BARKO

LOADERS

SERVICE MANUAL
80 XL & XLE
(BACK OF CAB AND TRAILER MOUNT)
Machine
Serial Number

NOTE: The Grapple Service and Installation Information is not included in this manual. See separate
Grapple Service and Installation manual which accompanies all grapples from the factory.

The information and illustrations in this manual have

been approved as accurate at the time of printing.
However, the manual may contain information on options
not present on your loader. The right is reserved by
Barko Hydraulics,LLC to make changes and
improvements in it's product at anytime without notice
or obligation.

BARKO
HYDRAULICS,LLC
1 Banks Avenue, Superior, WI 54880
phone: 715-392-5641 fax: 715-392-3931
website: www.barko.com email: barko@barko.com

052407 OPERATORS: 800-00266 PARTS: 800-00267 SERVICE: 800-00268

 TABLE OF CONTENTS
INTRODUCTION ................................................................. 3
Introduction ............................................................. 4
Abbreviations and Symbols .................................... 5
Hydraulic Pressure Warning Sheet ......................... 6
Warranty ................................................................ 7
Know Your Machine ................................................ 8
Safety Summary ..................................................... 9
Model Description ................................................... 12
Loader Mounting Instructions .................................. 13
Pump Speeds / Cycle Times .................................. 17
Fire Prevention ....................................................... 18
MAINTENANCE .................................................................. 19
A. Preventive Maintenance .......................................... 19
Safety While Servicing ............................................ 20
Preventive Maintenance .......................................... 21
Special New-Machine Instructions .......................... 21
Service Schedule .................................................... 22
Lubrication Points ................................................... 23
Lubricants .............................................................. 24
Special Torque Specifications ................................. 25
General Torque Specifications ................................. 27
B. Hydraulic System ...................................................... 28
Hydraulic assembly (Straight Boom) ....................... 29
Hydraulic assembly (Telecopic Boom) .................... 30
Hydraulic Pressure Settings ................................... 31
Hydraulic Oil Reservoir Maintenance ....................... 32
Hydraulic Oil FIlter Maintenance ............................. 35
Eliminating Air From the System ............................ 36
Hydraulic Fittings, Hoses and Tubing ..................... 37
Hydraulic Cylinder Maintenance ............................. 38
Collector Maintenance ............................................ 40
F130 Valve Adjustments (Main Boom with Straight) 42
F130 Valve Adjustments (Main Boom with Tele) ...... 43
F130 Valve Adjustments (Stick/Rotate) ................... 44
P70 Valve Adjustments (Swing) .............................. 45
P70 Valve Adjustments (Stabilizer) ......................... 46
Pump (Metaris Mhp 365 Triple) ............................... 47
C. Electrical System ...................................................... 48
Electrical Schematic .............................................. 49
TROUBLE SHOOTING ....................................................... 50
Engine Trouble Shooting ......................................... 51
Hydraulic System Trouble Shooting ........................ 52
Electrical System Trouble Shooting ........................ 53
Machine Operations trouble Shooting ..................... 54
Symptoms of a Defective Collector ......................... 55
Symptoms of a Defective Swing Motor .................... 56
DECALS ............................................................................. 57
 Introduction

80 XL &XLE
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 INTRODUCTION
Your Barko Loader has been designed and manufactured with high quality materials and care in workmanship.
This manual is intended as a permanent reference to aid professional operator's in their work, and should be
available for use at any time. If the loader is not equipped with this manual, ask your supervisor to obtain one
for you.

Understand the correct servicing procedures before servicing the loader. It is important to know the correct
operating and servicing procedures of the loader and all safety precautions to prevent the possibility of property
damage and/or personal injury or death.

As a professional, trained operator, you are responsible for safety, both your own and that of your co-workers.
Your knowledge and use of all safety practices and correct servicing procedures in this manual, and your good
judgement, can be a major factor in preventing some of the thousands of injuries and deaths caused by
industrial accidents each year.

A professional operator should also be familiar with the information contained in other applicable sources such
as American National Standards, SAE, OSHA, etc.

DON'T FORGET - SAFETY FIRST!

INFORMATION REFERENCE
All requests for information, service or spare parts The Loader serial number plate is located on the left
should include loader serial number. For more side of the cab riser.
information contact:

Barko Hydraulics,LLC Loader

P.O. Box 16227 Model No.
Duluth, MN 55816
Serial No.
Phone Number: 715-392-5641
Facsimile: 715-392-3931

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.

80 XL &XLE
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 ABBREVIATIONS AND SYMBOLS
a/c = air conditioner no. = number
AC = Articulated Carrier (Art. Car.) NSS = Not Sold Separately
adj. = adjust or adjusting opt. = optional
appl. = application pg. = page
AR = As Required qt. = quart
assy = assembly RH (rh) = right hand
BC = Back of Cab sec. = secondary
b/m = bill of material see sep. ill. = see separate illustration (means:
brg. = bearing located elsewhere in manual)
CAR = Carrier SE = Stationary Electric
coll. = collector SER or SR = Stationary Electric Remote
cond. = conditioner s/n = serial number
CRL = Crawler str. = straight
cyl. = cylinder swhd = saw head
dia. = diameter TM = Truck Mount
dwg. = drawing w/ = with
Ft. Lbs. = Foot Pounds
gal. = gallon
HRT = Hydrostatic Rough Terrain carrier
ill. or illus. = illustration
In. Lbs. = Inch Pounds
incl. = includes or including
j.s. = joystick
Lbs. = pounds
LH (lh) = left hand
mtg. = mounting
N/A = Not Applicable

EXPLANATIONS OF OTHER OCCURRENCES IN THIS MANUAL:

- In a parts list, when there are item numbers with empty spaces (no description or part number), these
parts have been previously deleted from that parts list and are not recorded anywhere.

- In a parts list, when there are items with no part number and a dotted line (----) is in the part number
space, this means that the part number is not sold separately or is not available at this time.

- When references to "right hand" or "left hand" are used in this manual, it is done from the operator's seat
in the forward operating position.

SYMBOLS USED ON MACHINE

Horn Slower
Ignition
Key Switch
Air
Starter Conditioner
Power On
(Accessory)

Engine RPM
Power Off

Power On Faster

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 HYDRAULIC PRESSURE WARNING SHEET
MODEL 80 BC

WARNING
MAXIMUM HYDRAULIC SYSTEM PRESSURE
FOR THIS MACHINE IS 3,200 PSI.

MAXIMUM SWING PRESSURE IS 2,500 PSI.

SETTINGS HIGHER THAN THESE MAY

RESULT IN DEATH, SEVERE INJURY OR
PROPERTY DAMAGE.

In many instances, we have learned that the hydraulic relief valves of this equipment have
been reset, increasing the maximum pressures, and with it, the load the unit will lift
before the relief valve opens. In some instances, the consequences of increasing this
setting have been serious. The function of the relief valve is to provide a fuse action to
protect the machine and the operator from overloading. When overloaded, different
portions of the machine can become stressed to a level where parts fracture, possibly
resulting in death, severe injury or property damage. This is an extremely dangerous
practice.

Accordingly, you are advised that the settings of these valves are limited to the
maximums listed above. Pressure settings in excess of these levels render each and all
Barko warranties null and void and constitute an obvious misuse and abuse of our
product.
BARKO HYDRAULICS, LLC

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 WARRANTY

BARKO HYDRAULICS, LLC

BARKO HYDRAULICS, L.L.C. ("Barko") warrants to the Distributor and/or original Buyer each new hydraulic
knuckle boom loader, feller buncher or other product in BARKO HYDRAULICS Equipment Group including attachments
and accessories thereto, ("Product") sold by BARKO to be free from defects in material and workmanship under
normal use, maintenance and service.
BARKO will cause any major structural component of a BARKO product covered by this warranty which proves to
be defective in material or workmanship under normal use, maintenance and service within three (3) years ) or 6,000
hours, whichever occurs first from first day in service, provided first day in service is not later than one (1) year from
delivery to Distributor and/or original Buyer or other user, to be replaced without charge with a new or repaired part, at
BARKO election. BARKO also will cause the labor to remove any such defective part and to install the new or
repaired part to be provided without charge to the owner of said BARKO product. The parts and labor to meet this
warranty will be furnished by designated BARKO distributor.
BARKO will cause all other parts of product covered by this warranty which proves to be defective in material or
workmanship under normal use, maintenance and service within one (1 ) year or 2,000 hours, whichever occurs first
from first day in service, provided first day in service is not later than one (1) year from delivery to Distributor and/or
original Buyer or other user, to be replaced, without charge, with a new or repaired part, at BARKO election. BARKO
also will cause the labor to remove any such defective part and to install the new or repaired part to be provided
without charge to the owner of said BARKO product. The parts and labor to meet this warranty will be furnished by
BARKO designated distributor.
BARKO warrants all service parts purchased from BARKO and used on a BARKO manufactured unit, to be free
from defects in material and workmanship under normal use, maintenance and service for a period of six (6) months or
1,000 hours, whichever occurs first. BARKO will cause any such part which proves to be defective to be replaced
with a new or repaired part at BARKO election on a parts only basis.
Proof of any defect must be submitted to BARKO within ten (10) days from the date on which the defect was
discovered and any claim submitted within thirty (30) days after repair work is completed.

BARKO warranty does not cover:

1 Defects, damage or deterioration due to normal use, wear, tear, exposure, storage or corrosion.
2. Normal maintenance service, including replacement of filters, oil, seals and the like.
3. Damage due to failure to maintain or use the BARKO product or part according to manuals, schedules or good
practice.
4. Damage caused by abuse of equipment or parts by overloading, misapplication, improper operation or use,
installation of unapproved accessories or unauthorized alterations.
5. Damage resulting from repairs made in an unauthorized manner or installation of components not authorized by
BARKO.
6. The labor to remove and reinstall a defective replacement part after the expiration of the warranty period applicable
to the product in which part is located.
7. Overtime labor premiums.
8. Transportation of the BARKO product to the distributor's service facility or transportation of the distributor's
serviceman to the product's location.
9. Vendor components not manufactured by BARKO, such as engines, transmissions and components, Tires,
batteries or other parts normally warrantied and serviced by the manufacturer. The warranty of the respective
manufacturers of these components shall apply.

The Buyer accepts this warranty and the limitations and disclaimers set forth herein as part of the purchase of the
BARKO product or part to which this warranty applies.
THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED, STATUTORY, WRITTEN OR ORAL,
AND THERE IS NO IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.
Remedies available to any person claiming under this warranty are exclusive and expressly limited to obtaining the
parts and the labor, where applicable, in accordance with terms of this warranty.
BARKO liability for losses, damages or expenses of any kind arising from the design, manufacture or sale of the
product covered by this warranty, whether based on warranty, negligence, contract, tort or otherwise, is limited to an
amount not exceeding the cost of correcting the defects as herein provided, and, at the expiration of the applicable
warranty period, all such liability shall terminate.
BARKO shall in no event be liable for incidental, consequential or special damages to losses of use of the BARKO
product, a loss or damage to property other than the BARKO product, a loss of profits or other commercial loss, or any
special or consequential damages (except liability for consequential damages which by law may not be disclaimed).

Revised 2/98

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 KNOW YOUR MACHINE

The following is a list of ten important safety precautions and warnings you should read through and understand
before operating or servicing your machine.

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

2. Know how to put your machine in a zero energy state for purposes of inspection, maintenance,
or repair.

3. Clear operating area of all obstacles and personnel before operating loader.

4. Never approach power lines with any part of the machine or load! Current in a high voltage
power line may arc some distance to jump from the wire to a nearby "ground". KEEP WELL
CLEAR!

5. Allow only the operator on the machine. Keep riders off. Riders on machine are subject to injury
such as being struck by foreign objects and being thrown off the machine. Riders also obstruct
the operator's view, resulting in the machine being operated in an unsafe manner.

6. Never use a boom or attachment for a work platform or personnel carrier. Serious injury or death
may result.

7. When machine is not operating or when leaving cab, boom and attachment must be lowered to
the ground. Failure to do so may allow boom or attachment to move, causing property damage,
injury, or death.

8. Do not tamper with any hydraulic line when it is pressurized. Escaping fluid under pressure can
penetrate the skin, causing serious injury. Relieve pressure before unhooking hydraulic or other
lines. Tighten all connections before applying pressure. Keep hands and body away from
pinholes and nozzles which eject fluids under high pressure. Use a piece of cardboard to search
for leaks.

If any fluid is injected into the skin, it must be surgically removed within a few hours by a doctor
familiar with this type of injury or gangrene may result.

9. Under no circumstances should any modifications be made to Barko machinery without factory
authorization. Any modifications may void the warranty. This machine was designed to do a
specific job and alterations could result in property damage, injury or death.

10. Replace any safety decals that are faded, torn, missing, illegible, or otherwise damaged. See
your machine's Parts Manual for decal kits applicable to your machine and for locations of all
decals.

Don't stop here - read on.

80 XL &XLE
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 SAFETY SUMMARY
Failure to follow safety precautions in this manual can result in personal injury and/or property damage. Carefully read
safety cautions below and within this manual. Heed all decals mounted to machine.

DANGER - Indicate immediate hazards which WILL result in severe personal injury or death.

WARNING - Indicate hazards or unsafe practices which COULD result in severe personal injury or
death.

CAUTION - Indicate hazards or unsafe practices which could result in damage to machine or minor
personal injury.

DANGER
Never approach power lines with any part of the
machine. Current in a high voltage line may arc
some distance to jump from the wire to a nearby
"ground". KEEP WELL CLEAR!
WARNING
Combustible and flammable fluids can cause death
or severe injury. Do not smoke near fuels or
hydraulic fluids. Do not refuel while engine is hot or
running and without proper ventilation.

WARNING
Always lower boom to ground and shut down engine
before leaving operator's station. If necessary to
work on machine with lifted boom, securely support
machine and attachment.
WARNING
Wear required personal protective equipment at all
times to help prevent personal injury.

WARNING
Do not move loads over top of truck cab. Do not
allow driver to remain in truck cab while operating.
Severe injury, death or property damage may result.
WARNING
Safe and stable mounting of this machine on a truck
or trailer bed is the owner's responsibility. See
Mounting Instructions for recommended procedures.
WARNING
Set truck parking brake before operating machine.

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 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.
DANGER
Moving stabilizers will cause death or severe injury.
Stand clear. Operate stabilizers only when
personnel are clear.
DANGER
Falling boom or load will cause death or severe
injury. Stay clear if boom or load are not grounded.
Clear all persons from area of operation and
machine movement. Never move boom or loads
over the heads of other persons.
80 XL &XLE
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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 unsafe
manner.
Never use a boom attachment for a work platform or
personnel carrier.
WARNING
An unstable machine can cause death, severe injury,
or property damage. Do not operate machine
without lowering stabilizers on firm, level ground.
WARNING
Improper machine transport can cause death, severe
injury or property damage.
Before transporting:
- Lower and secure boom and attachment to truck
bed.
- Raise stabilizers.
- Shut down PTO.
WARNING
Mechanically connected controls will cause
movement of components at all times - even if
pump or engine is not operating. Always be certain
that boom and attachment are properly supported or
resting on firm ground before stopping engine to
minimize chance of
accidental movements of components causing injury
or death.
WARNING
Replace any safety decals that are faded, torn,
missing, illegible, or otherwise damaged.
 SAFETY SUMMARY CONTINUED...
WARNING WARNING
High pressure hydraulic fluid can penetrate skin
Loose or overtorqued bolts can cause death, severe
causing death, gangrene or other severe injury.
injury, or property damage. Maintain proper bolt
Seek immediate medical help to remove fluid.
torque. Visually check bolts daily. Check torque
- Keep hands and body away from areas ejecting
every 50 hours.
fluid. Use piece of cardboard to check for leaks.
Wear proper hand and eye protection.
- Relieve hydraulic pressure before loosening any CAUTION
hydraulic connections. Grease all boom, cylinder, and turntable bearing/
- Tighten all hydraulic connections before pinion points daily.
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,
WARNING and snow. Do not leave loose tools or rags on
machine.
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 injury or
WARNING
property damage. Always maintain 3-point contact with handles and
steps when mounting or dismounting. Never jump
If Barko-authorized welding must be done, first on or off machine.
disconnect both battery cables and all alternator
connections or electrical and structural damage to
machine may occur.

WARNING
Use caution when checking items beyond your
reach. Use an approved safety ladder.

WARNING
CAUTION
Do not exceed 15 p.s.i. nozzle pressure when drying
Use only hydraulic fluid in hydraulic oil reservoir.
parts with compressed air. Do not direct compressed
air against human skin. Serious injury could result.
Other fluids will cause machine damage.

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.

80 XL &XLE
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 MODEL DESCRIPTION
Use this diagram to identify your loader's components for future service reference:

CONTROL
LEVERS & MAIN STICK
CONTROL BOOM MAIN BOOM BOOM
VALVES CYLINDER CYLINDER
SWING MOTOR
AND GEARBOX
HEAD STICK
BOOM

TELESCOPIC
BOOM
CYLINDER

PLATFORM GRAPPLE
HANGER &
TURNTABLE ROTATOR
BEARING

LADDER

SUBFRAME GRAPPLE
CYLINDERS

STABILIZER
LEG AND
CYLINDER

GRAPPLE
ARMS

WARNING
Boom is shown in lifted, operating position. Always lower boom and
grapple to ground and shut down machine when not operating or
before maintenance of any kind.

80 XL &XLE
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 LOADER MOUNTING INSTRUCTIONS
Use these recommended procedures for mounting Back of Cab (BOC) and Trailer Mount (TRL MT) machines to truck or
trailer frame. The truck frame is usually made of channel, while the trailer frame is usually made of
I-beam. The following instructions show mostly channel, however the principles for mounting to I-beam are generally the
same, unless noted. See Figure 1.

NOTE: Machine shown may

not represent your machine
exactly.

LOADER FRAME

TOP NUT
TRUCK/TRAILER
FRAME (channel or
SPACER BLOCK
I-beam)
(one at each
mounting point)

MOUNTING STUD

CLAMPING PLATE
BOTTOM NUT
JAM NUT
Figure 1

MOUNTING INSTRUCTIONS
1. Position truck/trailer frame to provide enough clearance for placement of loader. Remove all items that may be in the
way such as fuel tanks, mounting brackets, air or vacuum tanks, batteries, etc.

2. If needed, install a power take-off compatible with transmission in truck to achieve a hydraulic pump operating speed
of 1500 RPM.

3. Place loader on truck/trailer frame where desired, using suitable lifting equipment.

4. At each mounting point install a steel spacer block slightly longer than opening between truck/trailer frame
channel (or I-beam) edges. Spacers should be made from 3 x 4.1 lb. channel or 1/4 x 2 x 2 angle. See figure 2.
Spacer blocks must fit snug. DO NOT WELD!

CAUTION
Do not cut spacer blocks too short, which will cause a loose fit, or too long
which will cause truck/trailer frame to spread. See Figure 2.

SPACER BLOCK

TRUCK FRAME CHANNEL

Figure 2 - End Views of Truck Frame Channel
80 XL &XLE
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 LOADER MOUNTING INSTRUCTIONS CONTINUED...
NOTE: To prevent distortions of truck/trailer frame and ensure solid base for loader, align spacer blocks with
edge of truck/trailer frame.

ADDITIONAL SPACERS
Additional spacers should be installed between loader frame and clamping plate around outside mounting studs.
Spacers should be made from 3 x 4.1 lb. channel or 1/4 x 2 x 2 angle and be cut .010 to.015 shorter than truck/trailer
frame channel height.
DO NOT WELD TO TRUCK FRAME!

These spacers will give additional strength and help to prevent undue stress in the mounting areas.

MOUNTING INSTRUCTIONS CONTINUED...

5. Install clamping plates, mounting studs and nuts, putting clamping plates under truck/trailer frame channel (or I-
beam). See Figure 1.

NOTE: Top nut must be secured to mounting stud by hammering threads of mounting stud (once nut is on) or by
tack welding.

6. When tightening bottom nuts, run them up so that clamping plate makes even contact with truck/trailer frame. See
Figure 3.

SPACER BLOCK LOADER FRAME MOUNTING STUD

TOP NUT

BOTTOM NUT
TRUCK FRAME CHANNEL
CLAMPING PLATE
Figure 3

SECURING SPACER BLOCKS TO MOUNTING STUDS

One or two "U" shaped clips (made from flat bar to fit around mounting studs) may be tack-welded to spacer blocks to
ensure that blocks do not fall out should mounting studs become loose. See Figure 4.

Top View
U-SHAPED CLIPS

SPACER BLOCK

SPACER BLOCK
MOUNTING STUD
Side
View
CLAMPING PLATE
NUT
Figure 4 - Top and Side View of Truck/Trailer Frame Channel
80 XL &XLE
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 LOADER MOUNTING INSTRUCTIONS CONTINUED...
Another means of securing spacer blocks to mounting studs is to drill two holes in each spacer block, fit spacer blocks
into place on truck/trailer frame, and insert a "U" bolt or nylon tie wrap around each mounting stud and through holes in
each spacer block. Do this with all four mounting studs and spacer blocks.

A hose clamp placed around each spacer block and mounting stud may also be used.

MOUNTING INSTRUCTIONS CONTINUED...

7. Be sure mounting studs are perpendicular to top of truck/trailer frame edges. If not, this may cause undue
stress to mounting studs which could result in property damage or personal injury. See Figure 5.

TOP NUT TOP NUT

LOADER FRAME LOADER FRAME
MOUNTING STUD
MOUNTING STUD

CLAMPING PLATE
CLAMPING PLATE BOTTOM NUT

BOTTOM NUT TRUCK/TRAILER FRAME

Figure 5

NOTE: Top nut must be secured to mounting stud by hammering threads of mounting stud (once nut is on) or by
tack welding.

If truck/trailer frame is tapered, fabricate a tapered shim and tack-weld it to clamping plate.

DO NOT WELD SHIM TO FRAME!

Clamping plates must be perpendicular to mounting studs.

When truck/trailer frame is tapered, it is also recommended that you weld a 2" x 1/4" flat bar from one clamping plate to
the other clamping plate on the same side of the truck/trailer frame to prevent clamping plates from working up the taper
and allowing nuts to loosen. See Figure 6.
TRUCK/TRAILER FRAME
TRUCK/TRAILER FRAME

2" X 1/4" FLAT BAR

(welded from one
clamping plate to
the other)
CLAMPING PLATE

CLAMPING PLATE SHIM

Figure 6 - Side View of Truck/Trailer Frame

8. Tighten each pair of nuts to 650 ft. lbs. of lubed torque.

9. Put on jam nuts under bottom nuts. See Figure 1.

80 XL &XLE
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 LOADER MOUNTING INSTRUCTIONS CONTINUED...

Check the torque of the mounting studs and nuts after the first 50 hours of operation and every 100 hours after that.
Retorque if necessary.

WARNING
Do not weld on any structural member of the loader
unless specifically authorized by Barko Hydraulics.
Any unauthorized welding or welding procedures
will void the warranty, and may cause structural
failure.
WARNING
Safe and stable mounting of this machine on a truck
or trailer frame is the owner's responsibility. Follow
all recommended Mounting Instructions.

POWER TAKE-OFF MOUNTING SUGGESTION

POWER TAKE-OFF

UNIVERSAL JOINT

DRIVE SHAFT
(LENGTH TO SUIT)

PUMP SUPPORT
WELDED TO TRUCK
FRAME
KEY

PUMP

KEY

UNIVERSAL JOINT

NUT KEY

WASHER
BOLT

80 XL &XLE
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 PUMP SPEEDS / CYCLE TIMES
(FACTORY RECOMMENDED SPECIFICATION IS 1500 RPM)
PUMP 560-02649

Pump Shaft End (main) Center (stick) End (swing)

Speed
1200 20 GPM 16 GPM 11 GPM
1300 21.5 GPM 17.25 GPM 11.75 GPM
1400 23.25 GPM 18.5 GPM 12.75 GPM
1500 25 GPM 20 GPM 13.75 GPM
1600 26.5 GPM 21.25 GPM 14.5 GPM

BOOM CYCLE TIMES

Pump
Speed Main Stick Telescopic
up down up down up down
1200 9.2sec 5.9 sec 10.4sec7.2 sec 3.3sec 1.8 sec
1300 8.5sec 5.5 sec 9.6sec 6.6 sec 3.1sec 1.7 sec
1400 7.9sec 5.1 sec 9.0 sec 6.2 sec 2.8sec 1.6 sec
1500 7.3sec 4.7 sec 8.3sec 5.7 sec 2.6sec 1.5 sec
1600 6.9sec 4.4 sec 7.8sec 5.4 sec 2.5sec 1.4 sec

SWING SPEED
Pump
Speed RPM
1200 7.0
1300 7.5
1400 8.2
1500 8.8
1600 9.3
NOTE: IT IS THE DEALER/CUSTOMER RESPONSIBILITY
TO SPEC OUT THE PROPER PTO RATIO TO
MEET THE CUSTOMERS NEEDS.

DETERMINE DIRECTION OF SHAFT ROTATION

TO DETERMINE DIRECTION OF SHAFT ROTATION, VIEW THE UNIT WITH THE SHAFT POINTING TOWARD
YOU, AND THE IDLER (DRIVEN) GEAR BENEATH THE SHAFT. WITH CLOCKWISE ROTATION, FLOW WILL BE LIFT
TO RIGHT. THE INLET PORT WILL BE ON THE LEFT, OUTLET ON THE RIGHT. THE FLOW IS IN THE OPPOSITE
DIRECTION WITH COUNTER-CLOCKWISE ROTATION. INVERTING THE PUMP WILL REVERSE THE INLET AND
OUTLET PORTS BUT NOT THE DIRECTION OF ROTATION.

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 FIRE PREVENTION
This machine has several components which are at high temperatures under normal operating conditions, such as the
engine, exhaust system, brake system and transmission.

Also, the 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 the machine often - periodic high pressure washing of the machine 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 the machine in
areas with explosive dust or
gases. These elements can be
ignited by arcs, sparks, hot
components, or exhaust fumes.
- Inspect the operator's station
every day. Clean if necessary.
Remove all flammable material
(rags, debris, fluid spills, etc.).
- Daily, inspect all hydraulic oil
tubes, hoses, and fittings for
damage and leakage. Tighten or
replace as necessary. Always
clean fluid spills.
- Before doing welding of any kind,
clean machine, cover rubber
hoses and any other flammable
parts. Never ground arc welder or
electrical accessories through
turntable or boom bearings as
arcing may occur causing bearing
damage. Always keep a fire
extinguisher nearby.
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.
- Never smoke while handling fluids
or working on fuel or hydraulic
system.
- Keep fire extinguisher and first aid
kit where they can be easily
reached in case of fire and keep
these items properly maintained.
- Operating personnel should be
instructed on what to do in
case of fire and be required
to demonstrate how to use
fire extinguisher and fire
suppression equipment.
- Any portable extinguisher or
fire suppression system
carried on machine that has been
used, should be recharged or
replaced before the machine
resumes operating. Extinguisher
manufacturers recommended
service interval should be
followed.
- Allow machine to cool down by
idling engine for a while before
shutdown. Many engine and
transmission fires start after shut-
down.

80 XL &XLE
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 Maintenance
Maintenance

A. PREVENTIVE MAINTENANCE

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 SAFETY WHILE SERVICING
The following maintenance section gives suggested guidelines for operational maintenance on your machine. It is not
intended for use as a service manual.

In severe conditions (extreme dust, heat, cold, humidity, etc.) you will need to service your machine more often. Your
experience will dictate a more severe servicing program.

Safety while servicing your machine is your responsibility. Only qualified and authorized personnel should be permitted
to maintain, repair, adjust and inspect machine.

Read and understand warnings and safety precautions in Safety Summary and elsewhere in this manual before doing
any service on machine. The following precautions should be used as a reminder to safe servicing.

BEFORE INSPECTION OR MAINTENANCE:

- Lower boom to ground.
- Shut down machine to a zero energy state.
- Allow machine to cool.
- Relieve all hydraulic pressure.
- Remove, block or guard against body contact with all
other sources of hazardous pressure, temperature,
electricity, or machine motion.
- Ensure machine, boom or attachment are not supported
on props that may collapse. Ensure boom and
attachment are grounded.

WARNING
Always shut down the machine and lower the boom
and attachment to the ground before working on the
machine. If necessary to work on a lifted boom or
attachment, securely
support the boom and attachment so that they
cannot move or fall in any way.
WARNING
Don't leave loose tools and rags on the
machine. Ensure that all walking and climbing
surfaces are clean.
WARNING
Handle fluids carefully. Do not smoke while filling
tank or working near fluids.
Refer to Lubricants whenever replacing oils, fluids,
or filling fuel tank.
WARNING
Do not support the machine on cinder blocks, hollow
tiles, or props that may crumble under a load. Do
not work under a machine that is supported solely by
a jack.
CAUTION
Use the intervals on the Service Schedule for
maintenance 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 injury to
operator or machine.

WARNING
WARNING
Relieve air pressure in the hydraulic reservoir before
Do not weld on any structural member unless breaking any hydraulic connection or before
specifically authorized by Barko Hydraulics. Any
opening the reservoir access cover.
unauthorized welding or welding procedures will
void the warranty, and may cause structural damage
and injury.

REMEMBER: SAFETY FIRST!

80 XL &XLE
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 PREVENTIVE MAINTENANCE

Preventive maintenance is really just a simple matter of common sense. If you keep any piece of mechanical equipment
clean and properly lubricated, and promptly replace any worn or damaged parts, you are going to "prevent" deterioration
and promote long life and safe, productive service. The only other requisite to such a program is the regular scheduling
of such maintenance.

Obviously, when you are operating under severe job conditions, such as a dusty job site, in extreme heat or cold, a long
operating day, or extremely heavy loads, the recommended intervals in the schedule should be shortened.

The suggested schedule on the following page is designed to be just a reminder of what should be done. For detailed
instructions on each item, consult the Table of Contents for where each is located in this manual.

WARNING

Instructions are necessary before doing service

on loader. See warnings and instructions both
at the beginning and throughout this manual.
After doing service or making repairs or
adjustments always check function of loader.

Safety glasses or goggles are always needed for

eye protection from electric arcs, from shorts or
welding, battery acid, compressed springs, fluids
under pressure, and flying debris or loose
material when engines are running or tools are
used. Use eye protection approved for type of
welding. Failure to obey warnings can cause
injury or death.

SPECIAL NEW-MACHINE INSTRUCTIONS

A new machine needs a special maintenance procedure after the first 50 hours of operation. In addition to an overall
inspection of the loader, the torque of the turntable mounting bolts and pin nuts of the boom and grapple should be
checked and retorqued, if necessary. Also, hydraulic filter elements should be changed and inspected. If excessive dirt
is found, the hydraulic reservoir should be drained, cleaned, and refilled.

80 XL &XLE
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 SERVICE SCHEDULE
8 HRS. 50 HRS. 100 HRS. 400 HRS. 1000 HRS.
SERVICE REQUIRED
DAILY WEEKLY MONTHLY 2 MONTHS 6 MONTHS

Hydraulic Reservoir - check level and quality

of oil.
Hoses, Connections, Cylinders - Inspect for
leaks and damage. Tighten, repair, or
replace parts if necessary.
Operator's Platform - Clean area of debris,
tools, rags, water, ice, and snow.
Fittings - Lubricate as shown on Lubrication
Points. Use a multi-purpose grease.
Bolts/Nuts - Visually inspect for wear or
damage.

Swing Motor Gearbox - Check fluid level.

Hydraulic Oil Filter - On new machines the
filter element should be replaced first at 50
hrs. 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.
Bolts/Nuts - Check for proper
torque every 50 hours. Retorque if necessary.
Hydraulic Oil Reservoir Breather - Replace.
Accumulators - Check pressure and maintain
at 900 PSI. (Stationary Electric only)
Hydraulic Oil Filter - Replace elements every
400 hours, after initial change at 50 hours on a
new machine.
Swing Motor Gearbox - Replace fluid.

Hydraulic Reservoir - Replace oil and clean

suction screens.
Entire Loader - Steam clean, inspect for
stress, wear, cracks, damage, and loose parts.

NOTE:
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.

80 XL &XLE
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 LUBRICATION POINTS (PERFORM DAILY)

GREASE 1 Grapple Arms 7 Grapple Hanger (2 fittings)

2 Grapple Rotator 8 Main Boom Cylinder
HYDRAULIC 3 Stabilizer Legs & Cylinders 9 Stick Boom Cylinder
OIL 4 Turntable Bearing & Pinion 10 Stick Boom Pivot
5 Main Boom Pivot 11 Hydraulic Oil Reservoir
GEAR FLUID 6 Grapple Cylinders 12 Swing Motor Gearbox

Swing Motor Gearbox - EP 80-90

gear fluid (fill until oil is as high
as top of cluster bearings - see
service manual for more
information).
NOTE: See Lubricants section in this manual for
proper type of grease to use.
10

5
7 2
12 6 6 6 6
8

1 1
3
3
11

3 3

WARNING
Boom is shown in lifted, operating position. Always lower boom and
grapple to ground and shut down machine when not operating or before
maintenance of any kind.
80 XL &XLE
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page 23
 LUBRICANTS
HYDRAULIC OIL
The following lists some features to look for in an oil. The hydraulic oil for the machine should feature:
- Rust resistant additives to prevent rust formation from moisture condensation.
- Anti-foaming agents to break up air bubbles and prevent "foaming" that may cause sluggish and
erratic operation.
- High stability to resist oxidation and prevent varnish formation and deposits that foul systems.
- Anti-wear properties to prevent scuffing and exccesive wear at high speeds and high pressures.
- Good viscosity index for easy flow at low temperatures without thinning out at high temperatures after
hours of use.

For operation in different temperatures, refer to the following chart for selection of hydraulic oil.

ISO Viscosity Average

Ambient Temp. System OperatingTemperature
Grade

46 32 o F. to 45 o F. 150
o
F. Max.

68 ABOVE 45o F. 190 o F. Max.

Below 32 degrees F. ambient, Chevron Rykon MV.

GREASE
Use grease shown on chart below, depending on the expected air temperature range.

AIR TEMPERATURE RANGE

Fahrenheit ( F ) -67 -40 -22 -4 14 32 50 68 86 104 122
Celsius ( C ) -55 -40 -30 -20 -10 0 10 20 30 40 50

NLGI NO. 2

HIGH TEMP. /EP

NLGI O OR I

ARCTIC GREASE

ALTERNATIVE LUBRICANTS
Conditions in certain geographical areas may require special lubricants and lubrication practices which do not appear in
this manual.

LUBRICANT STORAGE
The machine can operate at top efficiency only if clean lubricants are used. Use a clean container to handle all
lubricants. Store them in an area protected from dust, moisture, and other contaminants. Store drums on sides.

WARNING
Diesel fuel or hydraulic fluid under pressure can penetrate the skin or eyes.
Fluid leaks under pressure may not be visible. Use a piece of cardboard or
wood to find leaks but do not use bare hand. Wear safety goggles. If fluid
enters skin or eyes, get immediate medical attention.

80 XL &XLE
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 SPECIAL TORQUE SPECIFICATIONS
WARNING
Loose or overtorqued bolts can cause death,
severe injury, or property damage. Maintain
proper bolt torque. Visually check bolts daily.
Check torque every 50 hours.
LUBRICATE WITH ANTI-SEIZE COMPOUND PART NO. 514-00700

Swing Gearbox Mounting Bolts ......................................................... 64 Ft. Lbs.

Turntable Bearing Bolts HH ............................................................... 175 Ft. Lbs.

Turntable Bearing Bolts SHCS .......................................................... 144 Ft. Lbs.

Loader Mounting Studs & Nuts - 1-1/4" nuts ..................................... 650 Ft. Lbs.

Other torques, for the valves, pumps, and motors are found in the service literature
for those components.

TURNTABLE BEARING BOLT , AND SWING GEARBOX BOLT TORQUE

The Turntable Bearing Bolts should be checked and retorqued, if necessary, every 50 hours. Torque to 175 Ft. Lbs. of
lubed torque. See Figure 1.

The Swing Motor and Gearbox Mounting Bolts should be checked and retorqued, if necessary, every 50 hours. Torque
Gearbox Bolts to 64 Ft. Lbs. of lubed torque. See Figure 1.

SWING MOTOR

GEARBOX MOUNTING
BOLTS SWING MOTOR
GEARBOX

HEAD

TURNTABLE
BEARING

LOADER FRAME

TURNTABLE
BEARING BOLTS

FIGURE 1
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 SPECIAL TORQUE SPECIFICATIONS CONTINUED...

LOADER MOUNTING STUDS AND NUTS TORQUE

The 1-1/4" Loader Mounting Nuts should be torqued to 650 Ft. Lbs. These nuts should be checked for proper torque
every 50 hours. Retorque if necessary. See Figure 2.

NUT NUT

LOADER FRAME
BOTTOM PLATE

TRUCK FRAME CHANNEL

NUT NUT
CLAMP PLATE

FIGURE 2

80 XL &XLE
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page 26
 GENERAL TORQUE SPECIFICATIONS
NOTE: See next page for Special Torque Specifications that pertain specifically to this machine.
NOTE: Grade 9 bolts must be used with Grade 9 washers.

DIA.
COARSE
DRY
FINE
*COARSE
LUBRICATED
FINE
1/4 9 10 5 6
5/16 17 20 10 12
3/8 31 35 19 21
7/16 50 55 30 33
1/2 75 85 45 51
GRADE 5 9/16 110 120 66 72
5/8 150 170 90 100
SAE GRADE 5 3/4 265 300 160 180
RECOMMENDED 7/8 400 435 240 260
TORQUE FOOT 1 600 650 360 390
POUNDS 1-1/8 800 900 480 540
1-1/4 1120 1240 670 745
1-3/8 1470 1670 880 1000
1-1/2 1950 2200 1170 1320

DIA.
COARSE
DRY
FINE
*COARSE
LUBRICATED
FINE
1/4 12 14 7 9
5/16 25 27 15 17
3/8 44 49 26 30
7/16 70 78 42 47
1/2 107 120 64 72
9/16 154 171 92 102
GRADE 8 5/8 212 240 127 144
3/4 376 420 226 252
SAE GRADE 8 7/8 606 668 364 400
RECOMMENDED 1 909 995 545 597
TORQUE FOOT 1-1/8 1288 1444 773 866
POUNDS 1-1/4 1817 2012 1090 1207
1-3/8 2382 2712 1430 1627
1-1/2 3161 3557 1897 2134

DIA.
COARSE
DRY
FINE
*COARSE
LUBRICATED
FINE
1/4 17 19 10 12
5/16 34 37 20 22
3/8 60 68 36 41
7/16 96 108 58 65
1/2 145 165 87 100
GRADE 9 9/16 210 235 125 140
(MIN. 8 RADIAL 5/8 290 330 175 200
MARKS ON 3/4 515 575 310 345
HEAD) GRADE 9 7/8 830 980 500 590
(BOW-MALLOY) 1 1250 1350 750 810
RECOMMENDED 1-1/8 1750 1950 1050 1170
TORQUE FOOT 1-1/4 2500 2750 1500 1650
POUNDS 1-3/8 3250 3700 1950 2220
1-1/2 4350 4850 2600 2900

* NOTE: This is lubed torque. Lubricate with anti-seize compound part no. 514-00700.
80 XL &XLE
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page 27
 Maintenance
B. HYDRAULIC SYSTEM

80 XL &XLE
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page 28
HYDRAULIC ASSEMBLY (STRAIGHT BOOM) 604-00933

80 XL &XLE
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page 29
HYDRAULIC ASSEMBLY (TELECOPIC BOOM) 604-00935

80 XL &XLE
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page 30
 HYDRAULIC PRESSURE SETTINGS

RELIEF VALVES
The Relief Valve portion of the control valves in your Barko Loader limit the flow of hydraulic oil, which relieves the excess
pressure in the hydraulic system, if for any reason pressure is built up above a predetermined, safe, maximum.

WARNING
The relief valve pressure setting has been arrived
at by our engineers after considerable experience
with and testing of this loader. The setting will
provide maximum safety and efficiency of operation.
DO NOT ALTER THIS RELIEF SETTING! Relief settings
increased beyond this setting could cause death, severe
injury or property damage.

Altering the settings on a new machine will void

the warranty.

The following is a list of pressure settings used on your Barko 80 XL & XLE. Any questions should be directed to
the factory. Phone 715-392-5641.

THE BOOM AND GRAPPLE FUNCTION VALVES:

Main Boom - up (butt end of main boom cylinder) ......................... 3600 PSI at the Port Relief
Main Boom - down (rod end of main boom cylinder) ...................... 600 PSI at the Port Relief
Secondary Boom - up (butt end of secondary boom cylinder) ........ 3600 PSI at the Port Relief
Secondary Boom - down (rod end of secondary boom cylinder) .... 3600 PSI at the Port Relief

Both Main Reliefs .......................................................................... 3200PSI

Stabilizer Down ............................................................................. 3250 PSI

THE SWING SYSTEM:

Main Reliefs .................................................................................. 2550 P.S.I.
Port Reliefs ................................................................................... 2500 P.S.I.

GRAPPLE ROTATE PRESSURE:

See Grapple Information later in this manual.

80 XL &XLE
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page 31
 HYDRAULIC OIL RESERVOIR MAINTENANCE
The supply source for the hydraulic system, the hydraulic oil reservoir, is located on the frame under the ladder. The
reservoir features return line filters and suction strainers to keep the oil clean. Filters have replaceable elements. A
dipstick for checking oil quantity is located on the top of the reservoir. See Figure 1 below.

CAUTION
When making repairs on
FILLER CAP hydraulic system, keep all
FILLER SCREEN parts clean and remove
all dirt from the area
before you begin dis-
assembly. Use caps and
plugs to keep dirt out of
tubelines and openings.

INSPECTION COVER

DIPSTICK

DRAIN PLUG
(SCREWS
INTO THE
BOTTOM OF
THE
Figure 1
RESERVOIR.)

Check oil level in reservoir before each period of operation, or daily. If, at any time, you find the level is low, check the
loader for leaks around tubes, hoses, fittings, and couplings.

80 XL &XLE
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page 32
 HYDRAULIC OIL RESERVOIR MAINTENANCE CONTINUED...

HYDRAULIC OIL CHANGING PROCEDURE

This procedure should be used 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, funnels, oil
filling equipment, the oil filler opening, and, above all, the hydraulic oil itself must be kept absolutely clean. Dirt in the
hydraulic system can cause serious damage to pumps, valves, and cylinders.

DRAINING THE RESERVOIR SEE FIGURE 2.

1. After making certain there are no personnel in the area, raise the main boom and extend the secondary boom to
their limits, then disengage the power take-off and turn off truck engine. The main and stick booms should remain
raised.

WARNING
Do not allow anyone under or near the raised booms.
Death or severe injury will occur if booms should drop or move.

2. Remove the reservoir drain plug to drain the oil.

3. After the reservoir has drained, lower the main and secondary booms gradually to force oil out of
cylinders. DO NO START TRUCK ENGINE OR ENGAGE THE POWER TAKE-OFF!

FILLER CAP
FILLER SCREEN

INSPECTION COVER

DIPSTICK

CAUTION
When making repairs on
hydraulic system, keep all
parts clean and remove
all dirt from the area
before you begin dis-
assembly. Use caps and
plugs to keep dirt out of
tubelines and openings.

DRAIN PLUG
(Screws into
the bottom of
the reservoir.)
Figure 2
80 XL &XLE
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page 33
 HYDRAULIC OIL RESERVOIR MAINTENANCE CONTINUED...

CLEANING THE RESERVOIR SEE FIGURE 2 ON PREVIOUS PAGE.

1. Clean the area around the inspection cover on reservoir, and then remove the cover.

2. Remove the suction strainer(s) from inside the reservoir and clean with a solvent (if applicable).

3. Remove all dirt and sediment from inside the reservoir.

4. Remove the filler cap and clean the filler cap screen. Check for damage. If damaged, replace the screen.

5. After everything in and around the reservoir is completely clean, replace the suction strainer(s) (if applicable), drain
plug, filler cap, and inspection cover.

FILLING THE RESERVOIR

1. With the drain plug in place and tightened, refill the reservoir with the recommended hydraulic oil. Be sure the filler
cap screen is in place and clean.

2. Be sure the Shut-off Valve(s) is open. Valve(s) must be open before pumps are operated or damage may occur to
pump.

3. Start the truck engine and engage the power take-off, running it slowly until the new oil circulates throughout the
system.

4. With all the control valves in neutral, run the machine until the pump quiets down, then add more hydraulic oil, if
necessary.

5. As an operator works the booms and grapple, add more hydraulic oil as needed to maintain proper level in reservoir.
This will work the air out of the system and prevent cavitation, which is caused by air bubbles in the hydraulic oil as
it passes through a pump.

6. Check the hydraulic oil level again after the loader has been operating for an hour or two. Add more hydraulic oil if
necessary.

80 XL &XLE
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page 34
 HYDRAULIC OIL FILTER MAINTENANCE
On a new machine the filter elements must be changed after the first
50 hours of operating time and then every 400 hours after that.

The filter head must be unbolted, twisted, and lifted off to

reveal the filter element which can then be removed and FILTER HEAD AND
replaced. BOLTS BYPASS

O-RING TOP PLATE OF

HYDRUALIC OIL
RESERVOIR
FILTER
ELEMENT
FILTER HOUSING
(WELDED TO TOP
PLATE
OF HYDRAULIC OIL
RESERVOIR)
Figure 2

80 XL &XLE
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page 35
 ELIMINATING AIR FROM THE SYSTEM
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 air
may be drawn in where fluid will not necessarily leak out.

5. Fluid level too low. This can cause vortexing at pump inlet in reservoir, thus drawing in air.

6. Air trapped in filter with no means of 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. Air trapped 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.

80 XL &XLE
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page 36
 HYDRAULIC FITTINGS, HOSES AND TUBING
A heavy wall tubing and multi-wire hose network carries the 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 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.

80 XL &XLE
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page 37
 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 1
BARREL
GREASE FITTING (butt & tube assy) 3 4

2 5
NUT 8 Bolt Torque Pattern
7 1
6 4
PISTON 3 5
GREASE FITTING
2 8
STROKE
GLAND BUSHING 10 Bolt Torque Pattern
LIMITER
10 1
7 4
6 5
HEX HEAD CAP ROD
SCREWS 3 9
2 8

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 wrench.
3. Remove hydraulic supply and return lines (including load lock valves if applicable) from cylinder to allow free
movement of rod.
4. Remove rod assembly from the cylinder barrel.
5. Unscrew the nut from the piston end of the rod and remove the piston and gland.
6. Before removing old seals, note position they are in for proper reassembly (see diagram on next page).
7. Clean and inspect all parts. If worn or damaged, replace them.
8. 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 page).
Install item # 10 before item # 8.
Heating item # 10, 7, and the stiff portion of # 1 in a 200° oven for 5 minutes will make it more pliable.
Some kits may contain extra seals.
When installing the wear rings, items # 2 & 6, put the cuts on opposite sides.
9. 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.

NOTE: The more common cylinders use the following tool sizes:
Hex head cap screws require 15/16" wrench.
Nut requires 3-1/8" wrench.
80 XL &XLE
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page 38
 Piston and Gland shown may not be type used on
your machine but are shown as a reference.

1
2

6
6 Piston
7
8
10
9

11

4
5 SEAL PLIERS (PART # 412-00409) BEING USED
TO BEND SEAL FOR INSTALLATION.

Gland

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

ITEM NO. DESCRIPTION QTY.

1 SEAL-PISTON 1
2 WEAR RING 2
3 O-RING 1
4 BACK-UP RING 1
5 SQUARE RING ROD BUFFER 1
6 WEAR RING 2
7 SEAL 1
8 SEAL ROD DEEP 1
9 WIPER-SNAP (NEW STYLE) 1
10 MODULAR BACKUP RING 1
11 O-RING 1

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 COLLECTOR MAINTENANCE
All hydraulic components below the turntable bearing continue to be operable during rotation of the upper assembly
because of the hydraulic collector. Located on the rotating turntable assembly, the collector is so designed as to allow
the flow of hydraulic oil to the cylinders at all points in the turntable rotation. (On most stationary electric machines, an
electric collector is used.)

COLLECTOR SHOWN MAY NOT BE TYPE USED ON YOUR MACHINE BUT IS SHOWN AS A REFERENCE.
BARREL
TORQUE ARM SPOOL
MOUNTING
PLATE

TORQUE ARM
SAFETY
WIRE

SCREWS

RETAINING
PLATE
SEALS

SAFETY WIRE

SERVICING
When seals inside collector wear out, a new seal kit must be purchased from your Barko dealer. (Seal kit numbers are
in parts manual on collector parts list.) Port numbers are stamped into collector for easy reference.

HYDRAULIC COLLECTOR SEAL KIT INSTRUCTIONS

DISASSEMBLY
- Remove safety wire and screws from spool retaining plate on top of collector.
- Remove spool from barrel using proper driving equipment, being careful not to damage seal lands or
polished inside diameter of barrel.
- Remove seals from spool by cutting with sharp knife, being careful not to damage spool lands. If teflon rings are used,
they must be cut off also and the expansion ring under the teflon ring should be replaced (the expansion ring can be
cut off or stretched).

CLEAN AND INSPECT

- Clean all components thoroughly.
- Inspect for damage to port threads, screw holes and threads, hole elongation, broken spool lands,etc..
Replace or repair damaged components as necessary.
- Barrel with grooves worn deeper than .007 is no longer safely usable.

- Below are four different collector sizes. Find yours, and be sure that the spool lands on your collector are not worn
deeper than .004 below the standard spool land depth given. Spool with lands worn deeper than .004 is no longer
safely usable.

(7" spool O.D. = 6.985 spool land depth) (5" spool O.D. = 4.985 spool land depth)
(6" spool O.D. = 5.985 spool land depth) (3-1/2" spool O.D. = 3.485 spool land depth)

- Seal grooves of .160 standard width worn beyond .185 at outside diameter are no longer safely usable.
- Grooves of .130 standard width beyond .150 at outside diameter are no longer safely usable.
- Loaded lip seal grooves of .275 standard width worn beyond .325 at outside diameter are no longer safely usable.

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 HYDRAULIC COLLECTOR MAINTENANCE CONTINUED...

COLLECTOR SHOWN MAY NOT BE TYPE USED ON YOUR MACHINE BUT IS SHOWN AS A REFERENCE.

BEARING GUIDE RING BEARING GUIDE RING

LOADED LIP SEAL
SQUARE SEAL LOADED LIP
SEAL
O-RING

TOP OF
COLLECTOR

ASSEMBLY
1. All parts must be clean and free of oil and dust.
2. Install o-rings, loaded lip seals, or teflon rings on spool. See below for teflon rings:

TEFLON RING INSTALLATION:

NOTE: If any teflon rings are used, they must be heated in order to stretch them properly for installation.
Heat teflon rings to 200-400 degrees Fahrenheit.

WARNING
Do not heat teflon rings beyond 400 degrees Fahrenheit.
If teflon rings are heated beyond 400 degrees Fahrenheit
they will give off harmful toxic fumes.

When the right temperature is reached the teflon ring will act like a rubber band when shaken.

Using heat resistant gloves, grasp teflon ring and slip over end of spool to groove. Speed is essential before
contracting occurs.

Ensure ring is not twisted in groove.

NOTE: Rings that may be loose on spool may be sized by compressing with suitable hose clamp. Then
remove clamp before proceeding.

ASSEMBLY CONTINUED...
3. Install the two bearing guide rings at each end as shown.
4. Install the square seals on top of o-rings. Be careful not to over-stretch the seals.
5. Inspect for proper seal alignment and install spool in barrel using suitable assembly equipment.
6. Reinstall retaining plate and screws. Tighten screws.
7. Install safety wire on top end of collector.

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 F130 VALVE ADJUSTMENTS (MAIN BOOM WITH STRAIGHT)

To adjust the pressure, install a gauge on the Valve (picture below) Adjust pressure
at the adjustment screw on the main relief valve located on the valve bank inlet cover.
You need a 12mm wrench for the cap, 13mm wrench for the locknut and a 4mm allen
wrench. Extend Main and Hold, Pressure should be set to 3200 PSI.

Tie Rod bolts are to be torqued to 44 Ft. Lbs.

No Port Relief No Port Relief

600 PSI
Port Relief
Main Rod

Main Relief

3600 PSI Port

Relief Main Butt

3200 PSI

558-01821

Gauge

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 F130 VALVE ADJUSTMENTS (MAIN BOOM WITH TELE)

To adjust the pressure, install a gauge on the Valve (picture below) Adjust pressure
at the adjustment screw on the main relief valve located on the valve bank inlet cover.
You need a 12mm wrench for the cap, 13mm wrench for the locknut and a 4mm allen
wrench. Extend Main and Hold, Pressure should be set to 3200 PSI.

Tie Rod bolts are to be torqued to 44 Ft. Lbs.

3600 PSI 3600 PSI

Port Relief Port Relief

No Port Relief
No Port Relief

3600 PSI
600 PSI
Port Relief
Port Relief

3200 PSI
558-01822

Gauge

Main Relief

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 F130 VALVE ADJUSTMENTS (STICK/ROTATE)
To adjust the pressure, install a gauge on the Valve (picture below) Adjust pressure
at the adjustment screw on the main relief valve located on the valve bank inlet cover.
You need a 12mm wrench for the cap, 13mm wrench for the locknut and a 4mm allen
wrench. Extend Stick and Hold, Pressure should be set to 3200 PSI.

Tie Rod bolts are to be torqued to 44 Ft. Lbs.

3600 PSI
3600 PSI Port Relief
Port Relief

N2

N2
Check
Valve

3200 PSI

558-01823

Gauge

Main Relief

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 P70 VALVE ADJUSTMENTS (SWING)
To adjust the pressure, install a gauge on the Valve (picture below) Adjust pressure
at the adjustment screw on the main relief valve located on the valve bank inlet cover.
You need a 10mm wrench for the locknut, and a 3mm allen wrench. Hold pressure on
Swing (right or left), Pressure should be set to 2500 PSI.

Tie Rod bolts are to be torqued to 19 Ft. Lbs.

2550 PSI
Port Relief
2550 PSI
Port Relief

2500 PSI

558-01824

Gauge

Main Relief

Gauge

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 P70 VALVE ADJUSTMENTS (STABILIZER)
To adjust the pressure, install a gauge on the Valve (picture below) Adjust pressure
at the adjustment screw on the main relief valve located on the valve bank inlet cover.
You need a 10mm wrench for the locknut, and a 3mm allen wrench. Hold pressure on
Stabilizer down, Pressure should be set to 3250 PSI.

Tie Rod bolts are to be torqued to 19 Ft. Lbs.

3250 PSI
Main Relief
Gauge

2750 PSI Y2 Plugged

Port Relief

2750 PSI
Port Relief Y2 Plugged

558-01825

Gauge

Main Relief

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 PUMP (METARIS MHP 365 TRIPLE)
2

1 4

ITEM NO. PART NO. DESCRIPTION SERIAL NO. OR DATE QTY.

OF CHANGE

560-02649 Complete Pump 1

560-02675 SHAFT BEARING 1

560-02676 SEAL KIT ( 1 KIT PER GEAR SECTION) 1
includes 2 #1, 4 #2, 4 #3, and 2 #4
5 560-02677 SHAFT SEAL 1

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 Maintenance
C. ELECTRICAL SYSTEM

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ELECTRICAL SCHEMATIC

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 Trouble Shooting

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 TROUBLE SHOOTING
Use this section only as a general guide to finding solutions for machine problems.

If the machine should malfunction, find the problem in the headings listed then refer to the possible causes and remedies
listed with the problem.

The list of problems, causes, and remedies will only give an indication of where a possible problem can be and what
repairs are needed.

More, or other, possible servicing may be needed beyond the recommendations in the list or a factory service man may
be required.

ENGINE TROUBLE SHOOTING

PROBLEM CAUSE REMEDY

Engine cranks but will not start or Fuel tank empty. Check fuel level. Fill as
starts hard. necessary.

Water in fuel or water frozen in fuel
lines. Water frozen in fuel filter.
Debris or dirt in fuel.
Air filter element restricted with
dirt, snow, or water.
Thaw and /or drain water from fuel
tank. Thaw ice in fuel lines and
drain. Install new fuel filter.
Drain and flush fuel system.
Change fuel filter.
Clean or replace filter elements.

Air intake pipe screen plugged.

Clean air intake pipe screen.

Low engine oil pressure. Low engine oil level. Check engine oil level. Fill to
correct level. Check for and
repair, any leaks.

Low viscosity - (using too light of Drain engine oil and fill with
oil in summer.) heavier weight engine oil.

Engine overheats. Low coolant level. Fill to correct level and check for
leaks.

Loose, worn, or broken fan belt. Tighten or replace belt.

Radiator plugged. Clean and inspect radiator.

Air filter elements plugged. Clean or replace elements.

Engine will not start. Low or discharged battery. Recharge battery.

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 TROUBLE SHOOTING CONTINUED...
HYDRAULIC SYSTEM TROUBLE SHOOTING
PROBLEM
Pump or motor too noisy.
Hydraulic oil overheats.
No flow or pressure.
Hydraulic system pressure too
low.
Hydraulic pressure erratic.
Slow hydraulic functions.
CAUSE
Low hydraulic oil supply or wrong
viscosity.
Air in hydraulic oil.
Hydraulic oil dirty or low supply.
Oil cooler dirty.
Relief valve improperly adjusted.
Incorrect hydraulic oil viscosity.
Excessive load.
Pump not receiving hydraulic oil.
Damaged line.
External leak in system.
Air in hydraulic oil.
Contamination in hydraulic oil.
Hydraulic oil viscosity too high.
Low hydraulic oil supply.
Obstruction in line or line
damaged.
80 XL &XLE
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REMEDY
Fill hydraulic reservoir with proper
oil.
Check for foamy oil. Tighten
connections, replace o-rings or
lines.
Replace filters and hydraulic oil.
Fill hydraulic reservoir to proper
level.
Inspect and clean cooler fins.
Adjust to specifications.
Replace oil with proper viscosity.
Reduce load.
Any or all of the following:
- Replace dirty filters.
- Clogged inlet line.
- Clean reservoir breather
vent.
- Fill reservoir to proper level.
Replace line.
Tighten connections and bleed air
from system.
Tighten connections, fill reservoir
to proper level, and bleed air from
system.
Replace dirty filter and system
hydraulic oil.
Hydraulic oil may be too cold or
should be replaced with proper
viscosity.
Fill hydraulic reservoir with proper
hydraulic oil.
Inspect lines. Replace parts if
necessary.
 TROUBLE SHOOTING CONTINUED...

HYDRAULIC SYSTEM TROUBLE SHOOTING CONTINUED...

PROBLEM CAUSE REMEDY

No machine functions. Low hydraulic oil level. Fill hydraulic reservoir with proper
oil.

Plugged suction line. Clean or replace strainer.

ELECTRICAL SYSTEM TROUBLE SHOOTING

PROBLEM CAUSE REMEDY

Battery will not charge. Loose or corroded connection. Clean and tighten battery
connections.

Loose alternator belts. Tighten or replace belts.

Starter will not work or cranks Loose or corroded connections. Clean and tighten connections.
slowly.
Wrong engine oil. Replace engine oil. Refer to Fuel
and Lubricants.

Gauges do not work. Gauge sender needs service. Replace sender.

Loose gauge ground connection. Check ground connection.

Tighten if necessary.

Windshield Wiper/Washer does Wiper/Washer switch needs Replace switch.

not work. service.

Wiper or washer motor needs Repair or replace motor.

service.

Disconnected or damaged wiring. Inspect wiring. Connect or replace

wiring as necessary.

Defroster does not work. Defroster switch needs service. Replace switch.

Defroster fan motor needs service. Repair or replace motor.

Disconnected or damaged wiring.

Inspect wiring. Connect or replace
wiring as necessary.

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 TROUBLE SHOOTING CONTINUED...
MACHINE OPERATIONS TROUBLE SHOOTING
PROBLEM CAUSE REMEDY

Boom will not remain raised. Main or Secondary boom valve Replace valve.
needs service.

No oil flow or pressure. Any or all of the following:

No servo pressure. - Replace dirty filters.
- Fill reservoir to proper level.

Damaged or loose lines. Replace or tighten lines.

Worn cylinder seals. Replace seals.

Platform assembly does not Swing motor needs service. Repair or replace motor.
swing.
Leakage or blockage in hydraulic Repair or replace sources of leaks
system. or blocks.

Swing pump needs service. Repair or replace pump.

No steering control. (if applicable) Leakage or blockage in hydraulic Repair or replace sources of leaks
system. and blocks.

Carrier system not operational. Repair or replace as needed.

Machine steering in opposite Lines to cylinders connected to Correct connections.

direction. (if applicable) wrong ports at steering valve or
cylinder.

Steering wheel does not turn. (if Binding in steering column or Inspect. Repair or replace parts
applicable) misalignment of column. as necessary.

High return line pressure. Check for a pinched or damaged

return line.

Contamination in steering valve. Inspect hydraulic filter for

contamination. Clean or replace
as necessary.

Erratic steering. Air in oil. Check for foaming oil. Replace.

Solenoid steering select valve Inspect. Replace if necessary.

needs service.

Low oil level in reservoir. Add oil.

Sticky steering valve spool. Repair or replace steering valve

spool.

Loose cylinder piston. Repair or replace steering

cylinder.

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 SYMPTOMS OF A DEFECTIVE COLLECTOR

1 External leak’s on collector

2 Failure to build system pressure in any one of the pump sections

3 Excessive heat in the hydraulic system caused by high pressure leakage between ports

Note: The position of the four ports on the swivel drawing.

Port 1 The tank port, any leakage between Port 1 and port 2 will cause a pressure loss in the swing system.
As this pressure will be returning to the tank through the return hose, this can be best diagnosed by
running a jumper hose around the collector to the pressure inlet on the swing valve.

Port 2 Feeds pressure to the swing control valve, any leakage between Port 2 and port 3 will cause pressure loss
in the swing and the left hand valve (sitting in the seat) which controls the main boom, grapple open and
close and extend. This can generally be diagnosed by bottoming out the main boom up or grapple
functions at the same time as the swing. This will allow both ports to come up to pressure which will
eliminate the pressure loss caused by the worn seal.

Port 3 Feeds pressure to the left hand valve (sitting in the seat) which controls the main boom, grapple open &
close and extend, any leakage between port 3 and port 2 or 4 will cause a pressure loss to the left hand
valve. The best way to diagnose worn seal is to bottom out the main boom up, stick boom and swing at
the same time, if all functions come up to relief pressure simultaneously, but not individually it is an
indication of bypass in the collector.

Port 4 Feeds pressure to the stick boom and grapple rotate. Any leakage between port 4 and port 3 or port 5 will
cause a pressure loss to the right hand valve (sitting in the seat). As this pump section feed the stabilizer
valve first and then passes through the collector to the right hand valve you can diagnose by bottoming out
a stabilizer first, if this valve comes up to relief pressure but the right hand valve does not it can be an
indication of worn seals.

Port 5 Returns the leakage from the swing motor to the tank. This leakage from the swing motor does normally
exceed 1-2 gallons per minute, If the seal is bypassing from port 4 to port 5 you will get high flow out of
the swivel when you work the functions on the right hand valve (sitting in the seat).

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 SYMPTOMS OF A DEFECTIVE SWING MOTOR

Worn swing motors can be diagnosed by jamming the grapple in the ground or log pile and checking the pressure
at Low RPM and Hi RPM. If the pressure is more than 500 psi low atLow RPM this can be an indication of a worn
swing motor. To ensure that the problem is in the swing motor and not collector bypass measure the flow of the oil
coming out of the case drain of the motor. Leakage from the motor that exceeds 1-2 GPM when the motor is under
pressure is an indication of a worn swing motor.

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 NOTE
This section of the manual is used for the decal kits appropriate for the 80C
Back of Cab/Trailer Mount. Those kits are:

80 BC Kit (539-01066)

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):

Decals
Serial Number or Qty.
Part No. Description/Location
Date of Change.
539-00746 DECAL, "Barko" (on each side of main boom) 2
(beige with orange shadow)
539-00909 DECAL, "80C" (on each side of main boom) 2
(beige with orange shadow)

---- PLATE, serial number (on frame pedestal) 1

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.

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