Barko hydraulics Barko loaders 160b User manual

BARKOBARKO

BARKO

HYDRAULICS,LLCHYDRAULICS,LLC

HYDRAULICS,LLC

P.O. BOX 16227 / DULUTH, MN 55816

SHIPPING: 1 BANKS AVE. / SUPERIOR, WI 54880

Machine

Serial Number

The information and illustrations in this manual have

been approved as accurate at the time of printing.

However,themanualmaycontaininformationonoptions

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.

BARKOBARKO

BARKO

LOADERSLOADERS

LOADERS

SERVICE MANUALSERVICE MANUAL

SERVICE MANUAL

160B, 160C and 200 Truck Mount160B, 160C and 200 Truck Mount

160B, 160C and 200 Truck Mount

(includes slasher and carrier options)(includes slasher and carrier options)

(includes slasher and carrier options)

090498

NOTE: The operating, service and safety instructions for a Slasher Saw or Carrier Lower are

not included in this manual. See manufacturer's information.

OPERATORS 160B TMOPERATORS 160B TM

OPERATORS 160B TM: 800-00010 PARTSPARTS

PARTSPARTS

PARTS: 800-00071 SERVICESERVICE

SERVICESERVICE

SERVICE: 800-00140

OPERATORS 160C TMOPERATORS 160C TM

OPERATORS 160C TM: 800-00011

TABLE OF CONTENTSTABLE OF CONTENTS

TABLE OF CONTENTS

INTRODUCTIONINTRODUCTION

INTRODUCTION ............................................................................

............................................................................

...................................... 33

33

3

Introduction ........................................................ 4

Abbreviations and Symbols .............................. 5

Hydraulic Pressure Warning Sheet ................... 6

Warranty ............................................................ 7

Know Your Machine ........................................... 8

Safety Summary ................................................ 9

Model Description ............................................. 13

Loader Mounting Instructions ............................. 14

Fire Prevention .................................................. 16

MAINTENANCEMAINTENANCE

MAINTENANCE ..............................................................................

..............................................................................

....................................... 1717

1717

17

A. Preventive MaintenanceA. Preventive Maintenance

A. Preventive Maintenance............................................................

............................................................

.............................. 1717

1717

17

Safety While Servicing ...................................... 18

Preventive Maintenance.................................... 19

Special New-Machine Instructions..................... 19

Service Schedule .............................................. 20

Lubrication Points .............................................. 22

Fuel and Lubricants ........................................... 24

Special Torque Specifications .......................... 26

General Torque Specifications ......................... 28

B. Hydraulic SystemB. Hydraulic System

B. Hydraulic System ..................................................................................

..................................................................................

......................................... 2929

2929

29

Hydraulic Schematics ....................................... 30

Hydraulic Pressure Settings .............................. 32

Trouble Shooting the Swing System .................. 34

Hydraulic Reservoir Maintenance ..................... 36

Hyraulic Oil Filter Maintenance .......................... 38

Eliminating Air From the System ........................ 39

Hydraulic Fittings, Hoses and Tubing ............... 40

Hydraulic Cylinder Maintenance ....................... 41

Collector Maintenance ...................................... 43

Valve Maintenance (A20 control valve) ............. 45

Pump Maintenance (TA-19 swing) ..................... 55

Pump Maintenance (servo) ............................... 73

Pump Maintenance (tandem) ............................ 86

Swing Motor Maintenance ................................. 100

Swing Motor Gearbox Maintenance (S1C) ......... 103

Danfoss Swing Motor Maintenance (OMV800) .. 112

C. Electrical SystemC. Electrical System

C. Electrical System....................................................................................

....................................................................................

.......................................... 115115

115115

115

Electrical System Description ........................... 116

Electrical System Inspection ............................. 116

Using an Extra Battery to Start Machine ............. 116

Installing a New Battery ..................................... 117

Alternator Drive Belt Adjustment ........................ 118

Alternator Maintenance ..................................... 118

Electrical System Trouble Shooting .................. 120

D. Power Unit MaintenanceD. Power Unit Maintenance

D. Power Unit Maintenance ..........................................................

..........................................................

............................. 121121

121121

121

Engine Maintenance ......................................... 122

Pump Drive Maintenance .................................. 123

A. Two, Three and Four Pad Pump Drives ........ 123

B. Single Pad Pump Drives ............................... 126

C. Optional Disconnect Clutch ........................... 126

Air Cleaner Maintenance ................................... 127

Engine Mounting Instructions ............................. 131

E. Grapple Service and InstallationE. Grapple Service and Installation

E. Grapple Service and Installation ..............................

..............................

............... 132132

132132

132

Grapple Installation ........................................... 133

Grapple Lubrication ........................................... 135

Grapple Pressure Settings and Oil Flow ............ 135

Grapple Torque Specifications ......................... 135

Collector Shaft Seal Installation (20K rotators) ... 136

Grapple Trouble Shooting ................................. 137

TROUBLE SHOOTINGTROUBLE SHOOTING

TROUBLE SHOOTING ......................................................

......................................................

........................... 138138

138138

138

Engine Trouble Shooting .................................. 139

Hydraulic System Trouble Shooting .................. 140

Electrical System Trouble Shooting .................. 141

Machine Operations Trouble Shooting.............. 142

DECALSDECALS

DECALS........................................................................................................

........................................................................................................

.................................................... 143143

143143

143

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IntroductionIntroduction

Introduction

page 4page 4

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INTRODUCTIONINTRODUCTION

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 professioinal operator's in their work, and should be

available for use at any time. If the loader is not eqipped with this manual, ask your supervisor to obtain one

for you.

Understand the correct servicing procedures before servicing the loader. It is important to know the correct

operating and servicing procedures of the loader and all safety precautions to prevent the possibility of property

damage and/or personal injury or death.

As a professional, trained operator, you are responsible for safety, both your own and that of your co-workers.

Your knowledge and use of all safety practices and correct servicing procedures in this manual, and your good

judgement, can be a major factor in preventing some of the thousands of injuries and deaths caused by

industrial accidents each year.

A professional operator should also be familiar with the information contained in other applicable sources such

as American National Standards, SAE, OSHA, etc.

ADDITIONAL INFORMATION:

Logging Safety Resource Guide (APA, 95-A-1) is available from the American Pulpwood Association. This

guide lists sources of videotapes, slide programs, movies, and publications on various aspects of logging

safety.

DON'T FORGET - SAFETY FIRST!DON'T FORGET - SAFETY FIRST!

DON'T FORGET - SAFETY FIRST!

Loader

Model No.

Serial No.

Engine

Model No.

Serial No.

All requests for information, service or spare parts

should include loader serial number. For more

information contact:

Barko Hydraulics,LLC

P.O. Box 16227

Duluth, MN 55816

Phone Number: 715-392-5641

Facsimile: 715-392-3931

The Loader serial number plate is located on the left

side of the cab riser.

NOTE:NOTE:

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.

REFERENCEREFERENCE

REFERENCE

INFORMATIONINFORMATION

INFORMATION

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ABBREVIATIONS AND SYMBOLSABBREVIATIONS AND SYMBOLS

ABBREVIATIONS AND SYMBOLS

EXPLANATIONS OF OTHER OCCURRENCES IN THIS MANUAL:EXPLANATIONS OF OTHER OCCURRENCES IN THIS MANUAL:

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 MACHINESYMBOLS USED ON MACHINE

SYMBOLS USED ON MACHINE

IgnitionIgnition

Ignition

Key SwitchKey Switch

Key Switch

Power OnPower On

Power On

(Accessory)(Accessory)

(Accessory)

Power OffPower Off

Power Off

Power OnPower On

Power On

HornHorn

Horn

StarterStarter

Starter

EngineEngine

Engine

RPMRPM

RPM

FasterFaster

Faster

SlowerSlower

Slower

AirAir

Air

ConditionerConditioner

Conditioner

a/c = air conditioner

AC = Articulated Carrier (Art. Car.)

adj. = adjust or adjusting

appl. = application

AR = As Required

assy = assembly

BC = Back of Cab

b/m = bill of material

brg. = bearing

CAR = Carrier

coll. = collector

cond. = conditioner

CRL = Crawler

cyl. = cylinder

dia. = diameter

dwg. = drawing

Ft. Lbs. = Foot Pounds

gal. = gallon

HRT = Hydrostatic Rough Terrain carrier

ill. or illus. = illustration

In. Lbs. = Inch Pounds

incl. = includes or including

j.s. = joystick

Lbs. = pounds

LH (lh) = left hand

mtg. = mounting

N/A = Not Applicable

no. = number

NSS = Not Sold Separately

opt. = optional

pg. = page

qt. = quart

RH (rh) = right hand

sec. = secondary

see sep. ill. = see separate illustration (means:

located elsewhere in manual)

SE = Stationary Electric

SER or SR = Stationary Electric Remote

s/n = serial number

str. = straight

swhd = saw head

TM = Truck Mount

w/ = with

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WARNINGWARNING

WARNING

MODEL 160CMODEL 160C

MODEL 160C andand

andand

and 200200

200200

200

MAXIMUM HYDRAULIC SYSTEM PRESSUREMAXIMUM HYDRAULIC SYSTEM PRESSURE

MAXIMUM HYDRAULIC SYSTEM PRESSURE

FOR THIS MACHINE IS 2,200 PSI.FOR THIS MACHINE IS 2,200 PSI.

FOR THIS MACHINE IS 2,200 PSI.

MAXIMUM SWING PRESSURE IS 2,400 PSI.MAXIMUM SWING PRESSURE IS 2,400 PSI.

MAXIMUM SWING PRESSURE IS 2,400 PSI.

SETTINGS HIGHER THAN THESE MAYSETTINGS HIGHER THAN THESE MAY

SETTINGS HIGHER THAN THESE MAY

RESULT IN DEATH, SEVERE INJURY ORRESULT IN DEATH, SEVERE INJURY OR

RESULT IN DEATH, SEVERE INJURY OR

PROPERTY DAMAGE.PROPERTY DAMAGE.

PROPERTY DAMAGE.

ON MACHINES WITH DUAL PRESSUREON MACHINES WITH DUAL PRESSURE

ON MACHINES WITH DUAL PRESSURE

SYSTEM:SYSTEM:

SYSTEM:

MAXIMUM SWING ACCELERATION PRESSURE IS 3,000 PSI.MAXIMUM SWING ACCELERATION PRESSURE IS 3,000 PSI.

MAXIMUM SWING ACCELERATION PRESSURE IS 3,000 PSI.

MAXIMUM SWING BRAKING PRESSURE IS 2,000 PSI.MAXIMUM SWING BRAKING PRESSURE IS 2,000 PSI.

MAXIMUM SWING BRAKING PRESSURE IS 2,000 PSI.

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 dangerousThis is an extremely dangerous

This is an extremely dangerousThis is an extremely dangerous

This is an extremely dangerous

practice.practice.

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, LLCBARKO HYDRAULICS, LLC

BARKO HYDRAULICS, LLCBARKO HYDRAULICS, LLC

BARKO HYDRAULICS, LLC

HYDRAULIC PRESSURE WARNING SHEETHYDRAULIC PRESSURE WARNING SHEET

HYDRAULIC PRESSURE WARNING SHEET

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BARKO HYDRAULICS, LLCBARKO HYDRAULICS, LLC

BARKO HYDRAULICS, LLC

WARRANTYWARRANTY

WARRANTY

BARKO HYDRAULICS, L.L.C. ("Barko") warrants to the Distributor and/or original Buyer each new hydraulic

knuckle boom loader, feller buncher or other product in BARKO HYDRAULICS Equipment Group including attachments

and accessories thereto, ("Product") sold by BARKO to be free from defects in material and workmanship under

normal use, maintenance and service.

BARKO will cause any major structural component of a BARKO product covered by this warranty which proves to

be defective in material or workmanship under normal use, maintenance and service within three (3) years ) or 6,000

hours, whichever occurs first from first day in service, provided first day in service is not later than one (1) year from

delivery to Distributor and/or original Buyer or other user, to be replaced without charge with a new or repaired part, at

BARKO election. BARKO also will cause the labor to remove any such defective part and to install the new or

repaired part to be provided without charge to the owner of said BARKO product. The parts and labor to meet this

warranty will be furnished by designated BARKO distributor.

BARKO will cause all other parts of product covered by this warranty which proves to be defective in material or

workmanship under normal use, maintenance and service within one (1 ) year or 2,000 hours, whichever occurs first

from first day in service, provided first day in service is not later than one (1) year from delivery to Distributor and/or

original Buyer or other user, to be replaced, without charge, with a new or repaired part, at BARKO election. BARKO

also will cause the labor to remove any such defective part and to install the new or repaired part to be provided

without charge to the owner of said BARKO product. The parts and labor to meet this warranty will be furnished by

BARKO designated distributor.

BARKO warrants all service parts purchased from BARKO and used on a BARKO manufactured unit, to be free

from defects in material and workmanship under normal use, maintenance and service for a period of six (6) months or

1,000 hours, whichever occurs first. BARKO will cause any such part which proves to be defective to be replaced

with a new or repaired part at BARKO election on a parts only basis.

Proof of any defect must be submitted to BARKO within ten (10) days from the date on which the defect was

discovered and any claim submitted within thirty (30) days after repair work is completed.

BARKO warranty does not cover:

1 Defects, damage or deterioration due to normal use, wear, tear, exposure, storage or corrosion.

2. Normal maintenance service, including replacement of filters, oil, seals and the like.

3. Damage due to failure to maintain or use the BARKO product or part according to manuals, schedules or good

practice.

4. Damage caused by abuse of equipment or parts by overloading, misapplication, improper operation or use,

installation of unapproved accessories or unauthorized alterations.

5. Damage resulting from repairs made in an unauthorized manner or installation of components not authorized by

BARKO.

6. The labor to remove and reinstall a defective replacement part after the expiration of the warranty period applicable

to the product in which part is located.

7. Overtime labor premiums.

8. Transportation of the BARKO product to the distributor's service facility or transportation of the distributor's

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.

THISWARRANTYISIN LIEU OFALLOTHER WARRANTIESEXPRESSOR IMPLIED, STATUTORY,WRITTENORORAL,

ANDTHEREISNOIMPLIEDWARRANTYOFMERCHANTABILITYOR FITNESSFORAPARTICULARPURPOSE.

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 MACHINEKNOW YOUR MACHINE

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.

1.1.

1. Don't assume that because you know the control functions of other similar machinery, that youDon't assume that because you know the control functions of other similar machinery, that you

Don't assume that because you know the control functions of other similar machinery, that youDon't assume that because you know the control functions of other similar machinery, that you

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 thesecan run and/or service the Barko Loader. All machines differ in some ways, and these

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 alldifferences must be noted and acknowledged. Read this manual thoroughly and understand all

differences must be noted and acknowledged. Read this manual thoroughly and understand all

safety, operating, and servicing procedures before using the loader.safety, operating, and servicing procedures before using the loader.

safety, operating, and servicing procedures before using the loader.

2.2.

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

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

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

or repair.or repair.

or repair.

3.3.

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

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

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

4.4.

4. Never approach power lines with any part of the machine or load! Current in a high voltageNever approach power lines with any part of the machine or load! Current in a high voltage

Never approach power lines with any part of the machine or load! Current in a high voltageNever approach power lines with any part of the machine or load! Current in a high voltage

Never approach power lines with any part of the machine or load! Current in a high voltage

power linepower line

power line may arc some distance to jump from the wire to a nearby "ground". KEEP WELLmay arc some distance to jump from the wire to a nearby "ground". KEEP WELL

may arc some distance to jump from the wire to a nearby "ground". KEEP WELLmay arc some distance to jump from the wire to a nearby "ground". KEEP WELL

may arc some distance to jump from the wire to a nearby "ground". KEEP WELL

CLEAR!CLEAR!

CLEAR!

5.5.

5. Allow only the operator on the machine. Keep riders off. Riders on machine are subject to injuryAllow only the operator on the machine. Keep riders off. Riders on machine are subject to injury

Allow only the operator on the machine. Keep riders off. Riders on machine are subject to injuryAllow only the operator on the machine. Keep riders off. Riders on machine are subject to injury

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 obstructsuch as being struck by foreign objects and being thrown off the machine. Riders also obstruct

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.the operator's view, resulting in the machine being operated in an unsafe manner.

the operator's view, resulting in the machine being operated in an unsafe manner.

6.6.

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

Never use a boom or attachment for a work platform or personnel carrier. Serious injury or deathNever use a boom or attachment for a work platform or personnel carrier. Serious injury or death

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

may result.may result.

may result.

7.7.

7. When machine is not operating or when leaving cab, boom and attachment must be lowered toWhen machine is not operating or when leaving cab, boom and attachment must be lowered to

When machine is not operating or when leaving cab, boom and attachment must be lowered toWhen machine is not operating or when leaving cab, boom and attachment must be lowered to

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,the ground. Failure to do so may allow boom or attachment to move, causing property damage,

the ground. Failure to do so may allow boom or attachment to move, causing property damage,

injury, or death.injury, or death.

injury, or death.

8.8.

8. Do not tamper with any hydraulic line when it is pressurized. Escaping fluid under pressure canDo not tamper with any hydraulic line when it is pressurized. Escaping fluid under pressure can

Do not tamper with any hydraulic line when it is pressurized. Escaping fluid under pressure canDo not tamper with any hydraulic line when it is pressurized. Escaping fluid under pressure can

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 otherpenetrate the skin, causing serious injury. Relieve pressure before unhooking hydraulic or other

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 fromlines. Tighten all connections before applying pressure. Keep hands and body away from

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 searchpinholes and nozzles which eject fluids under high pressure. Use a piece of cardboard to search

pinholes and nozzles which eject fluids under high pressure. Use a piece of cardboard to search

for leaks.for leaks.

for leaks.

If any fluid is injected into the skin, it must be surgically removed within a few hours by a doctorIf any fluid is injected into the skin, it must be surgically removed within a few hours by a doctor

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.familiar with this type of injury or gangrene may result.

familiar with this type of injury or gangrene may result.

9.9.

9. Under no circumstances should any modifications be made to Barko machinery without factoryUnder no circumstances should any modifications be made to Barko machinery without factory

Under no circumstances should any modifications be made to Barko machinery without factoryUnder no circumstances should any modifications be made to Barko machinery without factory

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 aauthorization. Any modifications may void the warranty. This machine was designed to do a

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.specific job and alterations could result in property damage, injury or death.

specific job and alterations could result in property damage, injury or death.

10.10.

10. Replace any safety decals that are faded, torn, missing, illegible, or otherwise damaged. See yourReplace any safety decals that are faded, torn, missing, illegible, or otherwise damaged. See your

Replace any safety decals that are faded, torn, missing, illegible, or otherwise damaged. See yourReplace any safety decals that are faded, torn, missing, illegible, or otherwise damaged. See your

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.machine's Parts Manual for decal kits applicable to your machine and for locations of all decals.

machine's Parts Manual for decal kits applicable to your machine and for locations of all decals.

Don't stop here - read on.Don't stop here - read on.

Don't stop here - read on.

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DANGERDANGER

DANGER

Never approach power lines with any part of theNever approach power lines with any part of the

Never approach power lines with any part of the

machine. Current in a high voltage line may arcmachine. Current in a high voltage line may arc

machine. Current in a high voltage line may arc

some distance to jump from the wire to a nearbysome distance to jump from the wire to a nearby

some distance to jump from the wire to a nearby

"ground". KEEP WELL CLEAR!"ground". KEEP WELL CLEAR!

"ground". KEEP WELL CLEAR!

SAFETY SUMMARYSAFETY SUMMARY

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.

DANGERDANGER

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

WARNINGWARNING

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

death.

CAUTIONCAUTION

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

personal injury.

WARNINGWARNING

WARNING

Combustible and flammable fluids can causeCombustible and flammable fluids can cause

Combustible and flammable fluids can cause

death or severe injury. Do not smoke near fuelsdeath or severe injury. Do not smoke near fuels

death or severe injury. Do not smoke near fuels

or hydraulic fluids. Do not refuel while engine isor hydraulic fluids. Do not refuel while engine is

or hydraulic fluids. Do not refuel while engine is

hot or running and without proper ventilation.hot or running and without proper ventilation.

hot or running and without proper ventilation.

WARNINGWARNING

WARNING

Always lower boom to ground and shut downAlways lower boom to ground and shut down

Always lower boom to ground and shut down

engine before leaving cab. If necessary to workengine before leaving cab. If necessary to work

engine before leaving cab. If necessary to work

on machine with lifted boom, securely supporton machine with lifted boom, securely support

on machine with lifted boom, securely support

machine and attachment.machine and attachment.

machine and attachment.

DANGERDANGER

DANGER

Improper electrical connections will causeImproper electrical connections will cause

Improper electrical connections will cause

battery explosion, combustion or electricalbattery explosion, combustion or electrical

battery explosion, combustion or electrical

component damage, and may result in death orcomponent damage, and may result in death or

component damage, and may result in death or

severe injury.severe injury.

severe injury.

This is a 12 volt negative ground electricalThis is a 12 volt negative ground electrical

This is a 12 volt negative ground electrical

system.system.

system.

WARNINGWARNING

WARNING

Do not move loads over top of truck cab. Do notDo not move loads over top of truck cab. Do not

Do not move loads over top of truck cab. Do not

allow driver to remain in truck cab whileallow driver to remain in truck cab while

allow driver to remain in truck cab while

operating. Severe injury, death or propertyoperating. Severe injury, death or property

operating. Severe injury, death or property

damage may result.damage may result.

damage may result.

WARNINGWARNING

WARNING

Safe and stable mounting of this machine on aSafe and stable mounting of this machine on a

Safe and stable mounting of this machine on a

truck or trailer bed is the owner's responsibility.truck or trailer bed is the owner's responsibility.

truck or trailer bed is the owner's responsibility.

See Mounting Instructions in Service Manual forSee Mounting Instructions in Service Manual for

See Mounting Instructions in Service Manual for

recommended procedures.recommended procedures.

recommended procedures.

WARNINGWARNING

WARNING

Wear required personal protective equipment atWear required personal protective equipment at

Wear required personal protective equipment at

all times to help prevent personal injury.all times to help prevent personal injury.

all times to help prevent personal injury.

page 10page 10

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160B&C TM

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WARNINGWARNING

WARNING

Do not operate or work on machine until you:Do not operate or work on machine until you:

Do not operate or work on machine until you:

--

-Read and understand machine manuals,Read and understand machine manuals,

Read and understand machine manuals,Read and understand machine manuals,

Read and understand machine manuals,

safety decals, employer work rules, andsafety decals, employer work rules, and

safety decals, employer work rules, and

applicable government regulations.applicable government regulations.

applicable government regulations.

--

-Are trained and qualified in safe machineAre trained and qualified in safe machine

Are trained and qualified in safe machineAre trained and qualified in safe machine

Are trained and qualified in safe machine

operation and maintenance.operation and maintenance.

operation and maintenance.

--

-Consult supervisor to explain any unclearConsult supervisor to explain any unclear

Consult supervisor to explain any unclearConsult supervisor to explain any unclear

Consult supervisor to explain any unclear

instructions and warnings.instructions and warnings.

instructions and warnings.

--

-Contact Barko to replace lost manuals.Contact Barko to replace lost manuals.

Contact Barko to replace lost manuals.Contact Barko to replace lost manuals.

Contact Barko to replace lost manuals.

DANGERDANGER

DANGER

Moving stabilizers will cause death or severeMoving stabilizers will cause death or severe

Moving stabilizers will cause death or severe

injury. Stand clear. Operate stabilizers onlyinjury. Stand clear. Operate stabilizers only

injury. Stand clear. Operate stabilizers only

when personnel are clear.when personnel are clear.

when personnel are clear.

DANGERDANGER

DANGER

Falling boom or load will cause death or severeFalling boom or load will cause death or severe

Falling boom or load will cause death or severe

injury. Stay clear if boom or load are notinjury. Stay clear if boom or load are not

injury. Stay clear if boom or load are not

grounded.grounded.

grounded.

Clear all persons from area of operation andClear all persons from area of operation and

Clear all persons from area of operation and

machine movement. Never move boom or loadsmachine movement. Never move boom or loads

machine movement. Never move boom or loads

over the heads of other persons.over the heads of other persons.

over the heads of other persons.

WARNINGWARNING

WARNING

Allow only operator on machine. Keep ridersAllow only operator on machine. Keep riders

Allow only operator on machine. Keep riders

off. Riders on machine are subject to injury suchoff. Riders on machine are subject to injury such

off. Riders on machine are subject to injury such

as being struck by foreign objects and beingas being struck by foreign objects and being

as being struck by foreign objects and being

thrown off machine. Riders also obstructthrown off machine. Riders also obstruct

thrown off machine. Riders also obstruct

operator's view, resulting in machine beingoperator's view, resulting in machine being

operator's view, resulting in machine being

operated in an unsafe manner.operated in an unsafe manner.

operated in an unsafe manner.

Never use a boom attachment for a workNever use a boom attachment for a work

Never use a boom attachment for a work

platform or personnel carrier.platform or personnel carrier.

platform or personnel carrier.

WARNINGWARNING

WARNING

An unstable machine can cause death, severeAn unstable machine can cause death, severe

An unstable machine can cause death, severe

injury, or property damage. Do not operateinjury, or property damage. Do not operate

injury, or property damage. Do not operate

machine without lowering stabilizers on firm,machine without lowering stabilizers on firm,

machine without lowering stabilizers on firm,

level ground.level ground.

level ground.

WARNINGWARNING

WARNING

When using a Slasher Saw Attachment, be sureWhen using a Slasher Saw Attachment, be sure

When using a Slasher Saw Attachment, be sure

to get proper informational manuals fromto get proper informational manuals from

to get proper informational manuals from

Slasher manufacturer. Read and understandSlasher manufacturer. Read and understand

Slasher manufacturer. Read and understand

those manuals before using this machine forthose manuals before using this machine for

those manuals before using this machine for

Slasher purposes.Slasher purposes.

Slasher purposes.

WARNINGWARNING

WARNING

Improper machine transport can cause death,Improper machine transport can cause death,

Improper machine transport can cause death,

severe injury or property damage.severe injury or property damage.

severe injury or property damage.

Before transporting:Before transporting:

Before transporting:

--

-Lower and secure boom and attachment toLower and secure boom and attachment to

Lower and secure boom and attachment toLower and secure boom and attachment to

Lower and secure boom and attachment to

truck bed.truck bed.

truck bed.

--

-Raise stabilizers.Raise stabilizers.

Raise stabilizers.Raise stabilizers.

Raise stabilizers.

--

-Shut down engine.Shut down engine.

Shut down engine.Shut down engine.

Shut down engine.

SAFETY SUMMARY CONTINUED...SAFETY SUMMARY CONTINUED...

SAFETY SUMMARY CONTINUED...

page 11page 11

page 11

160B&C TM

800-00140

WARNINGWARNING

WARNING

Improper load handling and/or hydraulicImproper load handling and/or hydraulic

Improper load handling and/or hydraulic

pressure loss can cause load to impact cabpressure loss can cause load to impact cab

pressure loss can cause load to impact cab

guard, resulting in death or severe injury.guard, resulting in death or severe injury.

guard, resulting in death or severe injury.

--

-Do not rely on guard alone for personalDo not rely on guard alone for personal

Do not rely on guard alone for personalDo not rely on guard alone for personal

Do not rely on guard alone for personal

protection. Use safe and proper loadprotection. Use safe and proper load

protection. Use safe and proper load

handling techniques.handling techniques.

handling techniques.

--

-Do not operate machine with damaged orDo not operate machine with damaged or

Do not operate machine with damaged orDo not operate machine with damaged or

Do not operate machine with damaged or

unsecured guard or cab.unsecured guard or cab.

unsecured guard or cab.

--

-Do not repair damaged guard. Replace withDo not repair damaged guard. Replace with

Do not repair damaged guard. Replace withDo not repair damaged guard. Replace with

Do not repair damaged guard. Replace with

factory-authorized guard.factory-authorized guard.

factory-authorized guard.

--

-Do not modify guard without factoryDo not modify guard without factory

Do not modify guard without factoryDo not modify guard without factory

Do not modify guard without factory

authorization.authorization.

authorization.

--

-Do not operate before conducting Pre-StartDo not operate before conducting Pre-Start

Do not operate before conducting Pre-StartDo not operate before conducting Pre-Start

Do not operate before conducting Pre-Start

Maintenance Inspection. Check hydraulicMaintenance Inspection. Check hydraulic

Maintenance Inspection. Check hydraulic

components for leaks, loose fittings orcomponents for leaks, loose fittings or

components for leaks, loose fittings or

damage.damage.

damage.

WARNINGWARNING

WARNING

High pressure hydraulic fluid can penetrate skinHigh pressure hydraulic fluid can penetrate skin

High pressure hydraulic fluid can penetrate skin

causing death, gangrene or other severe injury.causing death, gangrene or other severe injury.

causing death, gangrene or other severe injury.

Seek immediate medical help to remove fluid.Seek immediate medical help to remove fluid.

Seek immediate medical help to remove fluid.

--

-Keep hands and body away from areasKeep hands and body away from areas

Keep hands and body away from areasKeep hands and body away from areas

Keep hands and body away from areas

ejecting fluid. Use piece of cardboard toejecting fluid. Use piece of cardboard to

ejecting fluid. Use piece of cardboard to

check for leaks. Wear proper hand and eyecheck for leaks. Wear proper hand and eye

check for leaks. Wear proper hand and eye

protection.protection.

protection.

--

-Relieve hydraulic pressure before looseningRelieve hydraulic pressure before loosening

Relieve hydraulic pressure before looseningRelieve hydraulic pressure before loosening

Relieve hydraulic pressure before loosening

any hydraulic connections.any hydraulic connections.

any hydraulic connections.

--

-Tighten all hydraulic connections beforeTighten all hydraulic connections before

Tighten all hydraulic connections beforeTighten all hydraulic connections before

Tighten all hydraulic connections before

applying hydraulic pressure.applying hydraulic pressure.

applying hydraulic pressure.

WARNINGWARNING

WARNING

Always maintain 3-point contact with handlesAlways maintain 3-point contact with handles

Always maintain 3-point contact with handles

and steps when mounting or dismounting. Neverand steps when mounting or dismounting. Never

and steps when mounting or dismounting. Never

jump on or off machine.jump on or off machine.

jump on or off machine.

WARNINGWARNING

WARNING

Mechanically connected controls will causeMechanically connected controls will cause

Mechanically connected controls will cause

movement of components at all times - even ifmovement of components at all times - even if

movement of components at all times - even if

pump or engine is not operating. Always bepump or engine is not operating. Always be

pump or engine is not operating. Always be

certain that boom and attachment are properlycertain that boom and attachment are properly

certain that boom and attachment are properly

supported or resting on firm ground beforesupported or resting on firm ground before

supported or resting on firm ground before

stopping engine to minimize chance ofstopping engine to minimize chance of

stopping engine to minimize chance of

accidental movements of components causingaccidental movements of components causing

accidental movements of components causing

injury or death.injury or death.

injury or death.

CAUTIONCAUTION

CAUTION

Grease all boom, cylinder, and turntableGrease all boom, cylinder, and turntable

Grease all boom, cylinder, and turntable

bearing/pinion points daily.bearing/pinion points daily.

bearing/pinion points daily.

WARNINGWARNING

WARNING

Transparent material such as safety glass mustTransparent material such as safety glass must

Transparent material such as safety glass must

be replaced when it is cracked or broken, orbe replaced when it is cracked or broken, or

be replaced when it is cracked or broken, or

when vision is obscured due to scratches.when vision is obscured due to scratches.

when vision is obscured due to scratches.

WARNINGWARNING

WARNING

Loose or overtorqued bolts can cause death,Loose or overtorqued bolts can cause death,

Loose or overtorqued bolts can cause death,

severe injury, or property damage. Maintainsevere injury, or property damage. Maintain

severe injury, or property damage. Maintain

proper bolt torque. Visually check bolts daily.proper bolt torque. Visually check bolts daily.

proper bolt torque. Visually check bolts daily.

Check torque every 50 hours.Check torque every 50 hours.

Check torque every 50 hours.

WARNINGWARNING

WARNING

Remove or secure all personal or maintenanceRemove or secure all personal or maintenance

Remove or secure all personal or maintenance

items such as lunch buckets, chains, shovels,items such as lunch buckets, chains, shovels,

items such as lunch buckets, chains, shovels,

tools, etc., before moving or operating machine.tools, etc., before moving or operating machine.

tools, etc., before moving or operating machine.

WARNINGWARNING

WARNING

Replace any safety decals that are faded, torn,Replace any safety decals that are faded, torn,

Replace any safety decals that are faded, torn,

missing, illegible, or otherwise damaged.missing, illegible, or otherwise damaged.

missing, illegible, or otherwise damaged.

SAFETY SUMMARY CONTINUED...SAFETY SUMMARY CONTINUED...

SAFETY SUMMARY CONTINUED...

WARNINGWARNING

WARNING

Make sure that all walking and climbing surfacesMake sure that all walking and climbing surfaces

Make sure that all walking and climbing surfaces

of machine are free of dirt, debris, water, grease,of machine are free of dirt, debris, water, grease,

of machine are free of dirt, debris, water, grease,

oil, and snow. Do not leave loose tools or ragsoil, and snow. Do not leave loose tools or rags

oil, and snow. Do not leave loose tools or rags

on machine. Replace all non-skid material that ison machine. Replace all non-skid material that is

on machine. Replace all non-skid material that is

torn, missing or damaged.torn, missing or damaged.

torn, missing or damaged.

page 12page 12

page 12

160B&C TM

800-00140

WARNINGWARNING

WARNING

Any unauthorized welding, alterations, additionsAny unauthorized welding, alterations, additions

Any unauthorized welding, alterations, additions

or modifications made to Barko machinery willor modifications made to Barko machinery will

or modifications made to Barko machinery will

void warranty. This machine was designed to dovoid warranty. This machine was designed to do

void warranty. This machine was designed to do

a specific job and alterations could result ina specific job and alterations could result in

a specific job and alterations could result in

injury or property damage.injury or property damage.

injury or property damage.

If Barko-authorized welding must be done, firstIf Barko-authorized welding must be done, first

If Barko-authorized welding must be done, first

disconnect both battery cables and all alternatordisconnect both battery cables and all alternator

disconnect both battery cables and all alternator

connections or electrical and structural damageconnections or electrical and structural damage

connections or electrical and structural damage

to machine may occur.to machine may occur.

to machine may occur.

WARNINGWARNING

WARNING

Hot and pressurized fluid can cause severeHot and pressurized fluid can cause severe

Hot and pressurized fluid can cause severe

burns. Let system cool before removing anyburns. Let system cool before removing any

burns. Let system cool before removing any

caps. Then remove caps slowly.caps. Then remove caps slowly.

caps. Then remove caps slowly.

WARNINGWARNING

WARNING

If this machine is equipped with electric motorIf this machine is equipped with electric motor

If this machine is equipped with electric motor

driven Auxiliary Oil Cooler, be sure battery isdriven Auxiliary Oil Cooler, be sure battery is

driven Auxiliary Oil Cooler, be sure battery is

disconnected before going near cooler fan. Ifdisconnected before going near cooler fan. If

disconnected before going near cooler fan. If

battery is not disconnected, fan may come on atbattery is not disconnected, fan may come on at

battery is not disconnected, fan may come on at

any time causing severe injury.any time causing severe injury.

any time causing severe injury.

CAUTIONCAUTION

CAUTION

Check the Air Cleaner Assembly daily for cracks,Check the Air Cleaner Assembly daily for cracks,

Check the Air Cleaner Assembly daily for cracks,

loose clamps, or any other damage. If debris isloose clamps, or any other damage. If debris is

loose clamps, or any other damage. If debris is

able to bypass the Air Cleaner for any reason, itable to bypass the Air Cleaner for any reason, it

able to bypass the Air Cleaner for any reason, it

can damage the engine.can damage the engine.

can damage the engine.

WARNINGWARNING

WARNING

Maintain all components of Muffler Assembly toMaintain all components of Muffler Assembly to

Maintain all components of Muffler Assembly to

meet noise and exhaust standards.meet noise and exhaust standards.

meet noise and exhaust standards.

WARNINGWARNING

WARNING

Use caution when checking items beyond yourUse caution when checking items beyond your

Use caution when checking items beyond your

reach. Use an approved safety ladder.reach. Use an approved safety ladder.

reach. Use an approved safety ladder.

WARNINGWARNING

WARNING

Hot exhaust pipe can cause severe burns. DoHot exhaust pipe can cause severe burns. Do

Hot exhaust pipe can cause severe burns. Do

not touch exhaust pipe when hot, or whennot touch exhaust pipe when hot, or when

not touch exhaust pipe when hot, or when

engine is running.engine is running.

engine is running.

WARNINGWARNING

WARNING

Do not exceed 15 p.s.i. nozzle pressure whenDo not exceed 15 p.s.i. nozzle pressure when

Do not exceed 15 p.s.i. nozzle pressure when

drying parts with compressed air. Do not directdrying parts with compressed air. Do not direct

drying parts with compressed air. Do not direct

compressed air against human skin. Seriouscompressed air against human skin. Serious

compressed air against human skin. Serious

injury could result.injury could result.

injury could result.

CAUTIONCAUTION

CAUTION

Use only hydraulic fluid in hydraulic oil reservoir.Use only hydraulic fluid in hydraulic oil reservoir.

Use only hydraulic fluid in hydraulic oil reservoir.

Use only diesel fuel in fuel reservoir.Use only diesel fuel in fuel reservoir.

Use only diesel fuel in fuel reservoir.

Other fluids will cause machine damage.Other fluids will cause machine damage.

Other fluids will cause machine damage.

CALIFORNIACALIFORNIA

CALIFORNIA

Proposition 65 WarningProposition 65 Warning

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are knownDiesel engine exhaust and some of its constituents are known

Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, andto the State of California to cause cancer, birth defects, and

to the State of California to cause cancer, birth defects, and

other reproductive harm.other reproductive harm.

other reproductive harm.

WARNINGWARNING

WARNING

Older air conditioning equipment may contain R-Older air conditioning equipment may contain R-

Older air conditioning equipment may contain R-

12, a substance which harms public health and12, a substance which harms public health and

12, a substance which harms public health and

environment by destroying ozone in the upperenvironment by destroying ozone in the upper

environment by destroying ozone in the upper

atmosphere. To remove R-12 from the airatmosphere. To remove R-12 from the air

atmosphere. To remove R-12 from the air

conditioning system, use service equipmentconditioning system, use service equipment

conditioning system, use service equipment

certified to meet the requirements of S.A.E. J2209certified to meet the requirements of S.A.E. J2209

certified to meet the requirements of S.A.E. J2209

or J1990.or J1990.

or J1990.

SAFETY SUMMARY CONTINUED...SAFETY SUMMARY CONTINUED...

SAFETY SUMMARY CONTINUED...

page 13page 13

page 13

160B&C TM

800-00140

STICK BOOMSTICK BOOM

STICK BOOM

CYLINDERCYLINDER

CYLINDER

MAINMAIN

MAIN

BOOMBOOM

BOOM

PLATFORM/CONTROL DECKPLATFORM/CONTROL DECK

PLATFORM/CONTROL DECK

EXHAUSTEXHAUST

EXHAUST

ASSEMBLYASSEMBLY

ASSEMBLY

SHROUDINGSHROUDING

SHROUDING

(POWER UNIT,(POWER UNIT,

(POWER UNIT,

PUMPS, ETC.PUMPS, ETC.

PUMPS, ETC.

INSIDE)INSIDE)

INSIDE)

MAIN BOOMMAIN BOOM

MAIN BOOM

CYLINDERCYLINDER

CYLINDER

TURNTABLETURNTABLE

TURNTABLE

BEARINGBEARING

BEARING

LOWERLOWER

LOWER

(SUBFRAME)(SUBFRAME)

(SUBFRAME)

SWING MOTORSWING MOTOR

SWING MOTOR

GEARBOXGEARBOX

GEARBOX

SWINGSWING

SWING

MOTORMOTOR

MOTOR

STABILIZERSTABILIZER

STABILIZER

CYLINDERCYLINDER

CYLINDER

STABILIZER LEGSTABILIZER LEG

STABILIZER LEG

STABILIZER PADSTABILIZER PAD

STABILIZER PAD

GRAPPLEGRAPPLE

GRAPPLE

HEADHEAD

HEAD

GRAPPLEGRAPPLE

GRAPPLE

ARMSARMS

ARMS

GRAPPLEGRAPPLE

GRAPPLE

CYLINDERSCYLINDERS

CYLINDERS

HYDRAULIC OILHYDRAULIC OIL

HYDRAULIC OIL

RESERVOIRRESERVOIR

RESERVOIR

CABCAB

CAB

HEADHEAD

HEAD

ASSEMBLYASSEMBLY

ASSEMBLY

WARNINGWARNING

WARNING

Boom is shown in lifted, operating position. Always shut down the machine and lowerBoom is shown in lifted, operating position. Always shut down the machine and lower

Boom is shown in lifted, operating position. Always shut down the machine and lower

boom and attachment to the ground when not operating or before maintenance of anyboom and attachment to the ground when not operating or before maintenance of any

boom and attachment to the ground when not operating or before maintenance of any

kind. If necessary to work on a lifted boom or attachment, securely support the boom andkind. If necessary to work on a lifted boom or attachment, securely support the boom and

kind. 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.attachment so that they cannot move or fall in any way.

attachment so that they cannot move or fall in any way.

MODEL DESCRIPTIONMODEL DESCRIPTION

MODEL DESCRIPTION

Use this diagram to identify your loader's components for future service reference:

STICK BOOMSTICK BOOM

STICK BOOM

page 14page 14

page 14

160B&C TM

800-00140

LOADER MOUNTING INSTRUCTIONSLOADER MOUNTING INSTRUCTIONS

LOADER MOUNTING INSTRUCTIONS

Use these recommended procedures for mounting the Truck Mount machine to truck/trailer frame. Truck/trailer

frame is usually made of channel or I-beam. The following instructions show mostly I-beam, however the

principles for mounting to channel are generally the same, unless noted.

1. Using suitable lifting equipment, place loader on truck/trailer frame over axles, leaving enough room for tailswing

of machine plus two ft.

2. At each mounting point (there will be four mounting points, see Figure 2), install a spacer block slightly longer

than opening between I-beam edges. See Figure 1. Spacer blocks must fit snug. DO NOT WELD!

CAUTIONCAUTION

CAUTION

Do not cut spacer blocks too short, which will cause a loose fit, or too longDo not cut spacer blocks too short, which will cause a loose fit, or too long

Do not cut spacer blocks too short, which will cause a loose fit, or too long

which will cause frame to spread. See Figure 1.which will cause frame to spread. See Figure 1.

which will cause frame to spread. See Figure 1.

Figure 1Figure 1

Figure 1

NOTE:NOTE:

NOTE: To prevent distortion of truck frame and ensure solid base for loader, align spacer blocks with edge of

truck frame.

3. Install mounting clamp plates, mounting studs and nuts, putting clamp plates on top of subframe and under

I-beam or channel. See Figure 2.

NUTNUT

NUT

SUBFRAMESUBFRAME

SUBFRAME

CLAMPCLAMP

CLAMP

PLATEPLATE

PLATE

JAM NUTJAM NUT

JAM NUT

I-BEAM-BEAM

-BEAM-BEAM

-BEAM

NUTNUT

NUT

NOTE:NOTE:

NOTE: Top nuts used on mounting studs must be secured to studs by hammering threads or tack welding.

See Figure 3 for proper mounting on either I-beam or channel frames.

STUDSTUD

STUD

Figure 2Figure 2

Figure 2

CLAMP PLATECLAMP PLATE

CLAMP PLATE

page 15page 15

page 15

160B&C TM

800-00140

CHANNELMOUNTEDCHANNELMOUNTED

CHANNELMOUNTED

Figure 3Figure 3

Figure 3

4. When tightening mounting studs and nuts, run the nuts up so that bottom clamp plate makes contact with

frame in a level, even manner. See Figure 4.

I--

--

-BEAM MOUNTEDBEAM MOUNTED

BEAM MOUNTEDBEAM MOUNTED

BEAM MOUNTED

SPACER BLOCKSPACER BLOCK

SPACER BLOCK

JAM NUTJAM NUT

JAM NUT

NUTNUT

NUT

BOTTOMBOTTOM

BOTTOM

CLAMPCLAMP

CLAMP

PLATEPLATE

PLATE

STUDSTUD

STUD

CHANNELCHANNEL

CHANNEL

SUBFRAMESUBFRAME

SUBFRAME

NUTNUT

NUT

TOPTOP

TOP

CLAMPCLAMP

CLAMP

PLATEPLATE

PLATE

NUTNUT

NUT

TOP CLAMP PLATETOP CLAMP PLATE

TOP CLAMP PLATE

SUBFRAMESUBFRAME

SUBFRAME

STUDSTUD

STUD

BOTTOM CLAMP PLATEBOTTOM CLAMP PLATE

BOTTOM CLAMP PLATE

I--

--

-BEAMBEAM

BEAMBEAM

BEAM

JAM NUTJAM NUT

JAM NUT

NUTNUT

NUT

SPACERSPACER

SPACER

BLOCKBLOCK

BLOCK

Figure 4Figure 4

Figure 4

5. Tighten each pair of nuts to 450 ft. lbs. of lubed torque.

6. Put jam nuts on right after torqued nuts.

Be sure mounting studs are perpendicular to top of frame edges. If not, this may cause undue stress to studs

which could result in property damage or personal injury. See Figure 5.

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

Figure 5Figure 5

Figure 5

WARNINGWARNING

WARNING

Safe and stable mounting of this machine onSafe and stable mounting of this machine on

Safe and stable mounting of this machine on

truck or trailer bed is owner's responsibility.truck or trailer bed is owner's responsibility.

truck or trailer bed is owner's responsibility.

Follow all recommended Mounting Instructions.Follow all recommended Mounting Instructions.

Follow all recommended Mounting Instructions.

WARNINGWARNING

WARNING

Do not weld on any structural member of loaderDo not weld on any structural member of loader

Do not weld on any structural member of loader

unless specifically authorized by Barko Hydraulics.unless specifically authorized by Barko Hydraulics.

unless specifically authorized by Barko Hydraulics.

Any unauthorized welding or welding proceduresAny unauthorized welding or welding procedures

Any unauthorized welding or welding procedures

will void warranty, and may cause structural failure.will void warranty, and may cause structural failure.

will void warranty, and may cause structural failure.

LOADER MOUNTING INSTRUCTIONS CONTINUED...LOADER MOUNTING INSTRUCTIONS CONTINUED...

LOADER MOUNTING INSTRUCTIONS CONTINUED...

page 16page 16

page 16

160B&C TM

800-00140

FIRE PREVENTIONFIRE PREVENTION

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 basison a daily basis

on a daily basison a daily basis

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.

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 cab, engine

compartment, and engine

cooling system every day. Clean

if necessary to prevent

overheating. Remove all

flammable material (rags, debris,

fluid spills, etc.)

- Inspect all electrical wiring and

connections for damage daily.

Keep the battery terminals clean

and 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 necessary. Always clean

fluid spills.

- Do not use ether or starting

fluids on diesel engines with glow

plugs. These starting aids can

explode and injure bystanders.

FIRE PREVENTIONFIRE PREVENTION

FIRE PREVENTION

CHECK LISTCHECK LIST

CHECK LIST

- Before doing welding of any kind,

clean machine and disconnect

battery cables. Cover rubber

hoses, battery, and 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.

WARNINGWARNING

WARNING

Do not weld on any structuralDo not weld on any structural

Do not weld on any structural

member unless specificallymember unless specifically

member unless specifically

authorized by Barkoauthorized by Barko

authorized by Barko

Hydraulics. Any unauthorizedHydraulics. Any unauthorized

Hydraulics. Any unauthorized

welding or weldingwelding or welding

welding or welding

procedures will void theprocedures will void the

procedures will void the

warranty, and may causewarranty, and may cause

warranty, and may cause

structural damage.structural damage.

structural damage.

- Stop engine and 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 connecting

and disconnecting procedures.

See Electrical System

Maintenance section in Service

Manual.

- 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.

page 17page 17

page 17

160B&C TM

800-00140

MaintenanceMaintenance

Maintenance

A. PREVENTIVE MAINTENANCEA. PREVENTIVE MAINTENANCE

A. PREVENTIVE MAINTENANCE

MaintenanceMaintenance

Maintenance

page 18page 18

page 18

160B&C TM

800-00140

The following maintenance section gives suggested guidelines for operational maintenance on your machine. It is

not intended for use as a service manual.

In severe conditions (extreme dust, heat, cold, humidity, etc.) you will need to service your machine more often.

Your experience will dictate a more severe servicing program.

Safety while servicing your machine is your responsibility. Only qualified and authorized personnel should be

permitted to maintain, repair, adjust and inspect machine.

Read and understand warnings and safety precautions in Safety Summary and elsewhere in this manual before

doing any service on machine. The following precautions should be used as a reminder to safe servicing.

SAFETY WHILE SERVICINGSAFETY WHILE SERVICING

SAFETY WHILE SERVICING

REMEMBER: SAFETY FIRST!REMEMBER: SAFETY FIRST!

REMEMBER: SAFETY FIRST!

WARNINGWARNING

WARNING

Always shut down the machine and lower theAlways shut down the machine and lower the

Always shut down the machine and lower the

boom and attachment to the ground beforeboom and attachment to the ground before

boom and attachment to the ground before

working on the machine. If necessary to work on aworking on the machine. If necessary to work on a

working on the machine. If necessary to work on a

lifted boom or attachment, securelylifted boom or attachment, securely

lifted boom or attachment, securely

support the boom and attachment so that theysupport the boom and attachment so that they

support the boom and attachment so that they

cannot move or fall in any way.cannot move or fall in any way.

cannot move or fall in any way.

WARNINGWARNING

WARNING

Don't leave loose tools and rags on theDon't leave loose tools and rags on the

Don't leave loose tools and rags on the

machine. Ensure that all walking and climbingmachine. Ensure that all walking and climbing

machine. Ensure that all walking and climbing

surfaces are clean.surfaces are clean.

surfaces are clean.

WARNINGWARNING

WARNING

Handle fuel carefully. Do not smoke while fillingHandle fuel carefully. Do not smoke while filling

Handle fuel carefully. Do not smoke while filling

fuel tank or working near fuel.fuel tank or working near fuel.

fuel tank or working near fuel.

Refer to Fuel and Lubricants wheneverRefer to Fuel and Lubricants whenever

Refer to Fuel and Lubricants whenever

replacing oils, fluids, or filling fuel tank.replacing oils, fluids, or filling fuel tank.

replacing oils, fluids, or filling fuel tank.

WARNINGWARNING

WARNING

Do not weld on any structural member unlessDo not weld on any structural member unless

Do not weld on any structural member unless

specifically authorized by Barko Hydraulics. Anyspecifically authorized by Barko Hydraulics. Any

specifically authorized by Barko Hydraulics. Any

unauthorized welding or welding procedures willunauthorized welding or welding procedures will

unauthorized welding or welding procedures will

void the warranty, and may cause structuralvoid the warranty, and may cause structural

void the warranty, and may cause structural

damage and injury.damage and injury.

damage and injury.

WARNINGWARNING

WARNING

Do not support the machine on cinder blocks,Do not support the machine on cinder blocks,

Do not support the machine on cinder blocks,

hollow tiles, or props that may crumble under ahollow tiles, or props that may crumble under a

hollow tiles, or props that may crumble under a

load. Do not work under a machine that isload. Do not work under a machine that is

load. Do not work under a machine that is

supported solely by a jack.supported solely by a jack.

supported solely by a jack.

CAUTIONCAUTION

CAUTION

Check the Hour Meter regularly to determine whenCheck the Hour Meter regularly to determine when

Check the Hour Meter regularly to determine when

the machine needs periodic maintenance. Use thethe machine needs periodic maintenance. Use the

the machine needs periodic maintenance. Use the

intervals on the Service Schedule except whenintervals on the Service Schedule except when

intervals on the Service Schedule except when

operating in extreme conditions; then shorteroperating in extreme conditions; then shorter

operating in extreme conditions; then shorter

intervals must be used.intervals must be used.

intervals must be used.

WARNINGWARNING

WARNING

Under no circumstances should any modificationsUnder no circumstances should any modifications

Under no circumstances should any modifications

be made to Barko machinery without factorybe made to Barko machinery without factory

be made to Barko machinery without factory

authorization. Any modifications may void theauthorization. Any modifications may void the

authorization. Any modifications may void the

warranty. This machine was designed to do awarranty. This machine was designed to do a

warranty. This machine was designed to do a

specific job and alterations could result in injury tospecific job and alterations could result in injury to

specific job and alterations could result in injury to

operator or machine.operator or machine.

operator or machine.

WARNINGWARNING

WARNING

Relieve air pressure in the hydraulic reservoirRelieve air pressure in the hydraulic reservoir

Relieve air pressure in the hydraulic reservoir

before breaking any hydraulic connection orbefore breaking any hydraulic connection or

before breaking any hydraulic connection or

before opening the reservoir access cover.before opening the reservoir access cover.

before opening the reservoir access cover.

- Lower boom to ground.

- Pull up on Swing Pedal Disengage Lever to disengage

swing pedal.

- Shut down machine to a zero energy state.

- Remove key from ignition.

- On joystick machines, disengage servo lever.

- Allow machine to cool.

- Relieve all hydraulic pressure.

- Disconnect battery.

- Remove, block or guard against body contact with all

other sources of hazardous pressure, temperature,

electricity, or machine motion.

- Ensure machine, boom or attachment are not

supported on props that may collapse. Ensure boom

and attachment are grounded.

BEFORE INSPECTION OR MAINTENANCE:BEFORE INSPECTION OR MAINTENANCE:

BEFORE INSPECTION OR MAINTENANCE:

page 19page 19

page 19

160B&C TM

800-00140

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.

Instructions are necessary before doing serviceInstructions are necessary before doing service

Instructions are necessary before doing service

on loader. See warnings and instructions bothon loader. See warnings and instructions both

on loader. See warnings and instructions both

at the beginning and throughout this manual.at the beginning and throughout this manual.

at the beginning and throughout this manual.

After doing service or making repairs orAfter doing service or making repairs or

After doing service or making repairs or

adjustments always check function of loader.adjustments always check function of loader.

adjustments always check function of loader.

Safety glasses or goggles are always needed forSafety glasses or goggles are always needed for

Safety glasses or goggles are always needed for

eye protection from electric arcs, from shorts oreye protection from electric arcs, from shorts or

eye protection from electric arcs, from shorts or

welding, battery acid, compressed springs, fluidswelding, battery acid, compressed springs, fluids

welding, battery acid, compressed springs, fluids

under pressure, and flying debris or looseunder pressure, and flying debris or loose

under pressure, and flying debris or loose

material when engines are running or tools arematerial when engines are running or tools are

material when engines are running or tools are

used. Use eye protection approved for type ofused. Use eye protection approved for type of

used. Use eye protection approved for type of

welding. Failure to obey warnings can causewelding. Failure to obey warnings can cause

welding. Failure to obey warnings can cause

injury or death.injury or death.

injury or death.

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.

SPECIAL NEW-MACHINE INSTRUCTIONSSPECIAL NEW-MACHINE INSTRUCTIONS

SPECIAL NEW-MACHINE INSTRUCTIONS

PREVENTIVE MAINTENANCEPREVENTIVE MAINTENANCE

PREVENTIVE MAINTENANCE

WARNINGWARNING

WARNING

page 20page 20

page 20

160B&C TM

800-00140

1000 HRS.1000 HRS.

1000 HRS.

400 HRS.400 HRS.

400 HRS.

100 HRS.100 HRS.

100 HRS.

50 HRS.50 HRS.

50 HRS.

8 HRS.8 HRS.

8 HRS.

DAILYDAILY

DAILY

SERVICE REQUIREDSERVICE REQUIRED

SERVICE REQUIRED

Fan and DrivebeltsFan and Drivebelts

Fan and Drivebelts - Check for looseness

and wear. Tighten or replace as needed.

Operator's PlatformOperator's Platform

Operator's Platform - Clean area of debris,

tools, rags, water, ice, and snow.

Fuel TankFuel Tank

Fuel Tank - Check level and fill if necessary.

Engine Crankcase OilEngine Crankcase Oil

Engine Crankcase Oil - Check level.

Engine RadiatorEngine Radiator

Engine Radiator - Check coolant level and

fill if necessary. Inspect exterior for dirt and

debris and clean if necessary.

Hoses, Connections, CylindersHoses, Connections, Cylinders

Hoses, Connections, Cylinders - Inspect for

leaks and damage. Tighten, repair, or

replace parts if necessary.

Pump DrivePump Drive

Pump Drive - Check fluid level.

Swing Motor GearboxSwing Motor Gearbox

Swing Motor Gearbox - Check fluid level.

Engine Air CleanerEngine Air Cleaner

Engine Air Cleaner - Inspect & replace

element,if needed.

Hydraulic ReservoirHydraulic Reservoir

Hydraulic Reservoir - check level and quality

of oil.

Hydraulic Oil ReservoirHydraulic Oil Reservoir

Hydraulic Oil Reservoir - On new machines

the oil must be changed after the first 50 hours,

and then every 1000 hours after that.

Hydraulic Oil FilterHydraulic Oil Filter

Hydraulic Oil Filter - On new machines the

filter element should be replaced first at 50

hrs. and then at 400 hrs. thereafter.

Engine ShroudingEngine Shrouding

Engine Shrouding - Clean and inspect.

SERVICE SCHEDULESERVICE SCHEDULE

SERVICE SCHEDULE

WEEKLYWEEKLY

WEEKLY MONTHLYMONTHLY

MONTHLYMONTHLY

MONTHLY 2 MONTHS2 MONTHS

2 MONTHS2 MONTHS

2 MONTHS 6 MONTHS6 MONTHS

6 MONTHS6 MONTHS

6 MONTHS

FittingsFittings

Fittings - Lubricate as shown on Lubrication

Points. Use a multi-purpose grease.

Bolts/NutsBolts/Nuts

Bolts/Nuts - Visually inspect for wear or

damage.

Control Lever LinkageControl Lever Linkage

Control Lever Linkage - Lubricate.

Bolts/NutsBolts/Nuts

Bolts/Nuts - Check for proper

torque every 50 hours. Retorque if necessary.

BatteryBattery

Battery - Clean and coat posts with grease.

Check electrolyte level and fill if necessary.

Engine Oil FilterEngine Oil Filter

Engine Oil Filter - Replace.

Hydraulic Oil Cooler and RadiatorHydraulic Oil Cooler and Radiator

Hydraulic Oil Cooler and Radiator - Clean.

Hydraulic Oil Reservoir BreatherHydraulic Oil Reservoir Breather

Hydraulic Oil Reservoir Breather - Replace.

Hydraulic CollectorHydraulic Collector

Hydraulic Collector - Check mounting bolts.

AccumulatorsAccumulators

Accumulators - Check pressure and maintain

at 900 PSI.

Barko Hydraulics Barko Loaders 160B User manual

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