295
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BARKO
LOADERS
SERVICE MANUAL
295 Articulated Carrier
Machine
Serial Number
NOTE: The Grapple Service and Installation Information is not included in this manual. See separate
Grapple Service and Installation manual which accompanies all grapples from the factory.
The information and illustrations in this manual have
been approved as accurate at the time of printing.
However, the manual may contain information on
options not present on your loader. The right is
reserved by Barko Hydraulics,LLC to make changes
and improvements in it's product at anytime without
notice or obligation.
BARKO
HYDRAULICS,LLC
mailing: PO Box 16227, Duluth, MN 55816 shipping: 1 Banks Avenue, Superior, WI 54880
phone: 715-392-5641 fax: 715-392-3931
website: www.barko.com email: barko@barko.com
013112
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
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
........................................................ 57
Introduction
295 AC
800-00158
page 3
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!
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: 715-392-5641
Fax: 715-392-3931
Website: www.barko.com
Email: barko@barko.com
REFERENCEINFORMATION
The machine serial number plate is located on the
front of the platform near the ladder.
Loader
Model No.
Serial No.
Engine
Model No.
Serial No.
NOTE: Information in this manual is current at the time of printing. Barko Hydraulics reserves the right to
make changes and improvements to it's products and manuals at any time without notice or
obligation.
295 AC
800-00158
page 4
ABBREVIATIONS AND SYMBOLS
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
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
Horn
Starter
Engine
RPM
Slower
Air
Conditioner
Power On
295 AC
800-00158
Faster
page 5
HYDRAULIC PRESSURE WARNING SHEET
WARNING
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.
BARKO HYDRAULICS, LLC
295 AC
800-00158
page 6
WARRANTY
BARKO HYDRAULICS, LLC
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 serviceman 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
295 AC
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page 7
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.
295 AC
800-00158
page 8
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 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.
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.
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.
DANGER
Never let anyone in or near pivot area of an
articulated machine.
295 AC
800-00158
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.
page 9
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
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.
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
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.
DANGER
Moving stabilizers will cause death or severe
injury. Stand clear. Operate stabilizers only
when personnel are clear.
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
Ensure that tire pressure is within rated limits to
prevent personal injury or damage to machine.
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.
295 AC
800-00158
page 10
SAFETY SUMMARY CONTINUED...
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
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
Remove or secure all personal or maintenance
items such as lunch buckets, chains, shovels,
tools, etc., before moving or operating machine.
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.
WARNING
Replace any safety decals that are faded, torn,
missing, illegible, or otherwise damaged.
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
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
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.
295 AC
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page 11
SAFETY SUMMARY CONTINUED...
WARNING
Always wear seat belt when operating or running
machine.
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
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
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.
WARNING
Hot exhaust pipe can cause severe burns. Do not
touch exhaust pipe when hot, or when engine is
running.
If Barko-authorized welding must be done, first
disconnect battery, electronic throttle, and radio,
or electrical and structural damage may occur.
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.
CAUTION
Use only hydraulic fluid in hydraulic oil reservoir.
Use only diesel fuel in fuel reservoir.
Other fluids will cause machine damage.
WARNING
Maintain all components of Muffler Assembly to
meet noise and exhaust standards.
295 AC
800-00158
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.
page 12
SAFETY SUMMARY CONTINUED...
WARNING
Use caution when checking items beyond your
reach. Use an approved safety ladder.
WARNING
Older air conditioning equipment may contain R12, 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.
Proposition 65 Warning
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
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.
CALIFORNIA
Diesel engine exhaust and some of its constituents are known to
the State of California to cause cancer, birth defects, and other
reproductive harm.
295 AC
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page 13
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.
295 AC
800-00158
page 14
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.
MODEL DESCRIPTION
Door Handle
Heater/Air
Conditioner Ducting
(not shown attached
to unit)
Servo Lever
(lifts entire armrest,
shutting off servo)
Operator's Seat
with Seatbelt
Cup and
Thermos Holder
Swing Pedal
Instrument Panel (wall
mounted)
Heater/Air
Conditioner Ducting
(not shown attached
to unit)
Instrument Panel
(seat mounted)
Heater/Air Conditioner
(located under and behind the seat
with attached ducting)
Platform/Control Deck
Hydraulic Oil Reservoir,
Shrouding, Power Unit
& Pumps
Counterweight
Swing Motor
Gearbox
Cab
Head
Assembly
Handrails
Main
Boom
Main Boom
Cylinder
Turntable Bearing
Transmission
Shift Lever
Ladder
Stick Boom
Cylinder
Grapple
Cylinders
LEFT SIDE VIEW
Stick Boom
Grapple
Hanger
Grapple
Rotator
Lower
(subframe)
Stabilizer Pad
295 AC
800-00158
page 15
Stabilizer
Leg and
Cylinder
Grapple
Arms
A. PREVENTIVE MAINTENANCE
Maintenance
295 AC
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page 16
Maintenance
SAFETY WHILE SERVICING
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.
BEFORE INSPECTION OR MAINTENANCE:
- 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.
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.
- 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.
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
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.
REMEMBER: SAFETY FIRST!
295 AC
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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.
page 17
PREVENTIVE MAINTENANCE
Preventive maintenance is really just a simple matter of common sense. If you keep any piece of mechanical
equipment clean and properly lubricated, and promptly replace any worn or damaged parts, you are going to "prevent"
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.
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.
SPECIAL NEW-MACHINE INSTRUCTIONS
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.
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page 18
SERVICE SCHEDULE
SERVICE REQUIRED
Hydraulic Reservoir - check level and quality
of oil.
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.
Pump Drive - Check fluid level.
Hoses, Connections, Cylinders - Inspect for
leaks and damage. Tighten, repair, or
replace parts if necessary.
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.
Fittings - Lubricate as shown on Lubrication
Points. Use a multi-purpose grease.
Bolts/Nuts - Visually inspect for wear or
damage.
8 hours
Daily
50 hours
Weekly
100 hours
Monthly
400 hours
2 Months
1000 hours
6 Months
Yearly
Swing Motor Gearbox - Check fluid level.
Engine Air Cleaner - Inspect & replace
element,if needed.
Engine Shrouding - Clean and inspect.
Hydraulic Oil Filter - On new machines the
filter element should be replaced first at 50
hrs. and then at 400 hrs. thereafter.
Swing Motor Gearbox - On new machines
the fluid should be changed first at 50
hrs. and then every 400 hours thereafter.
Hydraulic Oil Reservoir - On new machines
the oil must be changed after the first 50 hours,
and then every 1000 hours after that.
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.
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SERVICE SCHEDULE CONTINUED...
SERVICE REQUIRED
Tires - Check for correct pressure.
Axle Cradle Center Pivots - Lubricate.
Articulating Pivot Points - Lubricate.
Hydraulic Oil Filter - Replace elements every
400 hours, after initial change at 50 hours on a
new machine.
Pump Drive - Replace fluid.
Swing Motor Gearbox - Replace fluid. On new
machines the fluid should be changed first at 50
hrs. and then every 400 hours thereafter.
Transmission - Check fluid. Add if necessary.
Pilot Filters in Valve Banks - Remove, inspect
and clean.
Hydraulic Reservoir - Replace oil and clean
suction screens.
Entire Loader - Steam clean, inspect for
stress, wear, cracks, damage, and loose parts.
Planetary Axle - Drain and fill with lubricant.
Replace seals. Refer to Service Manual.
Wheel Bearings - Clean and inspect. Replace
if necessary. Pack with grease.
8 hours
Daily
50 hours
Weekly
100 hours
Monthly
400 hours
2 Months
1000 hours
6 Months
Yearly
Brakes - Adjust if necessary.
Drive Shaft Universal Joint - Lubricate.
Transmission - Change fluid (80-90 gear fluid).
Air Conditioner Air Intake Filter - Replace.
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.
TIRES
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.
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page 20
LUBRICATION POINTS
(PERFORM DAILY)
GREASE
HYDRAULIC
OIL
GEAR FLUID
Pump Drive (except direct drive models): EP 80-90 gear fluid.
Swing Motor Gearbox: EP 80-90 gear fluid (fill until oil is as high as top of
cluster bearings - see service manual for more information) (if lube reservoir
is used, maintain at half full).
Transmission: EP 80-90 gear fluid.
1 Grapple Arms
2 Grapple Rotator
3 Grapple Cylinders
4 Grapple Hanger (2 fittings)
5 Turntable Bearing & Pinion
6 Stick Boom Pivot
7 Main Boom Pivot
8 Stabilizer Legs/Pads
9 Stabilizer Cylinders (both ends)
10 Main Boom Cylinders
11 Stick Boom Cylinders
12 Hydraulic Oil Reservoir
13 Swing Motor Gearboxes (2)
14 Pump Drive
15 Steering Cylinders
16 Articulating Pivot Points
17 Axle Cradle Center Pivots
(as applicable)
18 Transmission
14
8
13
8
6
12
11
11
7
10
5
9
17
10
16
16
15
2
1
1
17
4
3
3
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18
page 21
FLUID SPECIFICATIONS
GREASE
Use grease shown on chart below, depending on the expected air temperature range.
AIR TEMPERATURE RANGE
Fahrenheit (F) -67 -40 -22 -4 14 32 50 68 86 104 122
Celsius (C) -55 -40 -30 -20 -10 0 10 20 30 40 50
NLGI NO. 2
HIGH TEMP. /EP
NLGI O OR I
ARCTIC GREASE
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.
- Anti-foaming agents to break up air bubbles and prevent "foaming" that may cause sluggish and erratic operation.
- High stability to resist oxidation 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 low temperatures without thinning out at high temp's after hours of use.
For operation in different temperatures, refer to the following chart for selection of hydraulic oil.
ISO Viscosity Grade
46 32° F. to 45° F.
68
Average Ambient Temp.
ABOVE 45° F.
Below 32° F. ambient, consult the factory.
System Operating Temperature
150° F. Max.
190° F. Max.
ENGINE OIL
Refer to the specifications in the engine manufacturer's manuals that are supplied with every new machine.
FUEL SPECIFICATIONS
Use grade no. 2-D fuel above 40 degrees F.
Use grade no. 1-D fuel below 40 degrees F.
Use grade no. 1-D fuel for all air temperatures at altitudes.
NOTE: Change the engine oil at one half the normal interval if fuel sulfur content exceeds 0.5%. Use fuel with
less than 1.0% sulfur. Use fuel with less than 0.5% sulfur if possible. Sediment and water should not
exceed 0.10% for maximum filter life.
The Cetane number should be 40 minimum. A fuel with a higher Cetane number may be required if operating the
machine where air temperatures are normally low or where altitudes are high. In cold weather operation, the cloud point
should be 10 degrees F. below lowest normal air temperatures.
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page 22
FLUID SPECIFICATIONS CONTINUED...
FUEL STORAGE
NOTE: Diesel fuels stored for a long time may form gum or bacteria and plug filters.
Keep fuel in a clean container and store in a protected area. Water and sediment must be removed before fuel gets to
the engine. Do not use de-icers to remove water from fuel. Do not depend on fuel filters to remove water.
NOTE: Keep all dirt, scale, water, or other foreign material out of fuel.
Store fuel drums on sides with plug up.
ALTERNATIVE LUBRICANTS
Conditions 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 lubricants are used. Use a clean container to handle all
lubricants. Store them in an area protected from dust, moisture, and other contaminants. Store drums on sides.
WARNING
Diesel fuel or hydraulic fluid under pressure can penetrate the skin or eyes.
Fluid leaks under pressure may not be visible. Use a piece of cardboard or
wood to find leaks but do not use bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention.
295 AC
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page 23
SPECIAL TORQUE SPECIFICATIONS
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
In critical applications (such as Turntable Bearing
Bolts and any grade 8 or grade 9 bolts), once the
old bolts and nuts have been loosened, they must
be replaced rather than re-tightened and retorqued. Original clamping force cannot be
achieved using the old bolts and nuts.
LUBRICATE WITH ANTI-SEIZE COMPOUND PART NO. 514-00700
Swing Motor Mounting Bolts ......................................................................... 64 Ft. Lbs.
Swing Motor Gearbox Mounting Bolts ........................................................... 310 Ft. Lbs.
Turntable Bearing Bolts (Do not re-use old bolts/nuts.) ................................ 500 Ft. Lbs.
K170 Upper
Valve Bank Nuts:
To be tightened in three steps:
1. Tighten all nuts in a clockwise pattern to:
2. Tighten all nuts in a clockwise pattern to:
3. Tighten all nuts in a clockwise pattern to:
Other torques, for the valves, pumps, and motors are found in the service literature for those components.
Valve Bank
(Ft. Lbs)
11
30
44
L90 Lower
Valve Bank
(Ft. Lbs.)
7
21
33
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page 24
GENERAL TORQUE SPECIFICATIONS
See Special Torque Specifications that pertain specifically to this machine.
WARNING
Grade 9 bolts must be used
with Grade 9 washers.
WARNING
Do not re-use grade 8 or grade
9 bolts or nuts - replace with
new ones.
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.
This is lubed torque.
*
Lubricate with anti-seize
compound part no. 514-
00700.
GRADE 5
SAE GRADE 5
RECOMMENDED
TORQUE FOOT
POUNDS
GRADE 8
SAE GRADE 8
RECOMMENDED
TORQUE FOOT
POUNDS
DIA.
1/4 9 10 5 6
5/16 17 20 10 12
3/8 31 35 19 21
7/16 50 55 30 33
1/2 75 85 45 51
9/16 110 120 66 72
5/8 150 170 90 100
3/4 265 300 160 180
7/8 400 435 240 260
1 600 650 360 390
1-1/8 800 900 480 540
1-1/4 1120 1240 670 745
1-3/8 1470 1670 880 1000
1-1/2 1950 2200 1170 1320
DIA.
1/4 12 14 7 9
5/16 25 27 15 17
3/8 44 49 26 30
7/16 70 78 42 47
1/2 107 120 64 72
9/16 154 171 92 102
5/8 212 240 127 144
3/4 376 420 226 252
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
DIA.
DRY
FINECOARSE
DRY
FINECOARSE
DRY
FINECOARSE
LUBRICATED
*
COARSE
LUBRICATED
*
COARSE
LUBRICATED
*
COARSE
FINE
FINE
FINE
GRADE 9
(MIN. 8 RADIAL
MARKS ON
HEAD) GRADE 9
(BOW-MALLOY)
RECOMMENDED
TORQUE FOOT
POUNDS
295 AC
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page 25
1/4 17 19 10 12
5/16 34 37 20 22
3/8 60 68 36 41
7/16 96 108 58 65
1/2 145 165 87 100
9/16 210 235 125 140
5/8 290 330 175 200
3/4 515 575 310 345
7/8 830 980 500 590
1 1250 1350 750 810
1-1/8 1750 1950 1050 1170
1-1/4 2500 2750 1500 1650
1-3/8 3250 3700 1950 2220
1-1/2 4350 4850 2600 2900
B. HYDRAULIC SYSTEM
295 AC
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Maintenance
page 26
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