114 122 124 126 110 094 102 118 126 128 130 120 098 106 122 126 130 134 130 102 110 126 130 134 138 140 114 126 134 136 138 150 118 130 138 140 142 160...

Page 79: ...rator s Manual 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 BEARING LUBRICATIO...

Page 80: ...page80 295AC 800 00158 Trouble Shooting...

Page 81: ...repair any leaks Drain engine oil and fill with heavier weight engine oil Engine overheats Low coolant level Loose worn or broken fan belt Radiator plugged Air filter elements plugged Fill to correct...

Page 82: ...Pump not receiving hydraulic oil Damaged line Any or all of the following Replace dirty filters Clogged inlet line Clean reservoir breather vent Fill reservoir to proper level Replace line Hydraulic...

Page 83: ...tighten connections Replace engine oil Refer to Fuel and Lubricants Gauges do not work Gauge sender needs service Loose gauge ground connection Replace sender Check ground connection Tighten if neces...

Page 84: ...erational Repair or replace sources of leaks and blocks Repair or replace as needed Machine steering in opposite direction if applicable Lines to cylinders connected to wrong ports at steering valve o...

Page 85: ...of main boom 2 beige w orange shadow 539 00925 Striping 8 orange brown wrapsaroundmachine 350 283 00008 DECAL Barko Strong Arm both sides of cab 2 PLATE serial number on front of platform left of 1 la...

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BARKO LOADERS 295, Service Manual

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