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930-937 Mulcher (S) - Lynn Hendrix Equipment

1. lt 39 88 a 3 3 it ae 525 oz EM 4 TIE 35 33388 5 55 cance WE a m agopougg 11 11 11 e zu 118 1 ono lo Fo an eo oD a ur Em PL POWER RE EMO GND n 1 2 DOOR LOCKING PIN WHT BLK LEFT FRONT WHT LEFT FRONT moor SE a un 5 MMIZZ gt UY 00000 08 90 NI 3105 09 930 937 Mulcher S 800 00258 page 62 JUNCTION BOX SIDE CONSOLE IN CAB AIR CONDITIONER ELECTRICAL SCHEMATIC HEATER TANVd 1051405 YOLOW 4451144 49914 21 34 xog JILSV Id 0 l 8 1504334 E 1504430 J IndOIN 39VJ83 LNI YAMOd NOA H LNTO page 63 930 937 Mulcher 800 00258 WOSN3S IVLSOWYSHL 0818 066 ONYVE OLV HEATER AIR CONDITIONER ELECTRICAL SCHEMA
2. CE 90 NI 3DSNDO 930 937 Mulcher S 800 00258 pa g e 59 903 00122 JUNCTION BOX CAB SIDE CONSOLE IN CAB ELECTRICAL SGHEMATIC 2999040 CUMMINS ENGI 903 00122 Replaced by 903 00140 Sta 8 20 07 T TI TT di TT Im ui 7 T x diis gt pd ii ELLA rn 9395 2 a 1 15 a 2 g x ly 5 Og 2 5 3 SLO i a T 8 8 C OQ f Hin P n 5413 956 HM ISI a 45 353 a ee LN FRONT FRAME 2820 Mv cent ae mul SOD ENGINE E AE mill lt RER m 1 85878508 8000066 JUNCTION BOX lt IN CAB ge ____ E Ss 526 TTT Y n 1414 41 11 x x Ln a SIDE CONSOLE IN CAB Loom CAB COMPONENTS Ema 186 T VEL YEL GRN 8V9 NI 3105 2
3. 41 Rexroth Drive PUMP 43 Sauer Drive Pump 44 Rexroth Drive Motor 45 Sauer Drive 46 Hydraulic Hose Hookup mulcher 47 Hydraulic Reservoir Maintenance 48 Hydraulic Oil Filter Maintenance o0 Eliminating Air From the Sytem 52 Hydraulic Fittings Hoses and Tubing 53 Hydraulic Cylinder Maintenance 54 Axle Maintenance John Deere o6 INTRODUCTION Your Barko Mulcher 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 machine is not equipped with this manual ask your supervisor to obtain one for you Understand the correct servicing procedures before servicing the machine It is important to know the correct operating and servicing procedures of the Mulcher 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 t
4. Slowly depress travel pedal to gradually pressurize forward travel WARNING Watch to make sure machine is not moving before making adjustments While watching pressure gauges and display gauge on M port should read 0 PSI until you reach begin of shift pressure When pressure begins to rise on the gauge located on the M port the reading on the G port is the begin of stroke point Loosen jamb nut Adjust begin of stroke set screw to between 3800 4000 PSI Turn screw in clockwise to lower begin of stroke point setting and out counterclockwise to raise begin of stroke point setting Tighten jamb nut Release travel pedal Repeat steps 9 thru 14 until required begin of stroke point setting is achieved and stable After obtaining desired setting Shut down engine Begin of Stroke Adjustment Screw Replace travel pump centering hose Remove pressure gauges CAUTION Ports may contain trapped pressure Use care when removing gauges and installing plugs 930 937 Mulcher S 800 00258 page 45 MULCHER MACHINE PRESSURE ADJUSTMENT PROCEDURE CONTINUED SAUER DRIVE MOTOR PRESSURE ADJUSTMENT PROCEDURE Begin of Stroke Adjustment Screw 1 Install pressure gauge on Test Port A located on the Test Port A drive motor 2 Install a second pressure gauge on Test Port 3 Switch parking brake ON 4 Switch low lock to OFF position 9 Disconnect travel pump spool centering hose Refer to Drive Pump A
5. 800 00258 HYDRAULIC HOSE HOOKUP Tilt Forward Tilt Back Tilt Back Tilt Forward Return Case Drain A Push Bar B Push Bar 242 Lift arms lift cylinders and lift hoses not shown Lift hoses run from end of lift cylinders through cutouts in each side of front frame plate to valve bank 0 937 Mulcher 800 00258 607 00145 HYDRAULIC SCHEMATIC eae Snore YOLOW 83HO INN 5 154 0092 3199 il QOY 21 Lind Wd9 2 22 ZZ LL ii SMd3QNITAO 315 IE JAVAL 4 1 page 31 930 937 Mulcher 800 00258 HYDRAULIC ASSEMBLY 7659 40035 REAR FRAME 12 9101 53 FLOAT OVERRIDE MULCHER 0 JOYSTICK FOOT CONTROLS 181 elec 9 14Celec 305 930 937 Mulcher S 800 00258 page 32 1 HYDRAULIC ASSEMBLY 7695 40035 FRONT FRAME a Y E 7 14 1111 t MULCHER CASE DRAIN LLL Y PT8 6 359 360 F4 F3 V007 FS Ad 364 265 ET 1500 51 PUSH PRESSURE 2000 PSI 9 avg sna 1111 A L
6. 930 937 Mulcher S 800 00258 page 60 ELECTRICAL SCHEMATIC 9500120 JOHN DEER NE 903 00120 Replaced by 903 00141 Starting 8 20 07 2 E i d T E n in pe T us ji b i LO Og ic f 03i i iL Bs E ii 5 apie tay 1 5 NN Hi BEREE oe E 9 912191919191919121 1219 ge 1919191919191019191919 5 5 8 1286 5 5 P NI gu 3 on a 3 EI i 59 EE i 1 55 AR 81 af os 5 xin 876 5 Au 8t 5 2 5 5 Nur 8 Tu 575 i ts l 90 NI 3DSNDO 930 937 Mulcher S 800 00258 page 61 FRONT FRAME ii ELECTRICAL SCHEMATIC 599050041 JOHN DEER NE 903 00120 Replaced by 903 00141 Sta 8 20 07 Te E A 14 t T C a bui D tresses firi Won N
7. shown Lift hoses run from end of lift cylinders through cutouts in each side of front frame plate to valve bank 0 937 Mulcher 800 00258 HYDRAULIC RESERVOIR MAINTENANCE The hydraulic oil reservoir is located on the rear of the frame on the right hand side The reservoir features return line filters and suction screens to keep the oil clean A sight gauge for checking oil level is located on the front of the reservoir Sight Gauge CAUTION g When making repairs on hydraulic sytem keep all parts clean and Hydraulic Oil Reservoir remove all dirt from the area before you begin disassembly Use caps and plugs to keep dirt out of tubelines and openings Filter Access Cover Breather Reservoir Access Cover Return Filter Sight Gauge 0 Hydraulic Oil Temperature Sender Drain Check oil level in reservoir before each period of operation or daily If at any time you find the level is low check the machine for leaks around tubes hoses fittings and couplings 930 937 Mulcher S 800 00258 page 48 HYDRAULIC RESERVOIR MAINTENANCE CONTINUED HYDRAULIC OIL CHANGING
8. F 67 40 22 4 14 32 50 68 86 104 122 Celsius C 55 40 30 20 0 0 10 20 30 40 50 NLGI NO 2 HIGH TEMP EP NLGI O ORI ARCTIC GREASE HYDRAULIC OIL The following lists some features to look for in an oil The hydraulic oil for the machine should feature Rustresistant 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 Average Ambient Temp System Operating Temperature Below 32 F ambient consult the factory 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 0 596 Use fuel with less than 1 096 sulfur Use fuel with less than 0 596 sulfur if possibl
9. HYDRAULIC SYSTEM 29 Condenser Installation 72 Hydraulic Hose Hookup 30 Air Conditioner Trouble Shooting 73 31 D POWER UNIT MAINTENANCE 81 Hydraulic 31 Engine Maintenance 82 Hydraulic Assembly 32 Pump Drive Maintenance 83 Rear Frame eMe 32 Two Three and Four Pad Pump Drives 83 mis 33 B Single Pad Pump Drives 86 937 NO FLOAT 34 C Optional Disconnect Clutch 86 Hydraulic 5 34 Air Cleaner Maintenance 87 Hydraulic Assembly 3 MACHINE 5 9 1 Rear 9 Front Frane 36 DECALS rer ee 92 Pressure Settings mulcher machines 37 UI Layout p 38 Rexroth Accessory 39 Differential Lock Servo Valve 40 Mulcher Pump
10. Loosen jamb nut WARNING Brake line heats up fast and can burn you Adjust braking pressure set screw to 2500 PSI If pressure is set higher than this the belts in the mulcher can be burn up Braking pressure is the set screw closest to the outside of the machine Tighten jamb nut Turn mulcher switch to off position Shut down engine Return electric wire back to original position Reconnect mulcher hoses or free mulcher drum Remove pressure gauge 930 937 Mulcher S 800 00258 page 42 MULCHER MACHINE PRESSURE ADJUSTMENT PROCEDURE CONTINUED REXROTH DRIVE PUMP CHARGE PRESSURE ADJUSTMENT PROCEDURE 1 Turn Dial to 6 or 7 on the Diagnostic Pressure Display or install pressure gauge on Drive pump pressure test port Start engine run at full throttle Loosen jamb nut on charge pressure relief Adjust charge pressure relief to between 450 500 PSI Tighten jamb nut Shut down engine Remove pressure gauge Charge Pressure Relief REXROTH DRIVE PUMP PRESSURE ADJUSTMENT PROCEDURE 10 11 12 13 14 Centering Hose Turn Dial to 6 on the Diagnostic Pressure Display or install pressure gauge on Drive pump forward and reverse pressure test ports Switch parking brake ON Disconnect travel pump spool centering hose Cap and plug fittings This allows pump to come on stroke with parking brake locked Start engine run just above an Idle Shift transfer case into high range Depress tra
11. misapplication improper operation or use installation of unapproved accessories or unauthorized alterations Damage resulting from repairs made in an unauthorized manner or installation of components not authorized by BARKO 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 Overtime labor premiums Transportation of the BARKO product to the distributor s service facility or transportation of the distributor s serviceman to the product s location 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 sal
12. or disconnecting cables at battery Battery gas can explode and cause serious injury INSTALLING A NEW BATTERY 1 Remove battery cables Remember position of positive terminal and negative terminal so you can connect them again correctly 2 Remove battery hold down bar Remove battery from compartment 3 Clean terminal posts of new battery and cable connections with wire brush 4 Install new battery in compartment Install hold down bar o Install and tighten battery cables Connect negative cable last to prevent sparks 930 937 Mulcher S 800 00258 page 66 ELECTRICAL SYSTEM MAINTENANCE CONTINUED AN WARNING Do not touch battery terminals with any metal Sparks may occur causing damage to battery and personal injury ALTERNATOR DRIVE 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 center of belt 3 Tighten alternator adjusting bolt and mounting bolt After a new drive belt has been installed it will be necessary to adjust it after 8 hours of machine operation Adjusting Belt Tension 1 2 of movement BELT ADJUSTING BOLT ADJUSTMENT BAR ALTERNATOR Figure 1 ALTERNATOR MAINTENANCE CHECKING THE WIRING 1 Turnthe starter switch on 2 Connect volt meter between the ground and See Figure 2 a the No 1 alternator connector b the No 2 alt
13. 10 11 12 WINCH PRESSURE FLOW 2500PSI 15GPM 1500PSI GATE PRESSURE PUSH BAR PRESSURE 2000 PSI qu PRESSURE SETTINGS MULCHER MACHINES MULCHER PRESSURE SETTINGS System Pressure P O R setting on the Drive 5000 PSI NOTE System Pressure P O R setting must be set 300 PSI under System Relief Pressures System Relief forward Pressure set at the Drive Pump 5300 PSI System Relief reverse Pressure set at the Drive 5300 PSI Charge Pressure set at the charge pressure relief valve on the Drive 450 500 PSI Differential Lock Servo Pressure TT TT E 625 PSI Mulcher Drive accelerating 4800 PSI M lcher Orive DraKiNg m 2500 PSI Mulcher Charge Pressure set at the charge relief on the Mulcher Pump see Figure 1 300 PSI Accessory Pump Standby Pressure eeu Ga Un EP 400 450 PSI Accessory Pump Max 3600 PSI VALVE BANK PRESSURE SETTINGS See Figure 1 NOTE Port reliefs on Front Valve Bank are non adjustable Galei T open port B 1500 PSI close port A 1500 PSI open port A 2000 PSI close port B 2000 PSI Mul
14. PROCEDURE This procedure should be performed once during the breaking in period of a new loader after one week or 50 hours of operation and then every six months or 1000 hours Throughout the oil changing procedure remember that cleanliness is absolutely necessary Hands tools pump oil filling equipment 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 cylinders DRAINING THE RESERVOIR 1 First be sure Mulcher attachment is lowered to the ground and secure and machine is shut down 2 Remove reservoir drain plug to drain hydraulic oil CLEANING THE RESERVOIR 1 Clean area around reservoir access cover on side of reservoir and then remove access cover 2 Remove all dirt and sediment from inside reservoir 3 Clean the breather screen and check for damage If damaged replace the screen 4 After everything in and around reservoir is completely clean replace drain plug and access cover o Hemove element from return filter and install a new one 6 Remove element from hand pump filter and install a new one FILLING THE RESERVOIR 1 With drain plug in place and tightened refill reservoir with recommended hydraulic oil see Fuel and Lubricants section using the hand pump 2 Startengine running it slowly until new hydraulic oil circulates throughout system 3 With all control valves in neutral run engine until pump quiets do
15. Voltage between the two brown wires should be between 0 and 5 volts when the sensor 15 not connected 3 Resistance of evaporator probe sensor Sensor unplugged SEECHART 4 If the probe functions properly but the core still freezes reposition the tip of the probe to the coldest part of the evaporator core Problem No Heat Control Make sure air temp sensor checks out see above Cab Temperature Sensor Water Valve 6 pin connector The water valve can be prone to jamming if the coolant loop has excessive contaminants init If the valve must be replaced due to grit or debris preventing operation flush the cooling system before replacing 1 Checking water valve with plug disconnected apply 12 or 24 volts between pins 4 and 6 on the valve empty cavity is between pins 4 and 6 The valve should move in one direction Reverse voltage and the valve should move in the opposite direction 2 Check the wiring for good contacts 3 The voltage between the orange and black wires pins and 4 should be or 12 or 24 volts depending on if the valve is opening or closing Ifthe valve is not moving the voltage will be atO 4 The voltage between the yellow and green wires pins 2 and 3 should be 5 volts 5 The voltage between the purple and green wires pins 1 and 3 should be between 0 and 5 volts 5V when valve is not connected 6 If valve does not operate replace valve If poweris not correct check ECU Problem
16. approved safety ladder 930 937 Mulcher S p a g e 1 2 800 00258 SAFETY SUMMARY CONTINUED WARNING WARNING If this machine is equipped with electric motor Do not exceed 15 p s i nozzle pressure when driven Auxiliary Oil Cooler be sure battery is drying parts with compressed air Do not direct disconnected before going near cooler fan f compressed air against human skin Serious battery is not disconnected fan may come on at injury could result any time causing severe injury 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 930 937 Mulcher S 800 00258 page 13 FIRE PREVENTION This machine has several components which are at high temperatures under normal operating conditions such as engine exhaust system brake system and transmission Also electrical system battery electrical connectors etc can be a source of arcs or sparks if damaged or incorrectly maintained Excessive debris will increase the condition for a fire hazard Flammable debris twigs leaves straw rags etc must be removed on a daily basis or more often if necessary from areas such as the engine exhaust battery electrical connectors parking brake components transmission area and belly pan drive line fuel hydraulic and brake systems Clean machine often Periodic high pressure washing of mac
17. available with various engine options These engines are equipped with a restriction indicator provided by the engine manufacturer Barko recommends that you consult the Operators manual provided by the engine manufacture for recommendations on air cleaner element change intervals Barko also recommends that you consult your Operators manual provided by the engine manufacturer to ensure that filter elements other than the ones provided by the engine manufacturer have been tested and meet there qualifications 930 937 Mulcher S 800 00258 page 20 SERVICE SCHEDULE CONTINUED 8 hours 50 hours 100 hours 400 hours 1000 hrs Hydraulic Oil Filters Replace elements every 400 hours after initial change at 50 hours on a new machine Hydraulic Reservoir Replace oil and clean suction screens Wheel Bearings Clean and inspect Replace if needed Pack with grease Pump Drive Pads Lubricate pump pad splines with 80 90 gear fluid See Pump Drive Maintenance in Service Manual for specifications 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 930 937 Mulcher S 800 00258 page 21 TIRES DAILY MAINTENANCE 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 AN WARNING Imprope
18. choke filter install the filter as shown in the photos below Re check the programming in the control head for proper programs RFI FILTER 930 937 Mulcher S 800 00258 page 7 5 AIR CONDITIONER TROUBLE SHOOTING 930 937 MULCHER CONTINUED INSTRUCTIONS FOR ADVANCED DIAGNOSTICS ATC SYSTEM AND PROGRAMMING Programming and Advanced Diagnostics Only on New StyleDiagnostics Only on Old Style Error code display is accessed by pressing the ON key three times quickly Press the ON key to cycle through all of the active error codes Wait five seconds to return to normal display mode The advanced diagnostics display mode is activated by pressing and holding the ON key for five seconds while the error code is active Press the ON key to cycle through the following displays CAb Cab temperature display EUAP Evaporator temperature display DUCt Duct temperature display Water valve position percent A C A C command percent FAn Fan speed percent Press the OFF key to return to normal display mode The firmware revision display mode is activated by pressing and holding the ON key for five seconds while the advanced diagnostics display mode is active Press the ON key to cycle between the following displays ECU ECU module revision CtrL Control panel revision Press the OFF key to return to normal display mode The parameter function is activated by pressing and
19. dirty filter may still have plenty of life left while carbon contamination is not visible to the eye And you can t see the dirt that is embedded deep within the filter paper Your best bet for lowest filter maintenance costs and best engine performance is to follow a restriction gauge It s a smart low cost investment NEVER LEAVE AN AIR CLEANER OPEN LONGER THAN NECESSARY Your open air cleaner is a direct entry to your engine If the element 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 DON T OVERLOOK A WORN OR DAMAGED GASKET IN THE HOUSING lf your cleaner has a cover gasket replace it with a new one Always check to be sure no piece of the old gasket remains in the housing and that the gasket is not worn If your filter model calls for a new gasket with each use never reuse the old one DON T usE DENTED OR BUNCHED FILTER ELEMENT Never install a dented or punctured element because it cannot protect properly against contamination A dent can make a firm seal impossible or can indicate damaged media An element with bunched pleats saps engine power and fuel dollars right from the start NEVER usE A WARPED COVER ON A HOUSING Replace with a new cover as soon as possible A warped or damaged cover cannot make a proper seal Also check to make sure there is no damage to the air cleaner housing that co
20. holding the OFF key for five seconds while the advanced diagnostics display mode is active Press the FAN UP FAN DOWN keys to select a config setting Press the TEMP UP TEMP DOWN keys to change the selected setting CFGF will globally set all 16 settings at once Press the OFF key to return to normal display mode Press the TEMP UP key and the TEMP DOWN keys simultaneously to change from Fahrenheit to Celsius 24 pin connector pinout A1 Secondary Load Shedding input A2 Evaporator Temperature Ground A3 Evaporator Temperature Signal A4 Cab Temperature Signal for all except 30K Thermistor 5 Ambient Temperature Ground A6 No Connection AT Water Valve Feedback 5VDC A8 Water Valve Feedback Ground 930 937 Mulcher S 800 00258 page 76 AIR CONDITIONER TROUBLE SHOOTING 930 937 MULCHER CONTINUED 9 No Connection A10 No Connection A11 No Connection A12 No Connection B1 Cab Temperature Signal for 30K Thermistor B2 Cab Temperature Ground B3 Ambient Temperature Signal B4 Water Valve Feedback Signal B5 No Connection 11 B6 No Connection B7 Serial Connection to Control Panel B8 Serial Connection to Control Panel B9 No Connection B10 No Connection B11 Water Valve Motor Positive B12 Water Valve Motor Negative 8 pin connector pinout A Power In 12VDC B Blower Output Positive C Blower Output Negative D Ground In E Pull to Ground for A C Clutch Activation F Pull to
21. hydraulic oil from the reservoir to the pumps and valves and then to cylinders and motors and finally back to the reservoir Operating pressure of the hydraulic system varies from model to model For your loader consult the Hydraulic Pressure Warning Sheet in this manual Replace any tubelines which are bent or have become flat There will be a restriction of fluid flow which will make hydraulic action slow and cause heat Replace hoses which show signs of wear damage or weather cracked rubber CAUTION When making repairs on hydraulic system keep all parts clean and remove all dirt from the area before you begin disassembly Use caps and plugs to keep dirt out of tubelines and openings PIPE THREAD SEALER The main causes of air being introduced into a hydraulic system are loose connections and fittings This not only creates aeration 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 adequate pipe thread sealer at all connections and fittings While other pipe thread sealers may meet specifications the methods which Barko uses are Teflon tape and Locktite Teflon Thread Sealer The sealer will form a flexible non hardening seal that can be easily broken at any time without stripping the threads or damaging the pipes or fittings It will also provide a non shrinking bond that will inhibit rust
22. 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 2 4 Do complete inspection the machine Rectify any problems replace any damaged parts Check torque of bolts and nuts retorque if necessary Change all filter elements Change hydraulic oil in hydraulic oil reservoir Resume the normal maintenance intervals after this See the Service Schedule for more information 930 937 Mulcher S 800 00258 page 18 SERVICE SCHEDULE 8 hours 50 hours 100 400 hours 1000 hrs Engine Radiator Check coolant level and fill if necessary Inspect exterior for dirt and debris and clean if necessary Engine Air Cleaner Inspect for cracks loose clamps or other damage Inspect dust cup for dust empty if needed Check restriction of Air Cleaner daily replace filter as needed Fan and Drivebelts Check for looseness and wear Tighten or replace as needed Pump Drive Check fluid level Add 80 90 gear fluid if needed Axle Outer Bearings Grease daily when operating in deep mud dirt or water Axle Wheel Retainer Cap Screws or Stud Nuts after first 10 hours check and tighten to proper torque value if needed Axle Differential Oil Level Check after first 10 hours Hoses Connections Cylinders Inspect for leaks and damage Ti
23. metal or allow jumper cable ends to touch each other Sparks may occur causing damage to battery and personal injury 4 Besure negative terminal of battery is connected to engine with negative battery cable 5 Connect end of first jumper cable to 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 other end of second jumper cable to a metal part of engine DO NOT connect last jumper cable end directly to negative terminal of machine battery This can cause spark to destroy battery and cause personal injury should battery explode Connect last jumper cable to a metal part of engine AN WARNING Batteries contain acid which burns eyes and skin on contact Wear goggles protective clothing and rubber gloves to keep acid off body In case of battery acid contact wash immediately with water and seek immediate medical attention 7 Check be sure cables are away from fans and belts 8 Startmachine engine 9 After engine starts remove negative jumper cable connected to engine FIRST 10 Next remove jumper cable from machine battery positive terminal 11 Then remove jumper cables from extra battery AN WARNING Do not jump start or charge a frozen battery Warm battery to 60 degrees F 16 degrees C before connecting to a charger Unplug charger before connecting
24. on bottom of cap 3 Start engine and run just above an idle 4 Loosen jamb nut on standy differencial set screw o Adjust standby differencial set screw to between 400 450 PSI 6 Tighten jamb nut replace cap Compensator Pilot Differential Lock 7 With engine just above idle stall out the lift or tilt function 8 Loosen amb nut on compensator set screw 9 Adjust compensator set screw with function stalled out set accessory pump pressure compensator to 3600 PSI 10 Tighten jamb nut replace cap 11 Shut down engine 12 Remove pressure gauge On machines with multiple pressure outputs in the cab check pressure gauge against cab display for accuracy Standby Differencial Seal Jamb Nut Set Screw 930 937 Mulcher S 800 00258 page 39 MULCHER MACHINE PRESSURE SETTINGS CONTINUED DIFFERENTIAL LOCK SERVO VALVE PRESSURE ADJUSTMENT PROCEDURE Servo Door Switch E y 9 New Style Switch Old Style Switch Pressure Adjustment Screw 1 Close the cab door to engage the servo There are servo switches one located in both doors Adjustments cannot be made if the servo is disengaged 2 Install pressure gauge on Pilot Supply Pressure Check Port PS2 on the bottom of the Differential Lock Servo Valve 3 Start the engine and run just above an idle 4 Turn ON the differential lock switch located on the instrument panel in the cab 5 Loosen the Jamb Nut 6
25. or corrosion in the threads and will not gall seize or block the threads APPLICATION The pipe thread sealer is intended for use on threaded steel pipe in fixed installations It can be easily applied by the tube it comes in This sealer is intended for use with petroleum fluids only Apply sealer sparingly and leave the first two threads near the end of the pipe or fitting bare Barko recommends the use of pipe thread sealer on all exterior pipe plug threads and pipe fittings 930 937 Mulcher S 800 00258 page 53 HYDRAULIC CYLINDER MAINTENANCE Hydraulic cylinders provide force used to operate booms attachment and stabilizers Proper maintenance of cylinders will promote long life and smooth operation Inspect cylinders daily for leaks or damage and repair or replace as necessary Lubricate cylinder grease fittings daily Cylinder shown may not be type used on your machine but is shown as a reference 6 Bolt Torque Pattern BUSHING 6 _ REASE FITTING BARREL butt amp tube assy 8 Bolt Torque Pattern 7 1 O N 5 2 GREASE FITTING 5 A STROKE LIMITER GLAND BUSHING 10 Bolt Torque Pattern 10 1 HEX HEAD CAP ROD SCREWS SEAL SERVICING 1 Remove cylinder from the machine 2 Remove the bolts screws from the gland NOTE Some cylinders have screw on gland caps held in place with an allen head set screw If so remove set screw and then removing gland cap using an adjustable chain
26. the element is the correct model number It may be too short for the housing 7 REINSTALL DUST CUP Be sure the dust cup seals 360 degrees around the air cleaner body and the directional arrows are pointing up 8 CHECK CONNECTIONS amp DUCTS FOR AIR TIGHT FIT Check that all clamps and flange joints are tight as well as cleaner mounting bolts Seal any leaks immediately they mean dirt is directly entering your engine All duct joints from air cleaner to engine must be tight 9 RESET THE RESTRICTION INDICATOR If air cleaner is equipped with a restriction indicator reset it to the green zone 930 937 Mulcher 5 page 89 800 00258 AIR CLEANER MAINTENANCE CONTINUED THE IMPORTANT DON TS TO ALWAYS REMEMBER DON T REMOVE ELEMENT FOR INPECTION Such a check will always do more harm to your engine than good Ridges of dirt on the gasket sealing surface can drop on the clean filter side when the gasket is released Stick with the schedule If you are on restriction maintenance follow your reading or get a new indicator if you don t trust it NEVER AN ELEMENT TO CLEAN IT THIS WILL ONLY DESTROY IT Rapping hard enough to knock off dust often damages the element and destroys your engine protection Deeply embedded dirt is never released by tapping It s always safer to keep operating until you can change to a fresh filter NEVER JUDGE YOUR ELEMENT S LIFE BY LOOKING AT IT A
27. valve bank Final torque should be K170 valves M 43 Ft Lbs 60 Nm K220 valves 99 Ft Lbs 80 Nm 90 lt 33 Ft Lbs 45 Nm 930 937 Mulcher S 800 00258 page 27 GENERAL TORQUE SPECIFICATIONS See Special Torque Specifications that pertain specifically to this machine LUBRICATED WARNING ICOARSE FINE COARSE FINE 9 10 5 Grade 9 bolts must be used with Grade 9 washers 25 WARNING Do not re use grade 8 or grade GRADE 5 9 bolts or nuts replace with new ones SAE GRADE 5 RECOMMENDED TORQUE FOOT WARNING POUNDS Loose or overtorqued bolts can cause death severe injury or property damage Maintain proper bolt torque Visually check bolts daily Check DIA DRY torque every 50 hours COARSE FINE COARSE 12 25 44 70 107 154 GRADE 8 212 376 SAE GRADE 8 606 RECOMMENDED 909 TORQUE FOOT POUNDS This is lubed torque Lubricate 22 DRY LUBRICATED compound part no COARSE FINE COARSE FINE 17 19 1 4 12 5 16 34 22 3 8 60 41 7 16 96 65 1 2 145 100 GRADE 9 9 16 210 140 MIN 8 RADIAL 2 8 290 200 MARKS ON 515 345 HEAD GRADE 830 590 9 1 1250 810 BOW MALLOY 1750 1170 RECOMMENDED 2500 1650 TORQUE FOOT 3250 2220 SOUND 1 4350 2900 930 937 Mulcher S 800 00258 page 28 B HYDRAULIC SYSTEM C C 25
28. 0 937 Mulcher S p a g e 1 7 800 00258 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 machine See warnings and instructions both at the beginning and throughout this manual After doing service or making repairs or adjustments always check function of machine 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
29. 06 AX 9909900000096 7 NV CNA WARRANTY BARKO HYDRAULICS LLC 2 BARKO HYDRAULICS L L C Barko warrants to the Distributor and or original Buyer each new hydraulic knuckle boom loader feller buncher Mulcher 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 servi
30. 1 0 800 00258 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 body away from areas ejecting fluid Use piece of cardboard to Wear proper hand and eye check for leaks protection Relieve hydraulic pressure before loosening any hydraulic connections Tighten all hydraulic connections before applying hydraulic pressure 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 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 Never use fuel for cleaning Clean up any fluid spills immediately ventilation purposes WARNING Before operating transparent material such as s
31. Adjust the Pressure Reducing Valve to 625 PSI DO NOT EXCEED 625 PSI OR DAMAGE TO THE AXLE WILL OCCUR Standby Compensator Pilot Differential Lock 7 Tighten Jamb Nut 8 Turn OFF the differential lock switch located on the instrument panel in the cab 9 Shutdown engine 10 Remove pressure gauge NOTE With the differential lock switch in the cab disengaged pressure will read 450 500 PSI this is standby pressure for the Accessory Pump 930 937 Mulcher S 800 00258 page 40 MULCHER MACHINE PRESSURE ADJUSTMENT PROCEDURE CONTINUED SAUER MULCHER PUMP CHARGE PRESSURE ADJUSTMENT PROCEDURE NOTE All following adjustment can be made using the Diagnostic Pressure Display in the cab Make sure you are on the correct setting or that the pressure transducer is on the ae correct test port when making adjustments Pressures are 2 not affected by servo switches cab doors lt DIAGNOSTIC PRESSUR 4 1 Turn Dial to 4 on the Diagnostic Pressure Display or install pressure gauge on Mulcher pump forward test port 2 Start engine run at full throttle Mulcher pressure is directly affected by engine speed if the pressures are set at a low engine speed your pressure could exceed the capacity of the mulcher head and full engine speed Make sure the mulcher attachmentis notrunning 3 Loosen jamb nut on charge pressure set screw 4 Adjust charge pressure set screw to between 300 400 PSI Adjustments
32. BARKO A 930 937 MULCHER SERVICE MANUAL 930 937 Mulcher Machine Serial Number NOTE The operating and safety instructions for a Attachment are not included in this manual See separate Attachment 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 presenton your loader Therightis reserved by Barko Hydraulics LLC to make changes improvements in its product at any time without notice or obligation BARKO HYDRAULICS LLC 1 BANKS AVENUE SUPERIOR WI 54880 phone 715 392 5641 e fax 715 392 3931 website www barko com e email barkohydraulics barko com OPERATORS 800 00256 PARTS 800 00257 SERVICE 800 00258 TABLE OF CONTENTS INTRODUCTION 3 ELECTRICAL 5 58 2 4 Electrical Schematic 59 Abbreviations and 5 Electrical Schematic JohnDeere 61 s 7 Heater Air Conditioner Electrical Schematic 63 Know Your Machine 8 Electrical System Maintenance 65 Safety Summary 9 Electrical System Description 65 Fire Prevention 14 Elec
33. EERE ONLY WING NUT AIR CLEANER BODY CUMMINS ONLY Figure 2 930 937 Mulcher S 800 00258 page 87 AIR CLEANER MAINTENANCE CONTINUED AIR CLEANERS WITH VACUATOR VALVE On vacuator valve equipped models see figure 3 dust cup service is cut to a minimum A quick check to see that the vacuator valve is not inverted damaged or plugged is all that is necessary DUST CUP Squeeze valve daily to keep open VACUATOR VALVE Figure 3 CHECKING AIR CLEANER RESTRICTION Check the Air Cleaner Restriction Indicator daily for restriction Restriction is caused by dust and dirt accumulating on the Air Cleaner Element The method used to check the restriction will depend upon the type of Air Cleaner on the machine AIR CLEANERS WITH RESTRICTION INDICATORS These air cleaners have a restriction indicator mounted to the Air Cleaner body see Figure 4 The indicator plunger will be in the green zone when the Air Cleaner is empty and will move up towards the red zone when the Air Cleaner is full of dust and dirt When in the red zone this means the Air Cleaner element needs to be replaced See Replacing The Air Cleaner Element later on AIR CLEANERS WITHOUT RESTRICTION INDICATORS Measure the restriction 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 restriction has reached the maximum al
34. IR INTAKE FILTER CLEANOUT FAN MULCHERS This fan is located in front of the fresh air intake filter and is used to purge the filter of dust debris and clean it out The switch to activate this fan is located on the instrument panel however the air conditioner fan must be turned OFF before turning the cleanout fan on The cleanout fan pulls air back through the filter to purge it and will not work properly if the air conditioner fan is turned on Periodically throughout mulcher operation turn off the air conditioner and turn on the cleanout fan to purge the fresh air intake filter of dust and debris This does not eliminate the need for filter replacement which on mulchers must occur on a regular basis but helps to keep the fresh air intake filter from being continually plugged RECEIVER DRYER INSTALLATION When installing replacing the receiver dryer always install it in a vertical position with sight glass and fittings at the top in order for the heater air conditioner to work properly 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 930 937 Mulcher S 800 00258 page 72 AIR CONDITIONER MAINTENANCE 930 937 MULCHER CONTINUED AIR CONDITIONER TROUBLE SHOOTING To display diagnostics depress the ON key three times The digital display will then display any active fault codes Pressing th
35. N Do not 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 AN 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 AN CAUTION 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 REMEMBER SAFETY FIRST 93
36. No A C Clutch Power 1 If A C clutch does not engage check the red power wire to clutch relay 2 Check clutchrelay forengagement Setthetemperature control to a HIGH value and turn the defrost DEF button on The relay should engage Turn the defrost button off and the relay should disengage Note there may be a few seconds of delay before engagement or disengagement 3 The yellow wire to clutch relay grounds relay Check that ECU is grounding yellow wire and relay operates Manually ground yellow totestrelay Problem Blower Fan Not Turning On Blower Fan 1 Ifeverything else works but the blower fan does not turn on check the wiring If the wiring is found to be good check for voltage on orange power wire to motor and check black ground wire for ground If there 15 no voltage orange power wire replace ECU 2 If power is on orange power wire to motor motor should operate Test motor with independent power and ground If motor doesn t operate with independent power and ground replace motor If motor does operate with independent power replace ECU 930 937 Mulcher S 800 00258 page 74 AIR CONDITIONER TROUBLE SHOOTING 930 937 MULCHER CONTINUED ATC CONTROLLER INTERFERENCE It has been discovered that the Programmable Control Panel may have some RFI interference that causes the panel to change programs This does not happen on all units We have a choke filter available If your system does not have the
37. PS 1311 TT a 2 ea T B SLi lt WINCH PRESSURE FLOW 2500PSI 15GPM GATE PRESSURE 2 5 gt CU Y 930 937 Mulcher S 800 00258 page 33 607 00149 HYDRAULIC SCHEMATIC SSVdAd ISd 98 rnm 3 LETTER on LIVHS INXA HHH YOLOW 31V9 HSNd Li lind 22 1 5 141 LL NI 92 6 ii 9 5 92 43315 34 930 937 Mulcher 800 00258 765 40040 HYDRAULIC ASSEMBLY REAR FRAME G09 oa eta 6 81 72 Qi N page 35 930 937 Mulcher 800 00258 v09 XMULCHER CASE DRAIN d its 77 more aaa WOH n 131 843H2 InW SIOYLNOD 1004 115 1 007 al L HYDRAULIC ASSEMBLY FRONT FRAME 1311 5 174 409 C MULCHER CASE DRAIN Ei avg lt 36 363 lim V4 321 350 930 937 Mulcher S 800 00258 page 36 COHOSNIAC2 7 lt 1 4 ________ NE 1411 lt 71765 40040 9
38. TEMP UP TEMP DOWN keys to change the selected setting Barko Programming PO 1 P1 2 P2 1 P3 4 P4 3 5 8 P6 8 0 P8 0 P9 1 2 3 0 PD 0 PE 0 PF 0 930 937 Mulcher S 800 00258 page 79 AIR CONDITIONER TROUBLE SHOOTING 930 937 MULCHER CONTINUED 5 Turn off when done programming 6 Check error code display by pressing the on key three times quickly Should read EQ 930 937 Mulcher S 800 00258 page 80 D POWER UNIT MAINTENANCE C ENGINE MAINTENANCE The standard source of power for the hydraulic system in this machine is a Cummins 6C diesel engine The John Deere engine is optional Complete specifications operating instructions and maintenance and lubrication information will be found in the Cummins or John Deere engine manual which accompanies the machine Either of these manuals may also include information on other similar engines Be sure to use only the information which applies to the engine used on your machine 930 937 Mulcher S 800 00258 page 82 PUMP DRIVE MAINTENANCE FOR FUNK PUMP DRIVES A TWO THREE AND FOUR PAD PUMP DRIVES 2 PAD PUMP DRIVE 3 PAD PUMP DRIVE 4 PAD PUMP DRIVE Figure 1 LUBRICANT RECOMMENDATIONS AND FLUID CHANGING PROCEDURES A Lubricant Type EP 80 90 gear fluid except for direct drive models B Lubricant Grade Weather Temperature Below 10 degrees F 23 d
39. TIC TH d 8 19121102 0990 2 xis 565 E nem ul 5 ES CN 1504334 804 6962 ELME 18222 1 28 sam 99 81 S4 13 v9 3 78 pu z o Suto Sh pri 81 5 8 99 8 ADT3A 95 2144 9 6 02 29 0 S9 T 5 9014 930 81 NADJA 9 lt 81 NAUES 9 Ev SSANAVH Ack ELECTRICAL SYSTEM MAINTENANCE ELECTRICAL SYSTEM DESCRIPTION This machine has 12 Volt electrical system with alternator negative ground and 12 Volt battery There are two basic circuits in the electrical system 1 Charging circuit alternator and battery 2 Starting circuit switch solenoid battery and starter NOTE Disconnect battery ground cable before making any repairs to electrical circuits In addition to the two basic circuits there is an accessories circuit and operating light circuit s ELECTRICAL SYSTEM INSPECTION Check for Clean and tight battery cables Be sure all cables are clean and tight Remove any acid or corrosion from battery cables with baking soda and water solution Cover terminals with grease
40. afety 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 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 Stay clear of drivelines when engine is running N 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 CAUTION Grease all pivot and cylinder points daily 930 937 Mulcher S p a g e 1 1 800 00258 SAFETY SUMMARY CONTINUED 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 both battery cables and all alternator connections or electrical and structural damage to machine may occur WARNING Hot and pressurized fluid can cause severe Let system cool befo
41. ase slowly to allow oil to drain into all sumps Confirm the oil level after allowing time for oil to flow into all compartments 3 Check differential oil level Remove the differential oil check plugs The oil level should be slightly above the check hole 930 937 Mulcher S 800 00258 page 56 AXLE MAINTENANCE JOHN DEERE CONTINUED GREASE See Figure 2 Depending on the expected air temperature range during use use grease shown on chart in Figure 2 Greases recommended are John Deere Moly High Temperature EP grease preferred SAE Multipurpose Grease with Extreme Pressure EP performance and containing 3 to 5 per cent molybdenum disulfide preferred Grease meeting MIL G 10924C specifications may be used as arctic grease NOTE Grease areas until grease flows out past the outer seal A low pressure hand grease gun is preferred rather than a power grease gun to prevent overgreasing and possible seal damage AXLE OUTER BEARING GREASE FITTING SAE NLGI 2 ec SAE NLGI 0 or 1 Arctic Grease BRAKE OPERATING OIL The same oil used to fill the axle differential assembly should also be used as the brake fluid The choice of oil used is of utmost importance to reduce the tendency for wet disk brakes to chatter under severe applications For the best durability and operation John Deere Hy Gard Transmission and Hydraulic Oils should be used Hy Gard is a m
42. can be made with machine off to keep components cooler 5 Tighten jamb nut 6 Shutdown engine HYDRAULIC PRESSURE PSI 7 Remove pressure gauge Charge Pressure Adjustments 930 937 Mulcher S 800 00258 page 41 MULCHER MACHINE PRESSURE ADJUSTMENT PROCEDURE CONTINUED SAUER MULCHER PUMP PRESSURE ADJUSTMENT PROCEDURE Mulcher Pump 1 10 11 12 13 14 15 16 11 18 19 20 21 Turn Dial to 4 on the Diagnostic Pressure Display or install pressure gauge on Mulcher pump acceleration test port Immobilized mulcher drum or cap off mulcher pressure and return lines Start engine run at full throttle Turn mulcher switch to ON position Loosen jamb nut on pump acceleration adjustment Adjustments for the Sauer Pump are located on the bottom of the pump Adjustments can be made with machine off to keep components cooler Adjust acceleration pressure set screw to 4800 PSI Acceleration pressure is the set screw farthest from the outside of the machine Tighten jamb nut Turn mulcher switch to off position Shut down engine Swap the electric wire to the other side of the pump controller located on bottom side of pump Turn Dial to 5 on the Diagnostic Pressure Display or install pressure gauge on Mulcher pump braking test port Start engine run at full throttle Electircal Connection Turn mulcher switch to ON position New Connection
43. ce 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
44. cher Head Lift up port A 4000 PSI down port B 4000 PSI Mulcher Head up port B 4000 PSI down port A 2500 PSI iue E up port A 2500 PSI close port B 2500 PSI System Pressure set at Accessory Pump 3600 PSI 4 4 s 1 Figure 1 Top View of Mulcher Valve Bank 930 937 Mulcher S 800 00258 37 MULCHER MACHINE PRESSURE ADJUSTMENTS CONTINUED PUMP LAYOUT Sauer Safety relief Mulcher Pump Rexroth Accessory Pump Max Pressure POR Compensater Standby Mulcher Pump Max Charge Metaris Rexroth Differencial pressure set screws Pressure Fan Pump Drive Pump Sauer Mulcher Pump Rexroth Accessory Pump Forward Pressure Sauer Drive OM Pump Reverse Pressure Compensater Standby Charge Denison Fan harge Differencial Pressure Pump Pressure 930 937 Mulcher S 800 00258 page 38 REXROTH ACCESSORY PUMP MULCHER MACHINE PRESSURE ADJUSTMENTS CONTINUED REXROTH ACCESSORY PUMP ADJUSTMENT PROCEDURE Standby Compensator 1 Install pressure gauge on the standby pressure check located on the firewall under manifold 2 Remove caps on pressure adjustment screws When removing be careful not to loose seal
45. djustment Procedure 6 Capand plug fittings This allows pump to come on stroke with parking brake locked 7 Start engine run just above an idle 8 Shifttransfer case into high range 9 Slowly depress travel pedal to gradually pressurize forward travel WARNING Watch to make sure machine is not moving before making adjustments 10 While watching pressure gauges gauge on Test Port M4 should read 0 PSI until you reach begin of shift pressure When pressure begins to rise on the gauge located on Test Port M4 the reading on Test Port A is the begin of stroke point Test Port B Test Port M4 11 Loosen jamb nut 12 Adjust begin of stroke set screw to between 3800 4000 PSI Turn screw in clockwise to lower begin of stroke point setting and out counterclockwise to raise begin of stroke point setting 13 Tighten jamb nut 14 Release travel pedal 15 Repeat steps 9 thru 14 until required begin of stroke point setting is achieved and stable 16 After obtaining desired setting Shut down engine 17 Replace travel pump centering hose 18 Remove pressure gauges CAUTION Ports may contain trapped pressure Use care when removing gauges and installing plugs 930 937 Mulcher S 800 00258 page 46 HYDRAULIC HOSE HOOKUP MULCHER Tilt Forward Tilt Back Tilt Back Tilt Forward Return Case Drain A Push Bar B Push Bar 227 Lift arms lift cylinders lift hoses are
46. e Sediment and water should not exceed 0 1096 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 930 937 Mulcher S 800 00258 page 25 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 leak
47. e machine resumes operating Extinguisher manufacturers recommended service interval should be followed Donotuse ether or starting fluids on diesel engines with glow plugs These starting aids can explode and injure bystanders Before doing welding of any kind clean machine and disconnect battery cables Cover rubber hoses battery amp other flammable parts Never ground arc welder or electrical accessories through machine components as arcing may occur causing bearing damage Keep fire extinguisher nearby AN 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 structural damage Stop engine amp allow it to cool before adding fuel Never smoke while handling fuel or working on fuel or hydraulic system Read Engine Manual accompanying this manual for complete engine operating and engine safety instructions Use proper battery hook up procedures See Electrical System section in service manual The following areas are the most common places for fires to start Hydraulic 930 937 Mulcher S 800 00258 page 14 Exhaust Manifold Engine Block Turbocharger Pump Drive Parking Brake Serial MODEL DESCRIPTION Numb Entry Door Ta di Emergency door on ag opposite side of cab Centralized Fuel Reservoir Cab Lube System Hydraulic Oil Reservoir on op
48. e ON again will scroll through any existing error codes Fault Codes Displayed EOO Cab Sensor Shorted Displayed EO1 Cab Sensor Open Displayed E02 Evaporator Probe Shorted Displayed E03 Evaporator Probe Open Displayed E04 Outlet Sensor Shorted ERROR E05 not used Outlet Sensor Open ERROR E06 not used Ambient Sensor Shorted ERROR E07 not used Ambient Sensor Open ERROR E06 not used Water Valve Shorted Displayed EO9 Water Valve Open Displayed E10 Low Voltage c Displayed E17 Communications to Panel from ECU Displayed E17 Additional Troubleshooting No Display Turn on Control Panel with the ON key Check to see if the display illuminates e Verify that the Control Panel is plugged into the wire harness Check to see if wire harness 15 wired into vehicle properly Problem Control Panel Not Working or Nothing Works Control Panel 1 If the control panel shows a display when turned on the control panel 1 getting power 2 Disconnect one of the sensors Cab temperature or evaporator pr
49. e next to metal install around pilot Cross new gasket material ends as shown behind bolt hole and let ends extend beyond flange Use caution in assembly to case to On flywheel housings involving more than 4 bolt prevent gasket dislocation 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 TYPICAL ADAPTOR PLATE CORD GASKET LET ENDS EXTEND BEYOND FLANGE 5 REPLACEMENT OF OIL SEAL Install oil seal from engine side of engine adaptor The rubber lip of the oil seal must point toward the inside of pump drive gear box NOTE Drive in direction of arrow Drive Plate Models When installing drive plate on flywheel be sure the long end of the drive plate hub is toward the engine The hub should slide into the pilot bearing bore of the flywheel to ensure proper alignment of the drive hub and drive shaft 930 937 Mulcher S NOTE Arrow indicates engine side omia page 85 PUMP DRIVE MAINTENANCE CONTINUED B SINGLE PAD PUMP DRIVES This type of Pump Drive See Figure 4 is mounted to the engine and is virtually maintenance free Figure 4 If a Disconnect Clutch optional is ordered on your machine the following maintenance must be done C OPTIONAL DISCONNECT CLUTCH If clutch does not pull heats or operating lever jumps out adjustment is required To adjust clutch remove hand hole plate
50. e 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 98 930 937 Mulcher S 800 00258 page 7 00043000 SIS SSIS SOS SSS ISS SOP SIS SPD PG 20 000000000000000000000 30033 000000000000000 0000000000000 5 225 9 54 NAN QQ0OQQQOQQQC yyy VS 2 16 6 66466666666 lt 442 DU 90060 i 1000000000000000 091 QUU v9 d KNOW YOUR MACHINE The following is a list of ten important safety precautions and warnings you should read throu
51. egrees Use 75 W Funk Use 40W Durst Terrell Above 10 degrees F and up to 100 degrees F 37 8 degrees C Use 80 W 90 Above 100 degrees 37 8 degrees Use 85 W 140 C Filling Capacities For Funk until fluid comes back out of the fill hole Do not overfill For Durst Terrell the following are approximate amounts fill to level plugs or dipstick level only vertical mount 1 1 2 quarts 1 42 Liters Do not overfill horizontal mount 4 1 2 quarts 4 23 Liters Do not overfill CAUTION Do not overfill This will result in overheating and possible malfunction of the unit It is recommended that the fluid level be checked daily at the same 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 D Checking Changing Adding Fluid 1 Stop engine before checking or adding fluid 2 Check unit for operational warning tags Heed all warnings 3 Clean around fluid fill before checking or adding fluid 4 Change the fluid after every 400 hours of operation Also the fluid in the unit should be changed whenever the fluid level shows traces of dirt or effects of high temperature evidenced by discoloration or strong odor 930 937 Mulcher S 800 00258 page 83 PUMP DRIVE MAINTENANCE CONTINUED 5 Drain the fluid while the unit is still warm examining for contamination or metal particles 6 Clean all magnetic drain plugs before
52. ernator connector the BAT connector Alternator No 1 terminal No 2 terminal BAT terminal Figure 2 930 937 Mulcher S 800 00258 page 67 ELECTRICAL SYSTEM MAINTENANCE CONTINUED If any of these tests show zero voltage repair or replace wiring 4 Check voltage again until correct reading appears CHECKING ALTERNATOR OUTPUT 1 Disconnect negative battery cable 2 Remove wire from BAT connector on alternator and fasten it to one connector of an ammeter Fasten other connector of ammeter to BAT connector of alternator 3 Connect battery cable again 4 Remove hot wire from electric solenoid on fuel injection pump and turn engine with starter for approximately 30 seconds to cause a partial discharge of battery o Install hot wire on electrical solenoid and start engine and run at full engine RPM 6 The ammeter reading must be within 10 percent of rated 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 Usesteps 1 through 5 of Checking Alternator Output 2 Putasmall screwdriver in test hole See Figure 3 Alternator No 1 terminal No 2 terminal BAT terminal Test Hole Figure 3 3 Ifthe ammeter reading is not within 10 percent of rated amperage marked on alternator case regulator may be damaged Check diode trio rectifier stator or
53. gh and understand before operating your machine 10 Don t assume that because you know the control functions of other similar machinery that you can run the Barko Mulcher All machines differ in some ways and these differences must be noted and acknowledged Read this manual thoroughly and understand all operating and safety procedures before operating the machine Know how to put your machine in a zero energy state for purposes of inspection maintenance or repair Clear operating area of all obstacles and personnel before operating machine Never approach power lines with any part of the machine Current in a high voltage power line may arc some distance to jump from the wire to a nearby ground KEEP WELL CLEAR Never use the mulcher attachment or any other part of the machine as a work platform or personnel carrier Serious injury or death may result 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 When machine is not operating or before leaving cab shut down machine and lower mulcher attachment to the ground Failure to do so may allow mulching attachment to move or fall Causing property damage injury or death Do not allow personnel under raised lift arms or head for any reason unless lift arms are su
54. ghten repair or replace parts if necessary Operator s Platform Clean area of debris tools rags water ice and snow Bolts Nuts Visually inspect for wear or damage Py Fittings Lubricate as shown Lubrication Points Use a multi purpose grease Transmission Check fluid level Add fluid if necessary See Lubrication Points for type Hydraulic Oil Filter On new machines the filter element should be replaced first at 50hrs and then at 400 hrs thereafter Hydraulic Oil Reservoir On new machines the oil must be changed after the first 50 hours and then every 1000 hours after that 930 937 Mulcher S 800 00258 page 19 SERVICE SCHEDULE CONTINUED 8 hours 50 hours 100 hours 400 hours 1000 hrs Axle Wheel Retainer Cap Screws or StudNuts after first 50 hours check and tighten to proper torque value if needed Axle Differential Level Check afterfrrstSOhrs 212 11 10 Safety treads safety signs seat belt Check for damaged or missing items and replace 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 Axle Differential Oil Change after first 100 hours Entire Machine Steam clean when dirty or every month Inspect for stress wear cracks damage and loose parts Accumulators Check pressure and maintain at 1200 PSI Your Barko built machine is
55. ground when ON G Pull to Ground when Defrost H Pull to Ground when Heating Configuration setting information Defrost AC Function 1 Force On 2 Force Off Cfg1 Econ Function O Econ 1 A C 2 None Cfg2 Use full blower in defrost mode 1 Yes Cfg3 Cab Sensor 0 1 0K 1 2 83K 2 3 0K 3 5 0K 4 10K 5 30K 8 None Cfg4 Evap Sensor 0 1 0K 1 2 83K 2 3 0K 3 5 0K 4 10K 5 30K 8 None Cfg5 Ambient Sensor 0 1 0K 1 2 83K 2 3 0K 3 5 0K 4 10K 5 30K 8 None Cfg6 Duct Sensor 0 1 0K 1 2 83K 2 3 0K 3 5 0K 4 10K 5 30K 8 None Cfg Load Shed O None 1 Vin 2 Input 1 3 Both Cfg8 Cfg9 CfgA CfgB CfgC CfgD CfgE CfgF Configuration Set O Custom 930 937 Mulcher S 800 00258 page 77 AIR CONDITIONER TROUBLE SHOOTING 930 937 MULCHER CONTINUED Programming 1 on 2 Error code display mode is accessed by pressing the ON key three times quickly 3 The advanced diagnostics display mode is activated by pressing and holding the ON key for five seconds while the error code display is active CAb will display 4 The parameter function is activated by pressing and holding the OFF key for five seconds while the advanced diagnostics display mode is active 930 937 Mulcher S 800 00258 page 78 AIR CONDITIONER TROUBLE SHOOTING 930 937 MULCHER CONTINUED Press the FAN DOWN keys to select a config setting Press the
56. hat 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 INFORMATION All requests for information service or spare parts should include loader serial number For more information contact Barko Hydraulics L LC One Banks Avenue Duluth MN 55816 Phone 715 392 5641 Fax 715 392 3931 Website www barko com Email barkohydraulics barko com REFERENCE The Mulcher serial number plate is located on the front frame assembly 930 937 Mulcher 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 930 937 Mulcher S p a g e 4 800 00258 ABBREVIATIONS AND SYMBOLS air conditioner Artic
57. head cap screws require 15 16 wrench Nut requires 3 1 8 wrench 930 937 Mulcher S 800 00258 page 54 Piston and Gland shown may not be type used on your machine but are shown as a reference SEAL PLIERS PART 412 00409 BEING USED TO BEND SEAL FOR INSTALLATION 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 manufacture date item 5 and 7 may be on either side of item 6 NOJDESCRIPTION SEAL PISTON WEAR RING O RING BACK UP RING SQUARE RING ROD BUFFER WEAR RING SEAL SEAL ROD DEEP WIPER MODULAR BACKUP RING O RING 1 2 3 4 5 6 7 8 9 1 1 930 937 Mulcher S 800 00258 page 55 AXLE MAINTENANCE JOHN DEERE LUBRICANTS DIFFERENTIAL OIL TYPES See Figure 1 The choice of oil used in the axle assembly is of utmost importance to reduce the tendency for wet disk brakes to chatter under severe applications For the best durability and operation Deere Hy Gard Transmission and Hydraulic Oils should be used Hy Gard is a mineral based oil with special additives for wet disk brakes These oils are formulated to reduce gear and bearing wear reduce brake noise reduce foaming and maintain brake capacity and torque Use of other oils may compromise one or more of those properties with less than desirable results NEVER use a hydraulic brake fluid SAE J70 of the type co
58. hine is suggested especially if flammable liquid spills have occurred FIRE PREVENTION CHECK LIST The following list provides data which will help to prevent fires Do not use machine in areas with explosive dust or gases These elements can be ignited by arcs sparks hot components or fumes Inspect cab engine compartment and engine cooling system every day Clean if needed to prevent overheating Remove all flammable material rags debris fluid spills etc Inspect electrical system for damage daily Keep battery terminals clean amp tight Replace or repair any damaged part Daily inspect all fuel and hydraulic oil tubes hoses and fittings for damage and leakage Tighten or replace as needed Always clean fluid spills Allow machine to cool down by idling engine for a while before shutdown Many engine and transmission fires start after shut down This waiting time can be used to inspect machine and perform certain maintenance procedures Keep fire extinguisher water hose connected to water tank and first aid kit where 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 use of fire extinguisher and fire suppression equipment Any portable extinguisher or fire suppression system carried on machine that has been used must be recharged or replaced befor
59. iction measurement tools you will use the full life of the filter at maximum efficiency 2 Improper Servicing Your engine is highly vulnerable to abrasive dust contaminants during the servicing process THE MOST COMMON CAUSE OF ENGINE DAMAGE IS DUE TO CARELESS SERVICE PROCEDURES By following the 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 to ensure that the air cleaner bonnet or pre cleaner is free AIR CLEANER of leaves twigs etc that are drawn in while the machine is BONNET OR working See Figure 1 eres e NOTE This is especially important in the fall months as the trees shed their leaves 2 Empty the pre cleaner dust cup or vacuator Frequency of this service will vary with dust conditions See Emptying The Dust Cup or Vacuator Valve 3 Checkthe restriction indicator daily When indicated change the element See Checking Air Cleaner Restriction EMPTYING THE DUST CUP Check the dust cup daily for dust build up When reinstalling the dust cup make sure it seals 360 degrees around the air cleaner body and the directional arrows are pointed in the UP position Dust cup does not need to be removed when the air cleaner is equiped with a vacuator See following vacuator instrucitons See Figure 2 Figure 1 SAFETY PRIMARY ELEMENT ELEMENT DUST CUP JOHN D
60. ineral based oil with special additives for wet disk brakes These oils are formulated to reduce gear and bearing wear reduce brake noise reduce foaming and maintain brake capacity and torque Use of other oils may compromise one or more of those properties with less than desirable results NEVER use a hydraulic brake fluid SAE 70 of the type commonly used in automotive applications Seals used at each brake piston use rubber compounds which are incompatible with this fluid and rapid deterioration of these packings is very likely to occur if such fluid is used 930 937 Mulcher S 800 00258 page 57 C ELECTRICAL SYSTEM C C 25 800 00258 2 Eg lt 8 1 5 LO 388 255 i 5 s 8 i 13 0 95 F TE i FRONT FRAME pec Ee Il 2 e gt 2 2 220 08 z Q 9 lt ELECTRICAL SGHEMATIC CUMMINS ENGI 903 00122 Replaced by 903 00140 Starting 8 20 07 TY HM M da ume T Ld Find T HT uid 25 jt 4 CIE Lo 4 KE ze KR 2008 771 si a m FU Tp
61. ing 6 orange brown on sides rear of machine 283 00020 DECAL Barko Strong Arm on both tanks 9539 01115 DECAL Barko Strong Arm on both tanks Charcoal w clear backround PLATE serial number on back side of front frame WARNING Replace any safety decals that are faded torn missing illegible or otherwise damaged WARNING Do not reproduce any decals listed or shown here for application on any Barko machine The decals used on Barko equipment are designed to meet strict specifications for adhesion temperature color layout and durability Any unauthorized reproduction of these decals will void the machine warranty Contact your Barko dealer to order any kits you may need 930 937 Mulcher S 800 00258 page 92
62. ir may be drawn in where fluid will not necessarily leak out 9 Fluid level too low This can cause vortexing at pump inlet in reservoir thus drawing in air 6 Airtrapped in filter with no means of bleed off 7 Return fluid discharged above fluid level in reservoir Poor baffling in the reservoir can also cause turbulence and resultant introduction of air 8 Airtrapped in system during original filling or when adding fluid for makeup DAMAGE TO THE SYSTEM The condition listed in the previous paragraph all contribute to inducing air into a hydraulic system This aeration can cause jerky and uneven movement in pumps and motors seizure overheating and possibly eventual failure HOW TO AVOID AERATION Regular inspection and regular maintenance are the best ways to prevent air from being introduced into a hydraulic system Keeping all connections and fittings tight is the easiest way to avoid the introduction of air Return fluid entering the reservoir will create aeration if it is discharged above the main body of the fluid in the tank To prevent this condition maintain sufficient fluid in the tank to keep the return line submerged The pump intake line should always be below the fluid surface for the same reason Improved service life depends on maintaining proper conditions within the system 930 937 Mulcher S 800 00258 page 52 HYDRAULIC FITTINGS HOSES AND TUBING A heavy wall tubing and multi wire hose network carries the
63. ith R134a refrigerant An overcharged system may cause damage to the compressor Fresh Air Pre Cleaner Compressor mounted to engine Air Conditioner Unit Evaporator Condenser Heater Hoses Air Conditioner Fresh Electric Actuated Air Intake Filter Water Valve 930 937 Mulcher S 800 00258 page 70 AIR CONDITIONER MAINTENANCE 930 937 MULCHER CONTINUED Hot High Pressure Gas Low Pressure Gas suction side Cold Low Outside Air Flow inside instrument Pressure Gas panel dash EXPANSION 1 gt I Nia 2 CONDENSER Saw Shear Machines Pn behind cab 112 lt 4 7 2 tat inside 285 shrouding Jm Mulcher Machines behind cab on Metered all topor Refrigerant shrouding EN ral EVAPORATOR Ny ae 7 Nd inside instrument panel dash Dy el High Pressure Liquid Thermostat near condenser Air Conditioner components are shown above connected together to illustrate system operation The components shown are not to scale The refrigerant and refrigerant oil are clear in color and not visible in this drawing The small arrows inside the components and connecting hoses show the direction of refrigerant flow The location of each component is in parenthesis Allow only certified personnel to service and maintain
64. l the second gauge on the Reverse Pressure Test POrt now Disconnect drive pump spool centering hose Cap and plug fittings This allows pump to come on stroke with parking brake locked Start engine run just above an Idle Engage parking brake Shift transfer case into high range Depress travel pedal to pressurize forward travel WARNING Watch to make sure machine is not moving Loosen jamb nut on Forward Pressure Adjustment Slowly adjust Forward Pressure Adjustment screw until pressure gauge reads 5000 PSI Tighten jamb nut Shut down engine Repeat steps for Reverse Pressure Adjustment Remove pressure gauge Connect spool centering hose 930 937 Mulcher S 800 00258 page 44 MULCHER MACHINE PRESSURE ADJUSTMENT PROCEDURE CONTINUED REXROTH DRIVE MOTOR PRESSURE ADJUSTMENT PROCEDURE HA CONTROL 1 10 11 12 13 14 15 16 17 18 Install pressure gauge on the M port located on the CHARGE RELIEF Turn dial to 6 on the Diagnostic Pressure Display or install a second pressure gauge on G port Switch parking brake ON Switch low lock to OFF position Disconnect travel pump spool centering hose Refer to Drive Pump Adjustment Procedure MINIMUM DISPLACEMENT ADJUSTMENT Cap and plug fittings Figure 4 Side View of Drive Motor This allows pump to come on stroke with parking brake locked Start engine run just above an idle Shift transfer case into high range
65. lowed by the engine manufacturer Contact the Barko Service Department for maximum values and any other questions concerning this method 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 REPLACING THE AIR CLEANER ELEMENT For minimum vehicle downtime replace dirty air cleaner element with a new element DO NOT CLEAN THE ELEMENT DO NOT CLEAN THE ELEMENT WITH AN AIR HOSE DO NOT SHAKE OR RAP ELEMENT DO NOT RUN ENGINE WITHOUT AN ELEMENT Do not leave air cleaner open to the environment longer than it takes to remove element inspect and clean inside of air cleaner body and install a new element When restriction indicates that element servicing is required see the replacement steps on the next page SAFETY ELEMENT SERVICE IF APPLICABLE The safety element is not intended to be cleaned For maximum engine protection and air cleaner service life replace the safety element with a new safety element every third primary element change 930 937 Mulcher S 800 00258 page 88 AIR CLEANER MAINTENANCE CONTINUED IMPORTANT STEPS TO FOLLOW EVERY TIME AN AIR CLEANER ELEMENT IS REPLACED 1 REMOVE THE OLD ELEMENT AS GENTLY AS POSSIBLE Loosen wing nut and remove old element Baby that dirty element until you get it clear out of the housing Accidentally bumping it while still inside means dropped dirt a
66. m diverter bypass valve assembly A Disposable Type Replace element if a disposable paper or synthetic media is used See next page 930 937 Mulcher S 800 00258 page 50 HYDRAULIC OIL FILTER MAINTENANCE CONTINUED B Cleanable Type Soak element in ultrasonic cleaner for fifteen minutes If an ultrasonic cleaner is not available soak in hot soapy water and ammonia solution for fifteen minutes Swish around and blow dry from the outside in 5 Replace element on diverter bypass valve assembly and install in filter housing Make sure that diverter o ring seats properly into filter head 6 Checkto make sure notch on diverter bypass valve assembly lines up with notch in filter head 7 Inspect cover o ring and replace it if necessary 8 Replace cover and tighten screws until they are snug Do not over tighten these screws FILTER ELEMENT REPLACEMENT INTERVALS On new machine filter elements should be replaced after 50 hours of operation and then every 400 hours of operation afterthat B THE SCREW ON ELEMENT FILTERS see Figure 2 These filters include the three drain filters located behind the cab rear wall inside the shrouding and the hand pump filter located near the hand pump that is used to fill the hydraulic oil reservoir They each contain a replaceable element See Parts Manual for complete parts breakdowns CHANGING FILTER ELEMENT 1 Unscrew filter element from filter head 2 Replace old element with new one Hand
67. mmonly used in automotive applications Seals used at each brake piston use rubber compounds which are incompatible with this fluid and rapid deterioration of these packings is very likely to occur if such fluid is used Alternative lubricants are available such as Amoco 1000 Transmission Hydraulic Oil Consult your dealer if you have a special situation Depending upon the expected air temperature range between oil changes use oil viscosity shown in Figure 1 OIL CHECK AND OR BRAKE INSPECTION PLUGS OIL FILL JDM J20A eO ac 4 Low Vis QUATROL Artic Oil OIL DRAIN S PLUG 400 Series Differential Housing shown Figure 1 CHECKING THE DIFFERENTIAL OIL LEVEL See Figure 1 1 Remove differential oil check plugs Oil level is correct when a few drops of oil flow out of the check hole 2 Add oil if needed NOTE The differential housing has three sumps connected by only a small hole Fill the case slowly to allow oil to drain into all sumps Confirm the oil level after allowing time for oil to flow into all compartments CHANGING THE DIFFERENTIAL OIL 1 Remove oil drain plug s and drain oil Reinsert drain plugs 2 Addoil The oil volumes are as follows 1200 Series 20 quarts 18 91 1600 Series 48 quarts 45 51 1400 Series 30 quarts 28 4 1 1800 Series 33 quarts 31 51 NOTE The differential housing has three sumps connected by only a small hole Fill the c
68. nd dust that may contaminate the clean side of your filter housing before the new filter element has a chance to do its job 2 ALWAYS CLEAN THE INSIDE OF THE HOUSING CAREFULLY Dirt left in the air cleaner housing spells death for your engine Use clean damp cloth to wipe every surface clean Check it visually to make sure it s clean before putting in a new element 3 ALWAYS CLEAN THE GASKET SEALING SURFACES OF THE HOUSING An improper gasket seal is one of the most common causes of engine contamination Make sure that all hardenend dirt ridges are completely removed both on the bottom and top of the cleaner 4 CHECK FOR UNEVEN DIRT PATTERNS ON YOUR ELEMENT I Your old element is a valuable clue to dust leakage or gasket sealing problems A pattern on the element clean side is a sign that the old element was not firmly sealed or that a dust leak exists Make certain the cause of that leak is identified and rectified before replacing the element o PRESS YOUR FRESH GASKET TO SEE IF IT SPRINGS BACK Make sure your new element is made with a highly compressible gasket that springs right back when your finger pressure is released A quality gasket is one of the most important parts of the element 6 MAKE SURE THE GASKET 15 SEATING EVENLY If you don t feel the gasket is seating evenly for a perfect seal you don t have protection Recheck to see if the sealing surface in the housing is clean or if
69. nd lift adaptor pads up from gear box 5 Lift driven gears and their bearings from pump drive box This can be done by hand since the bearings are slip fitted to the housing and pump adaptor bores Bearings are press fitted to gear hubs It may be necessary to tip gear slightly to clear pinion gear bearing pocket 930 937 Mulcher S 800 00258 page 84 PUMP DRIVE MAINTENANCE CONTINUED 6 After all driven gears and their bearings have been removed position gear box so that engine adaptor is facing up Remove place bolts and lift engine adaptor up from gear box Lift pinion gear and bearings from pump drive box 7 Should replacement of oil seal be required drive oil seal toward engine side of engine adaptor NOTE Drive in direction of arrow 8 remove bearings from gear hubs use gear puller or Arbor Press REASSEMBLY OF PUMP DRIVE For reassembly use the reverse procedure of 1 through 8 NOTE Plastic cord used for gasket material under pump adaptor plates and input housing is not reusable Replace with new material when reassembling See Figure 3 for installation of cord gasket Place bolts should not be reused Clean the old Locktite out of the bolt hole threads Install new place bolts with Locktite 262 on the engine adaptor and pump pad Place bolts are used in pump drive pad torque studs to 150 ft Ibs Remove protective paper strip from cord and with Do not attempt to reuse this gasket For assembly use adhesive sid
70. obe or unplug the water valve Press the ON key three times to enter the error checking mode The appropriate error code should be displayed If error code 15 displayed control to ECU is making connection If not check wire harness connections power the ECU module orreplace the control panel 3 Ifonly certain functions do not seem to work on the control panel inspect the keypad tail for being pinched If connector tailis pinched and or keys do not work replace control panel key pad SEE PHOTOS Arrow pointing to connector tail Problem Setpoint Temperature Not Maintained Properly Cab Temperature Sensor 4 pin white connector 1 Verify that fan is spinning Check for dust or debris and clean with dust off if necessary Clean connector plug 2 Voltage between Red and Black wires should be close to the vehicle voltage 12V or 24V 3 Voltage between two yellow wires should be between 0 and 5 volts when the sensor is not connected 4 Resistance across gray wires Sensorunplugged SEECHART 930 937 Mulcher S 800 00258 page 73 AIR CONDITIONER TROUBLE SHOOTING 930 937 MULCHER CONTINUED Problem Evaporator Core Icing Up Freezing Up Evaporator Probe 2 pin black connector 1 Set the control temperature to alow value Verify that the compressor is on Pull the probe and place 15 bath of ice water Compressor should turn off If not bump up the control temperature few degrees and try again 2
71. perate properly CAUTION Charge the 930 Mulcher Air Conditioner system with 1 14 oz of R134a refrigerant An overcharged system may cause damage to the compressor 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 RUNNING THE UNIT AS PREVENTIVE MAINTENANCE Run the air conditioner for a while every two weeks or so even in cold weather If the unit is unused for long periods of time seals shrink and components become stiff Running the unit is an easily performed procedure which can help prevent future problems FRESH AIR INTAKE FILTER This filter is located inside the instrument panel at the front see diagrams on first pages of Air Conditioner Maintenance and allows the air conditioner unit to draw fresh air from outside the cab for circulation On mulcher machines change the filter as often as needed to ensure normal operation of the filter This will be more often than for saw shear machines because of the dusty work environment of the filter during mulching See also Fresh air Intake Filter Cleanout Fan information below To change the filter remove the cover and replace the old one with a new one This is a disposable filter and should not be cleaned and reused FRESH A
72. posite side of machine Parallel Link Assemblies Shrouding over Power Unit Pumps Tilt Cylinders Front Frame Link Assemblies LINN Mulcher Attachmeny Lift Arms and Lift Cylinders Pivot Area and Steering Cylinders Lower Drivetrain and Rear Frame Exhaust Pipe Radiator Hydraulic Oil Reservoir Fuel Reservoir Transmission is under machine 930 937 Mulcher S 800 00258 page 15 A PREVENTIVE MAINTENANCE D 9 D 9 SAFETY WHILE SERVICING The following maintenance section gives suggested guidelines for operational maintenance on your machine 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 the machine Read and understand the warnings and safety precautions in the Safety Summary and elsewhere in this manual before doing any service on the machine The following precautions should be used as a reminder to safe servicing WARNING Always shut down the machine and lower the mulcher to the ground before working on the machine If necessary to work on a mulcher attachment securely support the attachment so that it cannot move or fall in any way AN CAUTIO
73. pport the attachment so that it cannot move or fall in any way 930 937 Mulcher S 800 00258 page 23 LUBRICATION POINTS CONTINUED PERFORM DAILY I GREASE 9 DRIVE TRAIN LUBRICATION Rear U joint Rear Slip Yoke Transmission U joint Front Slip Yoke Mid U joint if applicable Carrier Bearing if applicable Front U joint Axle Wheel Ends Axle Differentials see below for fluid type 10 Transmission see below for fluid type 11 Break see below for fluid type EAR AXLE 5 NA 0 0 n 10 3 4 5 6 7 Lf 8 1 or 2 es RENT AXLE m Axle Differentials John Deere Hy Gard or Amoco 1000 Transmission Hydraulic Oils Transmission 80 90 Gear Lube P d GREASE AXLE PIVOTS AND STEERING CYLINDER LUBRICATION The Centralized Lube System contains grease fittings which connect via hoses to axle pivots and steering cylinders Centralized Lube System location See detail at right 2 3 in 930 937 Mulcher S page 800 00258 CENTRALIZED LUBE SYSTEM RIGHT STEERING REAR CYLINDER AXLE PIVOT LEFT STEERING FRONT CYLINDER AXLE PIVOT Detail of Centralized Lube System 24 FLUID SPECIFICATIONS GREASE Use grease shown on chart below depending on the expected air temperature range AIR TEMPERATURE RANGE Fahrenheit
74. pported so that they cannot fall in any way Do not tamper with any hydraulic line while 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 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 930 937 Mulcher S 800 00258 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 J N DANGER N DANGER Never approach power lines with any pa
75. re removing any Then remove caps slowly burns caps WARNING Hot exhaust pipe can cause severe burns Do not touch exhaust pipe when hot or when engine is running 2416 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 CAUTION Use only hydraulic fluid in hydraulic oil reservoir Use only diesel fuel in fuel reservoir Other fluids will cause machine damage WARNING Always wear seat belt when operating or running machine pum CAUTION Check the Air Cleaner Assembly daily for cracks loose clamps or any other damage 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 Stay clear of pivot point Getting caught in the articulating area of this machine can cause death or severe injury Do not operate until area is clear of all personnel 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 WARNING Use caution when checking items beyond your reach Use an
76. replacing 7 Always use clean fluid in clean containers 8 Fill with fluid Do not overfill see B for temperature ratings see for capacities 9 Maximum operating fluid temperature 225 degrees F 107 2 degrees C WET SPLINE PUMP PADS If your pump drive is a Terrell it may have wet spline pump pads Oil for lubrication of the splines is added through the oil caps in the top of the pump pads the oil in the pump pad is kept separate from the oil inside the pump drive Add the specified amount see below to each pump pad Do not fill the pump pad completely full of oil C Pads 502 of 80 90 gear fluid D Pads of 80 90 gear fluid PUMP DRIVE DISASSEMBLY 1 Drain fluid from pump drive gear box by removing Allen head pipe plug from bottom of main case 2 Remove hydraulic pumps by removing capscrews or nuts from studs See Figure 2 Remove pumps straight away from pump drive ENGINE FLYWHEEL COVER ENGINE ADAPTOR PUMP DRIVE HYDRAULIC PUMPS FILL HOLE Figure 2 3 Remove pump drive from engine by removing capscrews holding engine adaptor housing to flywheel cover of engine Remove pump drive straight away from engine a Flex plate driven models The drive shaft will remain with either the drive plate or the pump drive box Be prepared to retrieve drive shaft from either 4 Pump drive gear box should be positioned so that the hydraulic pump adaptor pads are facing up Remove place bolts or nuts from studs a
77. rly inflated tires can cause excessive heat build up resulting in blowouts Always keep tires inflated to the proper pressure Unexpected blowouts may cause 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 TIRE INFLATION PRESSURE Tire pressure may vary slightly depending upon the tires 28L 26 Tires 30 PSI 930 937 Mulcher S 800 00258 page 22 GREASE X ENGINE OIL HYDRAULIC OIL EP 80 90 GEAR FLUID Is LUBRICATION POINTS PERFORM DAILY 1 Link to Attachment Pivots 9 Lift Cylinder to Front Frame Pivots 2 Link to Parallel Link Pivots 10 Upper Frame Pivots 3 Parallel Link to Lift Arm Pivots 11 Lower FramePivots 4 Lift Arm to Attachment Pivots 12 Hydraulic Oil Reservoir check level o Lift Arm to Front Frame Pivots 13 Pump Drive check level 6 Tilt Cylinder to Front Frame Pivots 14 Pump Drive Pads check level 7 Cylinder to Parallel Link Pivots 8 Lift Cylinder to Lift Arm Pivots For Drive Train Axle Pivots and Steering Cylinder Lubrication see next page For Attachment Lubrication see separate attachment manual See Pump Drive Maintenance for lubrication specifications Always shut down machine and lower Mulcher attachment to the ground before working on the machine If necessary to work on a lifted attachment securely su
78. rotor Damage to alternator can occur if battery connections are not connected properly wires from alternator are grounded engine is operated with battery cables disconnected cables are connected when using a fast charger or when welding on the loader Remove both cables from the battery extra battery cables booster cables are connected wrong 930 937 Mulcher S 800 00258 page 68 ELECTRICAL SYSTEM MAINTENANCE CONTINUED ELECTRICAL SYSTEM TROUBLE SHOOTING The following trouble shooting chart is provided as an assistance in locating and correcting problems which are most common PROBLEM CAUSE Battery does not hold it s charge 1 2 3 4 5 Alternator will not charge 1 2 5 Starter will not turn the engine 2 3 4 6 7 8 KEY TO CORRECT THE CAUSE Alternator belt is loose or damaged Battery connections are dirty of loose Battery is damaged The ground connection is not making a good contact The alternator is damaged The engine 15 locked The starter has damage The wiring or the solenoid is damaged 8509 10 85 930 937 Mulcher S 800 00258 page 69 AIR CONDITIONER SYSTEM LAYOUT 6 8 Heater Air 10 12 hose suction EE Com L pressor 5 956 CE Electric Actuated Water Valve CAUTION Charge the 930 937 Mulcher Air Conditioner system w
79. rt of the Do not allow personnel under raised head for machine Current in a high voltage line may arc any reason unless head is supported so that some distance to jump from the wire to a nearby they cannot fall in any way ground KEEP WELL CLEAR Do not operate machine during electrical storms WARNING WARNING Clear all persons and obstacles from area of operation and machine movement Do not move attachment over personnel Keep all personnel back 300 feet from machine when operating Flying debris can cause death or severe injury N WARNING Always lower the attachment to the ground and shut down machine before leaving cab N WARNING Know the prohibited uses or work areas for the machine and the hand signals used on the job 930 937 Mulcher S 800 00258 page 9 SAFETY SUMMARY CONTINUED 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 operator on machine Keep riders off Riders on machine are subject to injury such as being struck by foreign objects and being thrown off machine Riders also obstruct operator s view resulting in machine being operated in an un
80. s but do not use bare hand Wear safety goggles fluid enters skin or eyes get immediate medical attention 930 937 Mulcher S 800 00258 page 26 SPECIAL TORQUE SPECIFICATIONS WARNING WARNING Loose or overtorqued bolts can cause death In critical applications or for grade 8 or grade 9 severe injury or property damage Maintain bolts once the old bolts and nuts have been proper bolt torque Visually check bolts daily loosened they must be replaced rather than re Check torque every 50 hours tightened and re torqued Original clamping force cannot be achieved using the old bolts and nuts Lubricate with anti seize compound 514 00700 SPECIAL TORQUE SPECS FOR FRAME PIVOT On the Frame Pivot center section of machine there are cap screws that must be torqued as follows 1 80 85 Ft Lbs using Loctite 242 2 22 Ft Lbs using Loctite 271 3 90 95 Ft Lbs using Loctite 242 SPECIAL TORQUE SPECS FOR DRIVETRAIN Lubricate with anti seize compound 514 00 700 1 Rear axle mounting bolts 252Ft Lbs 2 Frontaxle mounting bolts 400Ft Lbs 3 Driveshaft mounting bolts 70 75 Ft Lbs 4 Wheel mounting bolts 226 Ft Lbs Change to Grade 8 bolts effective 09 01 08 and 310 Ft Lbs VALVE BANK STUDS NUTS Tighten in a clockwise pattern so that all nuts are tightened equally without binding on the
81. safe manner Never use the attachment or any other part of the machine as a work platform or personnel carrier Death or severe injury may result WARNING Be extra careful when traveling on a slope over rough ground near ditches and in congested areas The danger of tipping is always present Know your machine s capabilities CAUTION Ensure that tire pressure is within rated limits to prevent personal injury or damage to the machine WARNING Know how to put your machine in a zero energy state for purposes of inspection maintenance or repair DANGER Rotating mulcher blade will cause death or severe injury Do not start up mulcher until all personnel are 300 feet from Mulcher Shut down Mulcher head when not in use 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 Failure to keep the engine shrouding area free of flammable debris such as leaves twigs and wood chips may cause an extreme fire hazard KEEP THIS AREA CLEAN Keep a fire extinguisher on machine WARNING Before transporting Lower and secure attachment to trailer bed Shut down machine and apply parking brake Install articulating lock pin to prevent articulation Secure machine to trailer bed 930 937 Mulcher S p a g e
82. the air conditioning system The Clean Air Act of 1992 states that anyone who works on air conditioning systems must 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 Environmental Protection Agency EPA as organizations with approved independent testing and certification programs Contact your local EPA office for more information REFRIGERANT Always use refrigerant R134a in this equipment WARNING Air conditioning systems operate under extreme high pressure The containers refrigerants are sold in are also under pressure When released into the air a refrigerant boils away and becomes gas lts temperature drops INSTANTLY Improper handling can cause frostbite and eye damage it spills on your skin or in your eyes flood the area with cool water and SEEK MEDICAL ATTENTION IMMEDIATELY Breathing refrigerant gas can result in respiratory problems especially for people with cardiovascular disease Always wear safety goggles or a face shield and allow adequate ventilation when working with refrigerant 930 937 Mulcher S 800 00258 page 71 AIR CONDITIONER MAINTENANCE 930 937 MULCHER CONTINUED CHECKING ADDING REFRIGERANT Allow only certified personnel to service the heater air conditioner system For Barko 930 937 Mulcher 1 15 14 oz of refrigerant is required for the system to o
83. tighten new filter element to filter head CAUTION These filter elements are not re usable FILTER HEAD FILTER ELEMENT eas Figure 2 FILTER ELEMENT REPLACEMENT INTERVALS On new machine filter elements should be replaced after 50 hours of operation and then every 400 hours of operation after that 930 937 Mulcher S 800 00258 page 51 ELIMINATING AIR FROM THE SYTEM All hydraulic fluid contains some dissolved air usually about 10 by volume Under increased pressure the fluid will absorb much more air Aeration in a hydraulic circuit is the presence of free air in places where there ought to be only fluid Usually the air will be in the form of bubbles dispersed through the fluid Difficulties with aeration will occur more frequently as flow velocities increase in hydraulic components This section covers some of the causes of air being introduced into a system and the suggested practices to effectively reduce and eliminate this problem CAUSES The most common places for air to be introduced into a hydraulic system or for aeration to occur are listed below 1 Damaged inlet line loose or defective fittings or seals at any component 2 Damaged return line loose or defective fittings or seals at any component 3 Damaged or worn cylinder rod packing or seals 4 Cracked junction blocks tees or piping NOTE Because fluid acts as a sealant at atmospheric pressure when system drops below atmospheric pressure a
84. to prevent corrosion Proper tension on drive belt for alternator For drive belt adjustment see ALTERNATOR 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 A Proper electrolyte level in battery Add distilled water if necessary Proper voltage of battery Charge if necessary NOTE See Electrical Schematic in Parts Manual under ELECTRICAL section for complete electrical system USING AN EXTRA BATTERY TO START MACHINE If necessary to use an extra battery and jumper cables to start engine be careful This is a two person operation There must be one person in operator s seat and one person to connect and disconnect battery cables AN WARNING Lead acid batteries produce flammable and explosive gases Keep arcs sparks flames and lighted tobacco away from battery An explosion may occur if these warnings are not followed 1 Make sure ignition is in OFF position 2 Be sure battery to be used is same voltage as battery in machine 3 Battery terminals have identification marks Positive terminal is marked and negative terminal is marked AN WARNING When using an extra battery to jump start an engine make connections in order given in this manual 930 937 Mulcher S 800 00258 page 65 ELECTRICAL SYSTEM MAINTENANCE CONTINUED AN WARNING Do not touch battery terminals with any
85. trical System 1 65 Model Description 15 22 2 to Start Machine nstalling a New MAINTENANCE 16 Alternator Drive Belt Adjustment 67 A PREVENTIVE MAINTENANCE 16 Alternator Maintenance 67 Safety While Servicing 17 Electrical System Trouble Shooting 69 Preventive Maintenance 18 Air Conditioner Maintenance 70 Special New Machine Instructions 18 Air Conditioner System Layout 70 Service Schedule 19 AUN 22 Checking Adding Refrigerant 72 Lubrication Points 23 Running the Unit as Preventive Maintenance 72 Fluid Specifications 25 Fresh Air Intake Filter 72 Special Torque Specifications 2 Fresh Air Intake Filter Cleanout Fan mulchers 72 General Torque Specifications 28 Receiver Dryer Installation 72 B
86. turn clutch until adjusting lock pin can be reached Pull adjusting pin out and turn adjusting yoke to right or clockwise until operating lever requires a distinct pressure to engage A new clutch requires several adjustments until friction discs are worn in See Figure 5 Example of a Pump Drive with a Disconnect Clutch HAND HOLE PLATE OPERATING LEVER ADJUSTING YOKE ADJUSTING PIN Pull pin in this mounted inside clutch direction it is spring loaded Figure 5 For cold weather start up using Disconnect Clutch see Start up instructions in Operator s Manual 930 937 Mulcher S 800 00258 page 86 AIR CLEANER MAINTENANCE These recommendations have been developed by Barko to help you achieve maximum performance and life from the air intake system on your Barko built machine However Barko utilizes various engine manufacturers to meet the needs of our customers in all cases the guidelines in the Operators Manual supplied by the engine manufacturer should supersede these recommendations Proper air cleaner servicing will result in maximum engine protection against the ravages of dust Proper servicing can also save you time and money by increasing filter life and dust cleaning efficiency Two of the most common servicing problems are 1 Over servicing New filter elements increase in dust cleaning efficiency as dust builds up on the media DON T BE FOOLED by filter appearance it should look dirty By using proper filter restr
87. ulated Carrier Art Car adjust or adjusting application As Required assembly Back of Cab bill of material bearing Carrier collector conditioner Crawler cylinder diameter drawing Foot Pounds gallon Hydrostatic Rough Terrain carrier illustration Inch Pounds includes or including joystick pounds left hand mounting Not Applicable no NSS opt RH rh Sec see sep ill SE SER or SR s n str swhd TM w ill or illus In Lbs incl j s Lbs LH Ih mig N A number Not Sold Separately optional page quart right hand secondary see separate illustration means located elsewhere in manual Stationary Electric Stationary Electric Remote serial number Straight saw head Truck Mount with 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 na 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 4 Starter Ignition Key Switch Power On Accessor
88. uld cause a leak NEVER SUBSTITIUTE AN INCORRECT ELEMENT MODEL NUMBER Elements may look almost identical but can differ by a fraction of an inch in length a difference that makes a firm seal impossible You re always better off using the dirty element until you can get the correct model 930 937 Mulcher S page 90 800 00258 01044 NOTE This section of the manual is used for the decal kits appropriate for the 930 937 Mulcher Those kits are 930 Base Kit 5539 01064 930 Cab Kit 539 01051 930 Laminated Cab Kit 539 01062 Mulcher Kit 539 01004 If the decal kit information is missing from this section of your hard copy of this manual contact your Barko dealer to obtain copies of the kits and insert them here If you are accessing this manual via Barko s Compact Disc CD the appropriate decal kits can be viewed under Decals on the Barko CD They are listed by kit name Decals to be ordered separately not included in any kit Serial Number or D IL Part No Date of Change 9539 01049 DECAL Barko each side of shrouding orange w brown shadow 539 01110 DECAL Barko on each side of shrouding White w charcoal border 9539 01048 DECAL 930 on each side of shrouding orange w brown border 039 0111 DECAL 930 on each side of shrouding White w charcoal 539 01122 DECAL 937 on each side of shrouding White w charcoal border 9539 00972 Strip
89. vel pedal to pressurize forward travel WARNING Watch to make sure machine is not moving before making adjustments Loosen jamb nut While watching the gauge slowly adjust P O R screw in Clockwise until engine starts to labor This is the setting of the system relief valve This pressure should be 5300 5400 PSI Return pressure to 5000 PSI Turn Dial to 7 on the Diagnostic Pressure Display and repeat steps 7 10 for reverse process Plug and Cap Tighten jamb nut Shut down engine Replace travel pump centering hose NOTE P O R controls maximum system pressure in both directions 930 937 Mulcher S 800 00258 page 43 MULCHER MACHINE PRESSURE ADJUSTMENT PROCEDURE CONTINUED SAUER DRIVE PUMP CHARGE PRESSURE Note Adjustments can be made to the set screw with engine off SAUER DRIVE PUMP MAX PRESSURE 10 11 12 13 14 ADJUSTMENT PROCEDURE Forward Pressure Test Port Install pressure gauge on Forward Pressure Test Port Start engine run at full throttle Loosen jamb nut Adjust set screw Charge pressure should be 450 PSI Tighten jamb nut Shut down engine Reverse Pressure Test Port Remove pressure gauge To do this check pressure shut down the engine adjust set screw restart engine and check pressure Repeat until pressure is correct ADJUSTMENT PROCEDURE Install pressure gauge on Forward Pressure Test Port If you have the ability to view 2 pressures at once instal
90. wn then add more hydraulic oil if necessary 4 Operate controls adding more hydraulic oil as needed to maintain proper level in reservoir This will work air out of system and help to prevent cavitation which is caused by air bubbles in hydraulic oil as it passes through a pump 5 Check hydraulic oil level again after machine has been operating for an hour or two 930 937 Mulcher S 800 00258 page 49 HYDRAULIC OIL FILTER MAINTENANCE A THE RETURN FILTER One Return Filter is used and is located on top of the hydraulic oil reservoir See Figure 1 KEY TO CLEAN FLUIDS Regular maintenance of filter elements is the key to clean fluid and long component life Filters do not function when elements are clogged with contaminant to the point of bypass Therefore it its important to do three things 1 Check the filter indicator frequently to determine when element needs servicing Make sure filter is fitted with correct replacement element The correct replacement element should be listed on filter nameplate or see Parts Manual 3 A periodic fluid sample of system should be analyzed SERVICING ELEMENTS 1 Shut down system and relieve all pressure in filter line 2 Loosen screws on cover Turn slightly to clear cover screws and remove cover Allow excess fluid to drain SCREWS COVER O RING DIVERTER BYPASS VALVE ELEMENT FILTER HOUSING Figure 1 3 Remove diverter bypass valve assembly 4 Remove element fro
91. wrench 3 Remove hydraulic supply and return lines including load lock valves if applicable from cylinder to allow free movement of rod Remove rod assembly from the cylinder barrel Unscrew the nut from the piston end of the rod and remove the piston and gland Before removing old seals note position they are in for proper reassembly See diagram on next page Clean and inspect all parts If worn or damaged replace them Install new seals ensure order is as shown in diagram NOTE Special pliers part number 412 00409 can be used to aid in assembly see photo on next Install item 10 before item 8 Heating item 10 7 and the stiff portion of 1 in a 200 oven for 5 minutes will make it more pliable Some kits may contain extra seals When installing the wear rings items 2 amp 6 put the cuts on opposite sides Start gland on rod and hammer on until it is past the stub 10 Slide piston onto stub ensure O ring 3 is on stub and piston is in proper orientation small recess is O ring side large recess is nut side 11 Tighten nut to torque listed in parts manual 12 Oil new cylinder seals lightly before installing rod assembly in cylinder barrel oil barrel if necessary 13 Reinstall gland cap tighten bolts in a cross pattern to torque specified in parts manual 14 Reinstall on machine and reattach hydraulics lines A NOTE The more common cylinders use the following tool sizes Hex
92. y 2 Power Off Power On 2 Faster 930 937 Mulcher S 800 00258 page 5 88 Slower Air ay Conditioner 44 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 930 937 Mulcher S 800 00258 page 6 15 fe 222727 900000 7 y 000000000 99 9999 9 f PF 9 onoo060000060606000 80000000000000000000000000000000000006 ae WAN ws SSA SS Sey JC 0

930-937 Mulcher (S) - Lynn Hendrix Equipment

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