Barko loaders Crawler 475a User manual

475A475A

475A CrawlerCrawler

CrawlerCrawler

Crawler

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

012501

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.

BARKOBARKO

BARKO

HYDRAULICS,HYDRAULICS,

HYDRAULICS,LLCLLC

LLCLLC

LLC

mailing: PO Box 16227, Duluth, MN 55816 shipping: 1 Banks Avenue, Superior, WI 54880

phone:715-392-5641 fax:715-392-3931

website: www.barko.com email: [email protected]

OPERATORS: 800-00040 PARTS: 800-00101 SERVICE: 800-00167OPERATORS: 800-00040 PARTS: 800-00101 SERVICE: 800-00167

OPERATORS: 800-00040 PARTS: 800-00101 SERVICE: 800-00167

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

Fire Prevention .................................................. 13

Model Description ............................................. 14

MAINTENANCEMAINTENANCE

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

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

................................................... 1515

1515

15

A. Preventive MaintenanceA. Preventive Maintenance

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

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

........................... 1515

1515

15

Safety While Servicing ...................................... 16

Preventive Maintenance.................................... 17

Special New-Machine Instructions..................... 17

Service Schedule .............................................. 18

Lubrication Points .............................................. 20

Fluid Specifications ........................................... 22

Special Torque Specifications .......................... 24

General Torque Specifications ......................... 25

B. Hydraulic System MaintenanceB. Hydraulic System Maintenance

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

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

............... 2626

2626

26

Hydraulic Schematic ......................................... 27

Hydraulic Pressure Settings .............................. 28

Hydraulic Pressure Adjustment Procedure ....... 30

Hydraulic Reservoir Maintenance ..................... 35

Hydraulic Oil Filter Maintenance ........................ 38

Eliminating Air From the System ........................ 41

Hydraulic Fittings, Hoses and Tubing ............... 42

Hydraulic Cylinder Maintenance ....................... 43

Collector Maintenance ...................................... 45

Valve Maintenance (A20/A35 control valves) .... 47

Pump Maintenance (swing) ............................... 57

Pump Maintenance (boom & travel) .................. 58

Pump Maintenance (servo) ............................... 65

Motor Maintenance (drive) ................................. 69

Swing Motor Gearbox Maintenance (S10A) ....... 70

Swing Brake Maintenance ................................. 78

C. Electrical System MaintenanceC. Electrical System Maintenance

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

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

............... 8282

8282

82

Electrical System Description ........................... 83

Electrical System Inspection ............................. 83

Using an Extra Battery to Start Machine ............. 83

Alternator Drive Belt Adjustment ........................ 85

Alternator Maintenance ..................................... 85

Electrical System Trouble Shooting .................. 87

D. Power Unit MaintenanceD. Power Unit Maintenance

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

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

........................... 8888

8888

88

Engine Maintenance ......................................... 89

Pump Drive Maintenance .................................. 90

A. Two, Three and Four Pad Pump Drives ........ 90

B. Single Pad Pump Drives ............................... 93

C. Optional Disconnect Clutch ........................... 93

Air Cleaner Maintenance ................................... 94

E. Cat 330 Crawler Lower MaintenanceE. Cat 330 Crawler Lower Maintenance

E. Cat 330 Crawler Lower Maintenance ............

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

...... 9898

9898

98

Track Adjustment Procedure ............................. 99

Crawler Lower Lubrication Points ....................... 100

Crawler Lower Torque Specifications ................ 100

Final Drives - checking the oil level ................... 100

Final Drives - changing the oil ........................... 100

F. Structural MaintenanceF. Structural Maintenance

F. Structural Maintenance............................................................

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

.............................. 101101

101101

101

Turntable Bearing Maintenance ........................ 102

TROUBLE SHOOTINGTROUBLE SHOOTING

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

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

........................................ 106106

106106

106

Trouble Shooting............................................... 107

DECALSDECALS

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

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

................................................................. 112112

112112

112

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IntroductionIntroduction

Introduction

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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.

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

All requests for information, service or spare parts

should include loader serial number. For more

information contact:

Barko Hydraulics,LLC

P.O. Box 16227

One Banks Avenue

Duluth, MN 55816

Phone: 715-392-5641

Fax: 715-392-3931

Website: www.barko.com

Email: [email protected]

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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 475AMODEL 475A

MODEL 475A

BARKO HYDRAULICS, LLCBARKO HYDRAULICS, LLC

BARKO HYDRAULICS, LLC

MAXIMUM HYDRAULIC PRESSURE FORMAXIMUM HYDRAULIC PRESSURE FOR

MAXIMUM HYDRAULIC PRESSURE FOR

THIS MACHINE IS 4,250 PSI. SETTINGSTHIS MACHINE IS 4,250 PSI. SETTINGS

THIS MACHINE IS 4,250 PSI. SETTINGS

HIGHER THAN THIS MAY RESULT INHIGHER THAN THIS MAY RESULT IN

HIGHER THAN THIS MAY RESULT IN

HARM TO PERSONS AND PROPERTY.HARM TO PERSONS AND PROPERTY.

HARM TO PERSONS AND PROPERTY.

NOTE:NOTE:

NOTE: 4,250 PSI is the pump compensator pressure. Other pressure settings4,250 PSI is the pump compensator pressure. Other pressure settings

4,250 PSI is the pump compensator pressure. Other pressure settings4,250 PSI is the pump compensator pressure. Other pressure settings

4,250 PSI is the pump compensator pressure. Other pressure settings

may be lower, and must be noted.may be lower, and must be noted.

may be lower, and must be noted.

In many instances, we have learned that the hydraulic relief valves of this equipment

have been reset, increasing the maximum system pressure, 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 and serious physical damage to the equipment and personnel can

result. This is an extremely dangerous practice.This is an extremely dangerous practice.

This is an extremely dangerous practice.This is an extremely dangerous practice.

This is an extremely dangerous practice.

Accordingly, you are advised that the setting of this valve is limited to a maximum of

4,250 psi.4,250 psi.

4,250 psi. Pressure settings in excess of this level render each and all Barko

warranties null and void and constitute an obvious misuse and abuse of our product.

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 attach-

ments 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 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 you can run and/Don't assume that because you know the control functions of other similar machinery, that you can run and/

Don't assume that because you know the control functions of other similar machinery, that you can run and/Don't assume that because you know the control functions of other similar machinery, that you can run and/

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 andor service the Barko Loader. All machines differ in some ways, and these differences must be noted 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 servicingacknowledged. Read this manual thoroughly and understand all safety, operating, and servicing

acknowledged. Read this manual thoroughly and understand all safety, operating, and servicing

procedures before using the loader.procedures before using the loader.

procedures before using the loader.

2.2.

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

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

Know how to put your machine in a zero energy state for purposes of inspection, maintenance, 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 voltage power line mayNever approach power lines with any part of the machine or load! Current in a high voltage power line may

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

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

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

5.5.

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

Allow only the operator on the machine. Keep riders off. Riders on machine are subject to injury such asAllow only the operator on the machine. Keep riders off. Riders on machine are subject to injury such as

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,being struck by foreign objects and being thrown off the machine. Riders also obstruct the operator's view,

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.resulting in the machine being operated in an unsafe manner.

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 death mayNever use a boom or attachment for a work platform or personnel carrier. Serious injury or death may

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

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

result.result.

result.

7.7.

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

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

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.Failure to do so may allow boom or attachment to move, causing property damage, injury, or death.

Failure to do so may allow boom or attachment to move, causing property damage, injury, or death.

8.8.

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

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

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 allthe skin, causing serious injury. Relieve pressure before unhooking hydraulic or other lines. Tighten all

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 ejectconnections before applying pressure. Keep hands and body away from pinholes and nozzles which eject

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.fluids under high pressure. Use a piece of cardboard to search for leaks.

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

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.with this type of injury or gangrene may result.

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 a specific jobauthorization. Any modifications may void the warranty. This machine was designed to do a specific job

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

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 Decals section for decal kits applicable to your machine and for locations of all decals.machine's Decals section for decal kits applicable to your machine and for locations of all decals.

machine's Decals section 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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SAFETY SUMMARYSAFETY SUMMARY

SAFETY SUMMARY

Failure to follow safety precautions in this manual can result in death, severe personal injury and/or property damage.

Carefully read safety precautions below and within this manual. Heed all decals on machine.

DANGERDANGER

DANGER - Indicates an immediate hazard which WILL result in severe personal injury or death.

WARNINGWARNING

WARNING - Indicates a hazard or unsafe practice which COULD result in severe personal injury or death.

CAUTIONCAUTION

CAUTION - Indicates a hazard or unsafe practice which could result in minor personal injury or property

damage.

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 or permitdeath or severe injury. Do not smoke or permit

death or severe injury. Do not smoke or permit

open flames near fuels or hydraulic fluids. Do notopen flames near fuels or hydraulic fluids. Do not

open flames near fuels or hydraulic fluids. Do not

fill the tanks to capacity - allow room for fluidfill the tanks to capacity - allow room for fluid

fill the tanks to capacity - allow room for fluid

expansion. Do not remove the fuel cap or refuelexpansion. Do not remove the fuel cap or refuel

expansion. Do not remove the fuel cap or refuel

while engine is hot, running or without properwhile engine is hot, running or without proper

while engine is hot, running or without proper

ventilation. Never use fuel for cleaning purposes.ventilation. Never use fuel for cleaning purposes.

ventilation. Never use fuel for cleaning purposes.

Clean up any fluid spills immediately.Clean up any fluid spills immediately.

Clean up any fluid spills immediately.

WARNINGWARNING

WARNING

Be extra careful when traveling on a slope, nearBe extra careful when traveling on a slope, near

Be extra careful when traveling on a slope, near

ditches, congested areas or over rough ground.ditches, congested areas or over rough ground.

ditches, congested areas or over rough ground.

The danger of tipping is always present. KnowThe danger of tipping is always present. Know

The danger of tipping is always present. Know

your machine's capabilities.your machine's capabilities.

your machine's capabilities.

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

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!

DANGERDANGER

DANGER

Do not operate machine during electrical storms.Do not operate machine during electrical storms.

Do not operate machine during electrical storms.

WARNINGWARNING

WARNING

If machine malfunctions during operation, stopIf machine malfunctions during operation, stop

If machine malfunctions during operation, stop

machine motion as quickly as possible, lowermachine motion as quickly as possible, lower

machine motion as quickly as possible, lower

boom to the ground and shut down the machine.boom to the ground and shut down the machine.

boom to the ground and shut down the machine.

Service or repair the machine as needed beforeService or repair the machine as needed before

Service or repair the machine as needed before

running or operating again.running or operating again.

running or operating again.

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.

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SAFETY SUMMARY CONTINUED...

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, safetyRead and understand machine manuals, safety

Read and understand machine manuals, safetyRead and understand machine manuals, safety

Read and understand machine manuals, safety

decals, employer work rules, and applicabledecals, employer work rules, and applicable

decals, employer work rules, and applicable

government regulations.government regulations.

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.

WARNINGWARNING

WARNING

Allow only the operator on the machine. KeepAllow only the operator on the machine. Keep

Allow only the operator on the machine. Keep

riders off. Riders on machine are subject to deathriders off. Riders on machine are subject to death

riders off. Riders on machine are subject to death

or injury from being struck by foreign objects andor injury from being struck by foreign objects and

or injury from being struck by foreign objects and

being thrown from machine. Riders also obstructbeing thrown from machine. Riders also obstruct

being thrown from machine. Riders also obstruct

the operator's view, resulting in machine beingthe operator's view, resulting in machine being

the 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 work platformNever use a boom attachment for a work platform

Never use a boom attachment for a work platform

or personnel carrier.or personnel carrier.

or personnel carrier.

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. Do notall times to help prevent personal injury. Do not

all times to help prevent personal injury. Do not

wear loose fitting clothing or personal articles,wear loose fitting clothing or personal articles,

wear loose fitting clothing or personal articles,

loose or uncovered long hair, or jewelry.loose or uncovered long hair, or jewelry.

loose or uncovered long hair, or jewelry.

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

Do not exceed 15 PSI nozzle pressure whenDo not exceed 15 PSI nozzle pressure when

Do not exceed 15 PSI 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.

WARNINGWARNING

WARNING

Older air conditioning equipment may contain R-12,Older air conditioning equipment may contain R-12,

Older air conditioning equipment may contain R-12,

a substance which harms public health anda substance which harms public health and

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. J2209 orcertified to meet the requirements of S.A.E. J2209 or

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

J1990.J1990.

J1990.

WARNINGWARNING

WARNING

On machines equipped with an accumulator,On machines equipped with an accumulator,

On machines equipped with an accumulator,

release all pressure before working on therelease all pressure before working on the

release all pressure before working on the

system. After service work is done, repressurizesystem. After service work is done, repressurize

system. After service work is done, repressurize

the accumulator(s) to the proper specification.the accumulator(s) to the proper specification.

the accumulator(s) to the proper specification.

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.

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/attachment.Lower and secure boom/attachment.

Lower and secure boom/attachment.Lower and secure boom/attachment.

Lower and secure boom/attachment.

--

-Raise stabilizers.Raise stabilizers.

Raise stabilizers.Raise stabilizers.

Raise stabilizers.

--

-Shut down machine to a zero energy state.Shut down machine to a zero energy state.

Shut down machine to a zero energy state.Shut down machine to a zero energy state.

Shut down machine to a zero energy state.

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

death, severe injury or property damage.death, severe injury or property damage.

death, severe 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 battery, electronic throttle, and radio,disconnect battery, electronic throttle, and radio,

disconnect battery, electronic throttle, and radio,

or electrical and structural damage may occur.or electrical and structural damage may occur.

or electrical and structural damage may occur.

page 11page 11

page 11

475 A CRL

800-00167

SAFETY SUMMARY CONTINUED...

WARNINGWARNING

WARNING

Improper load handling and/or hydraulic pressureImproper load handling and/or hydraulic pressure

Improper load handling and/or hydraulic pressure

loss can cause load to impact cab guard,loss can cause load to impact cab guard,

loss can cause load to impact cab guard,

resulting in death or severe injury.resulting in death or severe injury.

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 handles andAlways maintain 3-point contact with handles and

Always maintain 3-point contact with handles and

steps when mounting or dismounting. Neversteps when mounting or dismounting. Never

steps when mounting or dismounting. Never

jump on or off machine. Do not rush. Walk, dojump on or off machine. Do not rush. Walk, do

jump on or off machine. Do not rush. Walk, do

not run.not run.

not run.

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

death, severe injury or property damage.death, severe injury or property damage.

death, severe injury or property damage.

WARNINGWARNING

WARNING

Grease all boom, cylinder, and turntable bearing/Grease all boom, cylinder, and turntable bearing/

Grease all boom, cylinder, and turntable bearing/

pinion points daily.pinion points daily.

pinion points daily.

WARNINGWARNING

WARNING

Transparent material such as safety glass must beTransparent material such as safety glass must be

Transparent material such as safety glass must be

replaced when it is cracked or broken, or whenreplaced when it is cracked or broken, or when

replaced when it is cracked or broken, or when

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

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.

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

475 A CRL

800-00167

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.

SAFETY SUMMARY CONTINUED...

WARNINGWARNING

WARNING

Hot and pressurized fluid can cause severe burns.Hot and pressurized fluid can cause severe burns.

Hot and pressurized fluid can cause severe burns.

Let system cool before removing any caps. ThenLet system cool before removing any caps. Then

Let system cool before removing any caps. Then

remove caps slowly.remove caps slowly.

remove caps slowly.

WARNINGWARNING

WARNING

Hot exhaust pipe can cause severe burns. Do notHot exhaust pipe can cause severe burns. Do not

Hot exhaust pipe can cause severe burns. Do not

touch exhaust pipe when hot, or when engine istouch exhaust pipe when hot, or when engine is

touch exhaust pipe when hot, or when engine is

running.running.

running.

DANGERDANGER

DANGER

Improper electrical connections will cause batteryImproper electrical connections will cause battery

Improper electrical connections will cause battery

explosion, combustion or electrical componentexplosion, combustion or electrical component

explosion, combustion or electrical component

damage, and may result in death or severe injury.damage, and may result in death or severe injury.

damage, and may result in death or 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

Always wear seat belt when operating or runningAlways wear seat belt when operating or running

Always wear seat belt when operating or running

machine.machine.

machine.

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.

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.

page 13page 13

page 13

475 A CRL

800-00167

FIRE PREVENTIONFIRE PREVENTION

FIRE PREVENTION

This machine may have several components which are at high temperatures under normal operating conditions, such

as the engine, exhaust system, brake system and transmission.

Clean the machine often. High pressure washing of the machine is suggested every 1000 hours (or 6 months) and

always after a spill.

The following list of hazards provides information which will help to prevent fires:

WARNINGWARNING

WARNING

Always keep a fire extinguisherAlways keep a fire extinguisher

Always keep a fire extinguisher

and first aid kit where they can beand first aid kit where they can be

and first aid kit where they can be

easily reached in case of fire andeasily reached in case of fire and

easily reached in case of fire and

keep these items properlykeep these items properly

keep these items properly

maintained.maintained.

maintained.

Operating personnel should beOperating personnel should be

Operating personnel should be

instructed on what to do in caseinstructed on what to do in case

instructed on what to do in case

of fire and be required toof fire and be required to

of fire and be required to

demonstrate how to use firedemonstrate how to use fire

demonstrate how to use fire

extinguisher and fire suppressionextinguisher and fire suppression

extinguisher and fire suppression

equipment.equipment.

equipment.

Any portable fire extinguisher orAny portable fire extinguisher or

Any portable fire extinguisher or

fire suppression system carriedfire suppression system carried

fire suppression system carried

on the machine that has beenon the machine that has been

on the machine that has been

used, should be recharged orused, should be recharged or

used, should be recharged or

replaced before the machinereplaced before the machine

replaced before the machine

resumes operating. Fireresumes operating. Fire

resumes operating. Fire

extinguisher manufacturersextinguisher manufacturers

extinguisher manufacturers

recommended service intervalsrecommended service intervals

recommended service intervals

should be followed.should be followed.

should be followed.

WARNINGWARNING

WARNING

Allow machine to cool down byAllow machine to cool down by

Allow machine to cool down by

idling the engine for a whileidling the engine for a while

idling the engine for a while

before shut-down. Many enginebefore shut-down. Many engine

before shut-down. Many engine

and transmission fires startand transmission fires start

and transmission fires start afterafter

afterafter

after

shut-down.shut-down.

shut-down.

WARNINGWARNING

WARNING

Before adding fuel, shut down theBefore adding fuel, shut down the

Before adding fuel, shut down the

engine and allow it to cool. Neverengine and allow it to cool. Never

engine and allow it to cool. Never

smoke while handling fuel orsmoke while handling fuel or

smoke while handling fuel or

working on either the fuel or theworking on either the fuel or the

working on either the fuel or the

hydraulic system.hydraulic system.

hydraulic system.

WARNINGWARNING

WARNING

Do not use the machine in areasDo not use the machine in areas

Do not use the machine in areas

with explosive dust or gases thatwith explosive dust or gases that

with explosive dust or gases that

can be ignited by arcs, sparks,can be ignited by arcs, sparks,

can be ignited by arcs, sparks,

hot components, or exhausthot components, or exhaust

hot components, or exhaust

fumes.fumes.

fumes.

WARNINGWARNING

WARNING

Daily inspect the machine forDaily inspect the machine for

Daily inspect the machine for

flammable debris, removing anyflammable debris, removing any

flammable debris, removing any

twigs, leaves, straw, rags, fluidtwigs, leaves, straw, rags, fluid

twigs, leaves, straw, rags, fluid

spills or leaks, dirt or grime. Payspills or leaks, dirt or grime. Pay

spills or leaks, dirt or grime. Pay

special attention to areas such asspecial attention to areas such as

special attention to areas such as

the engine, engine coolingthe engine, engine cooling

the engine, engine cooling

system, exhaust system, battery,system, exhaust system, battery,

system, exhaust system, battery,

electrical connections, brakeelectrical connections, brake

electrical connections, brake

systems, transmission/drivetrain,systems, transmission/drivetrain,

systems, transmission/drivetrain,

fuel system and hydraulic system.fuel system and hydraulic system.

fuel system and hydraulic system.

Clean as often as necessary toClean as often as necessary to

Clean as often as necessary to

help prevent overheating andhelp prevent overheating and

help prevent overheating and

combustion.combustion.

combustion.

WARNINGWARNING

WARNING

The electrical system (battery,The electrical system (battery,

The electrical system (battery,

electrical connections, etc.) can beelectrical connections, etc.) can be

electrical connections, etc.) can be

a source of arcs or sparks ifa source of arcs or sparks if

a source of arcs or sparks if

damaged or incorrectlydamaged or incorrectly

damaged or incorrectly

maintained. Daily inspect allmaintained. Daily inspect all

maintained. Daily inspect all

electrical wiring and connectionselectrical wiring and connections

electrical wiring and connections

for damage. Keep the batteryfor damage. Keep the battery

for damage. Keep the battery

terminals clean and tight. Replaceterminals clean and tight. Replace

terminals clean and tight. Replace

or repair any damaged part. Useor repair any damaged part. Use

or repair any damaged part. Use

proper battery connection andproper battery connection and

proper battery connection and

disconnection procedures.disconnection procedures.

disconnection procedures.

WARNINGWARNING

WARNING

Daily inspect all fuel and hydraulicDaily inspect all fuel and hydraulic

Daily inspect all fuel and hydraulic

oil tubes, hoses, and fittings foroil tubes, hoses, and fittings for

oil tubes, hoses, and fittings for

damage and leakage. Tighten ordamage and leakage. Tighten or

damage and leakage. Tighten or

replace as necessary. Alwaysreplace as necessary. Always

replace as necessary. Always

clean fluid spills.clean fluid spills.

clean fluid spills.

WARNINGWARNING

WARNING

Do not use ether or starting fluidsDo not use ether or starting fluids

Do not use ether or starting fluids

on diesel engines with glowon diesel engines with glow

on diesel engines with glow

plugs. These starting aids canplugs. These starting aids can

plugs. These starting aids can

explode and injure bystanders.explode and injure bystanders.

explode and injure bystanders.

WARNINGWARNING

WARNING

Before doing welding of any kind,Before doing welding of any kind,

Before doing welding of any kind,

clean machine and disconnectclean machine and disconnect

clean machine and disconnect

battery cables. Cover rubberbattery cables. Cover rubber

battery cables. Cover rubber

hoses, battery, and otherhoses, battery, and other

hoses, battery, and other

flammable parts. Never ground anflammable parts. Never ground an

flammable parts. Never ground an

arc welder or electricalarc welder or electrical

arc welder or electrical

accessories through turntable oraccessories through turntable or

accessories through turntable or

boom bearings as arcing mayboom bearings as arcing may

boom bearings as arcing may

occur causing bearing damage.occur causing bearing damage.

occur causing bearing damage.

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 welding procedureswelding or welding procedures

welding or welding procedures

will void the warranty, and maywill void the warranty, and may

will void the warranty, and may

cause structural damage.cause structural damage.

cause structural damage.

WARNINGWARNING

WARNING

Read the Engine Manual thatRead the Engine Manual that

Read the Engine Manual that

comes with every machine forcomes with every machine for

comes with every machine for

complete engine operating andcomplete engine operating and

complete engine operating and

engine safety instructions.engine safety instructions.

engine safety instructions.

page 14page 14

page 14

475 A CRL

800-00167

MODEL DESCRIPTIONMODEL DESCRIPTION

MODEL DESCRIPTION

GRAPPLEGRAPPLE

GRAPPLE

ROTATORROTATOR

ROTATOR

GRAPPLEGRAPPLE

GRAPPLE

ARMSARMS

ARMS

GRAPPLEGRAPPLE

GRAPPLE

CYLINDERCYLINDER

CYLINDER

FUELFUEL

FUEL

RESERVOIRRESERVOIR

RESERVOIR

TURNTABLETURNTABLE

TURNTABLE

BEARINGBEARING

BEARING

CRAWLERCRAWLER

CRAWLER

LOWERLOWER

LOWER

COUNTERWEIGHTCOUNTERWEIGHT

COUNTERWEIGHT

SHROUDINGSHROUDING

SHROUDING

(Engine,(Engine,

(Engine,

Pumps, etc.)Pumps, etc.)

Pumps, etc.)

HYDRAULIC OILHYDRAULIC OIL

HYDRAULIC OIL

RESERVOIRRESERVOIR

RESERVOIR

CABCAB

CAB

MAIN BOOMMAIN BOOM

MAIN BOOM

CYLINDERCYLINDER

CYLINDER

MAIN BOOMMAIN BOOM

MAIN BOOM

LIVE HEELLIVE HEEL

LIVE HEEL

BOOMBOOM

BOOM

LIVE HEELLIVE HEEL

LIVE HEEL

BOOMBOOM

BOOM

CYLINDERCYLINDER

CYLINDER

STICK BOOMSTICK BOOM

STICK BOOM

STICK BOOMSTICK BOOM

STICK BOOM

CYLINDERCYLINDER

CYLINDER

page 15page 15

page 15

475 A CRL

800-00167

MaintenanceMaintenance

Maintenance

A. PREVENTIVE MAINTENANCEA. PREVENTIVE MAINTENANCE

A. PREVENTIVE MAINTENANCE

MaintenanceMaintenance

Maintenance

page 16page 16

page 16

475 A CRL

800-00167

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 the boomAlways shut down the machine and lower the boom

Always shut down the machine and lower the boom

and attachment to the ground before working on theand attachment to the ground before working on the

and attachment to the ground before working on the

machine. If necessary to work on a lifted boom ormachine. If necessary to work on a lifted boom or

machine. If necessary to work on a lifted boom or

attachment, securely support the boom andattachment, securely support the boom and

attachment, securely support the boom and

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

attachment so they cannot move or fall in any way.

WARNINGWARNING

WARNING

Don't leave loose tools and rags on the machine.Don't leave loose tools and rags on the machine.

Don't leave loose tools and rags on the machine.

Ensure that all walking and climbing surfaces areEnsure that all walking and climbing surfaces are

Ensure that all walking and climbing surfaces are

clean.clean.

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 Fluid Specifications wheneverRefer to Fluid Specifications whenever

Refer to Fluid Specifications 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 death, severevoid the warranty, and may cause death, severe

void the warranty, and may cause death, severe

injury, property damage or structural damage to theinjury, property damage or structural damage to the

injury, property damage or structural damage to the

machine.machine.

machine.

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 death,specific job and alterations could result in death,

specific job and alterations could result in death,

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

severe injury or property damage.

WARNINGWARNING

WARNING

Relieve all hydraulic pressure before breaking anyRelieve all hydraulic pressure before breaking any

Relieve all hydraulic pressure before breaking any

hydraulic connection, opening the reservoir accesshydraulic connection, opening the reservoir access

hydraulic connection, opening the reservoir access

cover, or performing any maintenance on thecover, or performing any maintenance on the

cover, or performing any maintenance on the

machine.machine.

machine.

- Lower boom to ground.

- 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 17page 17

page 17

475 A CRL

800-00167

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.

AFTER THE FIRST 50 HOURS OF OPERATION OF A NEW MACHINEAFTER THE FIRST 50 HOURS OF OPERATION OF A NEW MACHINE

AFTER THE FIRST 50 HOURS OF OPERATION OF A NEW MACHINE

A new machine needs a special maintenance procedure after the first 50 hours of operation.

1. Do a complete inspection of the loader. Rectify any problems, replace any damaged parts.

2. Check torque (retorque if necessary):

- Turntable Bearing Mounting Bolts

- Mounting Bolts/Nuts on major machine components (gearboxes, motors, pumps, booms,

attachment, turntable bearing, lower assembly, tires, etc.)

3. Check torque of loader mounting bolts. Retorque if necessary.

4. Change all filter elements.

5. Change hydraulic oil in hydraulic oil reservoir.

6. Change gear fluid in swing motor gearbox.

Resume the normal maintenance intervals after this. See the Service Schedule for more information.

SPECIAL NEW-MACHINE INSTRUCTIONSSPECIAL NEW-MACHINE INSTRUCTIONS

SPECIAL NEW-MACHINE INSTRUCTIONS

PREVENTIVE MAINTENANCEPREVENTIVE MAINTENANCE

PREVENTIVE MAINTENANCE

WARNINGWARNING

WARNING

Instructions are necessary before doing service on loader. SeeInstructions are necessary before doing service on loader. See

Instructions are necessary before doing service on loader. See

warnings and instructions both at the beginning andwarnings and instructions both at the beginning and

warnings and instructions both at the beginning and

throughout this manual. After doing service or making repairsthroughout this manual. After doing service or making repairs

throughout this manual. After doing service or making repairs

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

or adjustments always check function of loader.

Safety glasses or goggles are always needed for eye protectionSafety glasses or goggles are always needed for eye protection

Safety glasses or goggles are always needed for eye protection

from electric arcs, from shorts or welding, battery acid,from electric arcs, from shorts or welding, battery acid,

from electric arcs, from shorts or welding, battery acid,

compressed springs, fluids under pressure, and flying debriscompressed springs, fluids under pressure, and flying debris

compressed springs, fluids under pressure, and flying debris

or loose material when engines are running or tools are used.or loose material when engines are running or tools are used.

or loose material when engines are running or tools are used.

Use eye protection approved for type of welding. Failure toUse eye protection approved for type of welding. Failure to

Use eye protection approved for type of welding. Failure to

obey warnings can cause death, severe injury or propertyobey warnings can cause death, severe injury or property

obey warnings can cause death, severe injury or property

damage.damage.

damage.

page 18page 18

page 18

475 A CRL

800-00167

SERVICE SCHEDULESERVICE SCHEDULE

SERVICE SCHEDULE

SERVICE REQUIREDSERVICE REQUIRED

SERVICE REQUIRED 8 HRS.8 HRS.

8 HRS.8 HRS.

8 HRS.

DAILYDAILY

DAILY

50 HRS.50 HRS.

50 HRS.

WEEKLYWEEKLY

WEEKLY

100 HRS.100 HRS.

100 HRS.

MONTHLYMONTHLY

MONTHLY

400 HRS.400 HRS.

400 HRS.

2 MONTHS2 MONTHS

2 MONTHS

1000 HRS.1000 HRS.

1000 HRS.

6 MONTHS6 MONTHS

6 MONTHS

Hydraulic ReservoirHydraulic Reservoir

Hydraulic Reservoir - check level/quality of oil.

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

needed. Inspect for dirt/debris and clean if needed.

Pump DrivePump Drive

Pump Drive - Check fluid level.

Hoses, Connections, CylindersHoses, Connections, Cylinders

Hoses, Connections, Cylinders - Check for leaks/

damage. Tighten, repair, or replace parts if needed.

Fan and DrivebeltsFan and Drivebelts

Fan and Drivebelts - Check for looseness/wear.

Tighten or replace as needed.

Operator's PlatformOperator's Platform

Operator's Platform - Clean area of debris,

tools, rags, water, ice, and snow.

Engine Air CleanerEngine Air Cleaner

Engine Air Cleaner - Check/replace element, if

needed.

Engine ShroudingEngine Shrouding

Engine Shrouding - Clean and inspect.

Hydraulic Oil FilterHydraulic Oil Filter

Hydraulic Oil Filter - On new machines filter

element should be replaced first at 50 hrs. - at 400

hrs. thereafter.

Hydraulic Oil ReservoirHydraulic Oil Reservoir

Hydraulic Oil Reservoir - On new machines oil must

be changed after first 50 hours, - every 1000 hours

after that.

FittingsFittings

Fittings - Lubricate as shown on Lubrication

Points. Use a multi-purpose grease.

Bolts/NutsBolts/Nuts

Bolts/Nuts - Visually inspect for wear or

damage.

Swing Motor GearboxSwing Motor Gearbox

Swing Motor Gearbox - Check fluid level.

Bolts/NutsBolts/Nuts

Bolts/Nuts - Inspect for tightness and\or damage on

boom and grapple.

Control Lever Linkage (if applicable)Control Lever Linkage (if applicable)

Control Lever Linkage (if applicable) - Lubricate.

Engine Oil FilterEngine Oil Filter

Engine Oil Filter - Replace.

BatteryBattery

Battery - Clean and coat posts with grease.

Check electrolyte level and fill if necessary.

Hydraulic Oil Cooler and RadiatorHydraulic Oil Cooler and Radiator

Hydraulic Oil Cooler and Radiator - Clean.

AccumulatorsAccumulators

Accumulators - Check pressure and maintain

at 900 PSI.

Hydraulic Oil Reservoir BreatherHydraulic Oil Reservoir Breather

Hydraulic Oil Reservoir Breather - Replace.

Hydraulic CollectorHydraulic Collector

Hydraulic Collector - Check mounting bolts.

Entire Loader -Entire Loader -

Entire Loader - Steam clean, inspect for

stress, wear, cracks, damage, and loose parts.

Hydraulic ReservoirHydraulic Reservoir

Hydraulic Reservoir --

--

- Replace oil and clean

suction screens.

Swing Motor GearboxSwing Motor Gearbox

Swing Motor Gearbox - Replace fluid.

Pump DrivePump Drive

Pump Drive - Replace fluid.

Hydraulic Oil FilterHydraulic Oil Filter

Hydraulic Oil Filter - Replace elements every

400 hours, after initial change at 50 hours on a

new machine.

page 19page 19

page 19

475 A CRL

800-00167

SERVICE SCHEDULE CONTINUED...

SERVICE REQUIREDSERVICE REQUIRED

SERVICE REQUIRED 8 HRS.8 HRS.

8 HRS.8 HRS.

8 HRS.

DAILYDAILY

DAILY

50 HRS.50 HRS.

50 HRS.

WEEKLYWEEKLY

WEEKLY

100 HRS.100 HRS.

100 HRS.

MONTHLYMONTHLY

MONTHLY

400 HRS.400 HRS.

400 HRS.

2 MONTHS2 MONTHS

2 MONTHS

1000 HRS.1000 HRS.

1000 HRS.

6 MONTHS6 MONTHS

6 MONTHS

Tracks -Tracks -

Tracks - Inspect for damaged shoes/missing or

loose bolts. Check master link for missing/loose

bolts. Inspect links for missing/leaking oil plugs.

Sprockets -Sprockets -

Sprockets - Check for wear/missing or broken

segments. Check for loose or missing hardware.

Recoil Mechanism GuardRecoil Mechanism Guard

Recoil Mechanism Guard - Check for damage and

loose or missing bolts.

Track Roller GuardTrack Roller Guard

Track Roller Guard - Check for damage and

loose or missing bolts.

Idlers/RollersIdlers/Rollers

Idlers/Rollers - Check for wear/leaks near shaft.

Final DriveFinal Drive

Final Drive - Change oil after first 100 hours of

service, - every 1000 hours after that. Check oil

level every 100 hours.

Track Idler YokeTrack Idler Yoke

Track Idler Yoke - Ensure idler yoke fully extended.

Track Roller FrameTrack Roller Frame

Track Roller Frame - Check for wear/cracks/broken

welds.

Final DriveFinal Drive

Final Drive - Drain, then fill with oil. Replace seals/

gaskets.

CRAWLER LOWER SERVICE SCHEDULECRAWLER LOWER SERVICE SCHEDULE

CRAWLER LOWER SERVICE SCHEDULE

NOTE: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.

page 20page 20

page 20

475 A CRL

800-00167

99

9

1212

12

11

111

11

1

22

2

33

3

33

3

33

3

33

3

44

4

55

5

66

6

77

7

88

8

88

8

99

9

1010

10

1010

10

99

9

1111

11

1313

13

1616

16

(Engine Oil)(Engine Oil)

(Engine Oil)

1414

14

(Gear Fluid)(Gear Fluid)

(Gear Fluid)

1515

15

(Engine Oil)(Engine Oil)

(Engine Oil)

1717

17

(Engine Oil)(Engine Oil)

(Engine Oil)

Pump Drive (except direct drive models) - EP 80-90 gear fluid.

Track Drive Gearbox - EP 80-90 gear fluid.

Crawler Final Drive - SAE 30 CD/TO-2 engine oil.

Crawler Front Idlers - SAE 30 CD/TO-2 engine oil.

Crawler Track Rollers and Carrier Rollers - SAE 30 CD/TO-2 engine oil.

Swing Motor Gearbox: EP 80-90 gear fluid (fill until oil is as high as top of cluster

bearings - see service manual for more information) (if lube reservoir is used,

maintain at half full).

GREASEGREASE

GREASE

GEAR FLUID ORGEAR FLUID OR

GEAR FLUID OR

ENGINE OILENGINE OIL

ENGINE OIL

1 Grapple Arms

2 Grapple Rotator

3 Grapple Cylinders

4 Grapple Hanger (2 fittings)

5 Main Boom Pivot

6 Stick Boom Pivot

7 Live Heel Boom Pivot

8 Main Boom Cylinders

9 Stick Boom Cylinder

10 Live Heel Boom Cylinders

11 Turntable Bearing and Pinion

12 Swing Motor Gearbox

**

*

13 Pump Drive

14 Track Drive Gearbox

15 Crawler Final Drive

16 Crawler Front Idlers

17 Crawler Track Rollers and

Carrier Rollers

**

*See Turntable Bearing

Lubrication on next page.

LUBRICATION POINTSLUBRICATION POINTS

LUBRICATION POINTS (PERFORM DAILY)(PERFORM DAILY)

(PERFORM DAILY)(PERFORM DAILY)

(PERFORM DAILY)

BARKO LOADERS Crawler 475A User manual

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