Barko 6025 User manual

The information and illustrations in this manual have been approved as accurate at the

time of printing. However, the manual may contain information on options not present

on your loader. The right is reserved by Barko Specialty Equipment to make changes

and improvements in it's product at any time without notice or obligation.

Service ManualService Manual

Service Manual

Machine

Serial Number

082014

6025 Chipper6025 Chipper

6025 Chipper

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 .................................................... 14

Fire Prevention .................................................... 15

Model Description............................................... 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

Common Replacement Parts .............................. 20

Lubrication Points ................................................ 21

Fluid Specifications ............................................. 23

Special Torque Specifications ........................... 25

General Torque Specifications ........................... 26

B. Hydraulic SystemB. Hydraulic System

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

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

......................................... 2727

2727

27

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

Hydraulic Fittings, Hoses & Tubing ..................... 29

Electrical System Maintenance ........................... 30

Electrical System Description .......................... 30

Electrical System Inspection ............................ 30

Battery Disconnect Switch................................ 30

Using an Extra Battery to Start Machine ........... 31

Installing a New Battery.................................... 32

Alternator Maintenance .................................... 32

Trouble Shooting the Electrical System ........... 33

IQAN XA2 ............................................................ 34

Blink Codes ..................................................... 34

Failure mode ................................................... 35

IQAN XS2 ............................................................ 39

Blink Codes ..................................................... 39

Failure mode ................................................... 40

D. Power Unit MaintenanceD. Power Unit Maintenance

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

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

............................. 4242

4242

42

Engine Maintenance ........................................... 43

Air Cleaner Maintenance ..................................... 49

E. Structural MaintenanceE. Structural Maintenance

E. Structural Maintenance ................................................................

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

................................ 5353

5353

53

TROUBLE SHOOTINGTROUBLE SHOOTING

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

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

......................................... 5454

5454

54

Trouble Shooting ................................................ 55

Engine ............................................................. 55

Hydraulic System ............................................ 56

Electrical System ............................................. 57

DECALSDECALS

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

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

.................................................................. 5858

5858

58

page 3page 3

page 3

240 Harvester Feller/

Buncher

IntroductionIntroduction

Introduction

MarkerMarker

Marker

page 4page 4

page 4

240 Harvester Feller/

Buncher

INTRODUCTIONINTRODUCTION

INTRODUCTION

Chipper

Model No.

Serial No.

The machine serial number plate is located near the right

hand swing plate.

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 chipper serial number. For more information

contact:

Barko Hydraulics,LLC

One Banks Avenue

Superior, WI 54880

Phone: 715-395-6700

Fax:715-392-3931

Website: www.barko.com

Email: [email protected]

page 5page 5

page 5

240 Harvester Feller/

Buncher

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

page 6page 6

page 6

240 Harvester Feller/

Buncher

WARNINGWARNING

WARNING

BARKO HYDRAULICS, LLCBARKO HYDRAULICS, LLC

BARKO HYDRAULICS, LLC

Raising hydraulic pressure onRaising hydraulic pressure on

Raising hydraulic pressure on

this machine above the factorythis machine above the factory

this machine above the factory

approved settings may causeapproved settings may cause

approved settings may cause

death, severe injury or propertydeath, severe injury or property

death, severe injury or property

damage and will void thedamage and will void the

damage and will void the

warranty.warranty.

warranty.

The consequences of increasing hydraulic pressure are

serious. The function of the relief valves is to provide a

fuse action to protect the machine and the operator from

overloading. When overloaded, the machine can

become stressed to a level where parts fracture causing

death, severe injury or property damage. This is anThis is an

This is anThis is an

This is an

extremely dangerous practice.extremely dangerous practice.

extremely dangerous practice.

Accordingly, you are advised that the pressure settings

of this machine are limited to the factory approved

settings. Pressures in excess of these settings render

each and all Barko warranties null and void and

constitute an obvious misuse and abuse of our product.

HYDRAULIC PRESSURE WARNING SHEETHYDRAULIC PRESSURE WARNING SHEET

HYDRAULIC PRESSURE WARNING SHEET

page 7page 7

page 7

240 Harvester Feller/

Buncher

BARKO HYDRAULICS,BARKO HYDRAULICS,

BARKO HYDRAULICS,

LLCLLC

LLC

WARRANTYWARRANTY

WARRANTY

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

loader, mulcher tractor or other product in BARKO's 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, as follows:

BARKO will cause any major structural component of a Product covered by this warranty which proves to be defective in material

or workmanship under normal use, maintenance and service within three (3) years (unlimited hours) 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's option. 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 any powertrain/hydraulic component of a Product covered by this warranty which proves to be defective in

material or workmanship under normal use, maintenance and service within two (2) years (unlimited hours) from the first day in service,

provided the first day of service is no later than one (1) year from delivery to the Distributor and/or original Buyer or other user, to be

replaced without charge with a new or rebuilt part, at BARKO's option. 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 product. The parts and labor

to meet this warranty will be furnished by a designated BARKO distributor. This powertrain/hydraulic component warranty will cover

electric motors, hydraulic pumps, hydraulic valves, hydraulic motors, swing drives, pump drives, hydraulic swivels, and hydraulic

cylinders (excluding seals).

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 (unlimited hours) 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's option. 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 Product. The parts and labor to meet this warranty will be furnished

by a designated BARKO 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's

option 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 for same must be submitted within thirty (30) days after repair work is completed.

BARKO warranty does not cover:

1 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 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 or alterations 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 the part is located.

7. Overtime labor premiums.

8. Transportation of the 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, axles and components, tires, batteries or

other parts normally warranted 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 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. BARKO

SHALL IN NO EVENT BE LIABLE FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES TO LOSSES OF USE OF THE

PRODUCT, A LOSS OR DAMAGE TO PROPERTY OTHER THAN THE 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).

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.

Revised 9/11

page 8page 8

page 8

240 Harvester Feller/

Buncher

KNOW YOUR MACHINEKNOW YOUR MACHINE

KNOW YOUR MACHINE

page 9page 9

page 9

240 Harvester Feller/

Buncher

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. Doopen flames near fuels or hydraulic fluids. Do

open flames near fuels or hydraulic fluids. Do

not fill the tanks to capacity - allow room for fluidnot fill the tanks to capacity - allow room for fluid

not 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 cleaningventilation. Never use fuel for cleaning

ventilation. Never use fuel for cleaning

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

purposes. Clean up any fluid spills immediately.

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

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.

page 10page 10

page 10

240 Harvester Feller/

Buncher

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. WARNINGWARNING

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 toriders off. Riders on machine are subject to

riders off. Riders on machine are subject to

death or injury from being struck by foreigndeath or injury from being struck by foreign

death or injury from being struck by foreign

objects and being thrown from machine. Ridersobjects and being thrown from machine. Riders

objects and being thrown from machine. Riders

also obstruct the operator's view, resulting inalso obstruct the operator's view, resulting in

also obstruct the operator's view, resulting in

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

machine being 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.

SAFETY SUMMARY CONTINUED...

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

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

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.

page 11page 11

page 11

240 Harvester Feller/

Buncher

WARNINGWARNING

WARNING

Improper hydraulic pressure loss can causeImproper hydraulic pressure loss can cause

Improper hydraulic pressure loss can cause

load to impact cab guard, resulting in death orload to impact cab guard, resulting in death or

load to impact cab guard, resulting in death or

severe injury.severe injury.

severe injury.

--

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

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

Do not rely on guards 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

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...

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 thaton machine. Replace all non-skid material that

on machine. Replace all non-skid material that

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

is torn, missing or damaged. WARNINGWARNING

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

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.

page 12page 12

page 12

240 Harvester Feller/

Buncher

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.

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 when enginenot touch exhaust pipe when hot, or when engine

not touch exhaust pipe when hot, or when engine

is running.is running.

is running.

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.

SAFETY SUMMARY CONTINUED...

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

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.

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 to truck/Lower and secure boom/attachment to truck/

Lower and secure boom/attachment to truck/Lower and secure boom/attachment to truck/

Lower and secure boom/attachment to truck/

trailer bed.trailer bed.

trailer bed.

--

-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, referIf Barko-authorized welding must be done, refer

If Barko-authorized welding must be done, refer

to service manual for welding proceedure. Ifto service manual for welding proceedure. If

to service manual for welding proceedure. If

procedure is not followed electrical andprocedure is not followed electrical and

procedure is not followed electrical and

structural damage may occur.structural damage may occur.

structural damage may occur.

page 13page 13

page 13

240 Harvester Feller/

Buncher

SAFETY SUMMARY CONTINUED...

CALIFORNIACALIFORNIA

CALIFORNIA

Proposition 65 WarningProposition 65 Warning

Proposition 65 Warning

Diesel engine exhaust and some of its constituents areDiesel engine exhaust and some of its constituents are

Diesel engine exhaust and some of its constituents are

known to the State of California to cause cancer, birthknown to the State of California to cause cancer, birth

known to the State of California to cause cancer, birth

defects, and other reproductive harm.defects, and other reproductive harm.

defects, and other reproductive harm.

page 14page 14

page 14

240 Harvester Feller/

Buncher

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 extinguisher andAlways keep a fire extinguisher and

Always keep a fire extinguisher and

first aid kit where they can be easilyfirst aid kit where they can be easily

first aid kit where they can be easily

reached in case of fire and keep thesereached in case of fire and keep these

reached in case of fire and keep these

items properly maintained.items properly maintained.

items properly maintained.

Operating personnel should beOperating personnel should be

Operating personnel should be

instructed on what to do in case of fireinstructed on what to do in case of fire

instructed on what to do in case of fire

and be required to demonstrate how toand be required to demonstrate how to

and be required to demonstrate how to

use fire extinguisher and fireuse fire extinguisher and fire

use fire extinguisher and fire

suppression equipment.suppression equipment.

suppression equipment.

Any portable fire extinguisher or fireAny portable fire extinguisher or fire

Any portable fire extinguisher or fire

suppression system carried on thesuppression system carried on the

suppression system carried on the

machine that has been used, shouldmachine that has been used, should

machine that has been used, should

be recharged or replaced before thebe recharged or replaced before the

be recharged or replaced before the

machine resumes operating. Firemachine resumes operating. Fire

machine resumes operating. Fire

extinguisher manufacturersextinguisher manufacturers

extinguisher manufacturers

recommended service intervals shouldrecommended service intervals should

recommended service intervals should

be followed.be followed.

be followed.

WARNINGWARNING

WARNING

Allow machine to cool down by idlingAllow machine to cool down by idling

Allow machine to cool down by idling

the engine for a while before shut-the engine for a while before shut-

the engine for a while before shut-

down. Many engine and transmissiondown. Many engine and transmission

down. Many engine and transmission

fires startfires start

fires start afterafter

afterafter

after shut-down.shut-down.

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 or workingsmoke while handling fuel or working

smoke while handling fuel or working

on either the fuel or the hydraulicon either the fuel or the hydraulic

on either the fuel or the hydraulic

system.system.

system.

WARNINGWARNING

WARNING

Do not use the machine in areas withDo not use the machine in areas with

Do not use the machine in areas with

explosive dust or gases that can beexplosive dust or gases that can be

explosive dust or gases that can be

ignited by arcs, sparks, hotignited by arcs, sparks, hot

ignited by arcs, sparks, hot

components, or exhaust fumes.components, or exhaust fumes.

components, or exhaust fumes.

WARNINGWARNING

WARNING

Daily inspect the machine forDaily inspect the machine for

Daily inspect the machine for

flammable debris, removing any twigs,flammable debris, removing any twigs,

flammable debris, removing any twigs,

leaves, straw, rags, fluid spills orleaves, straw, rags, fluid spills or

leaves, straw, rags, fluid spills or

leaks, dirt or grime. Pay specialleaks, dirt or grime. Pay special

leaks, dirt or grime. Pay special

attention to areas such as the engine,attention to areas such as the engine,

attention to areas such as the engine,

engine cooling system, exhaustengine cooling system, exhaust

engine cooling system, exhaust

system, battery, electricalsystem, battery, electrical

system, battery, electrical

connections, brake systems,connections, brake systems,

connections, brake systems,

transmission/drivetrain, fuel systemtransmission/drivetrain, fuel system

transmission/drivetrain, fuel system

and hydraulic system. Clean as oftenand hydraulic system. Clean as often

and hydraulic system. Clean as often

as necessary to help preventas necessary to help prevent

as necessary to help prevent

overheating and combustion.overheating and combustion.

overheating and combustion.

WARNINGWARNING

WARNING

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

The electrical system (battery,

electrical connections, etc.) can be aelectrical connections, etc.) can be a

electrical connections, etc.) can be a

source of arcs or sparks if damaged orsource of arcs or sparks if damaged or

source of arcs or sparks if damaged or

incorrectly maintained. Daily inspectincorrectly maintained. Daily inspect

incorrectly maintained. Daily inspect

all electrical wiring and connectionsall electrical wiring and connections

all electrical wiring and connections

for damage. Keep the batteryfor damage. Keep the battery

for damage. Keep the battery

terminals clean and tight. Replace orterminals clean and tight. Replace or

terminals clean and tight. Replace or

repair any damaged part. Use properrepair any damaged part. Use proper

repair any damaged part. Use proper

battery connection and disconnectionbattery connection and disconnection

battery connection and disconnection

procedures.procedures.

procedures.

WARNINGWARNING

WARNING

Daily inspect all fuel and hydraulic oilDaily inspect all fuel and hydraulic oil

Daily inspect all fuel and hydraulic oil

tubes, hoses, and fittings for damagetubes, hoses, and fittings for damage

tubes, hoses, and fittings for damage

and leakage. Tighten or replace asand leakage. Tighten or replace as

and leakage. Tighten or replace as

necessary. Always clean fluid spills.necessary. Always clean fluid spills.

necessary. Always clean fluid spills.

WARNINGWARNING

WARNING

Do not use ether or starting fluids onDo not use ether or starting fluids on

Do not use ether or starting fluids on

diesel engines with glow plugs. Thesediesel engines with glow plugs. These

diesel engines with glow plugs. These

starting aids can explode and injurestarting aids can explode and injure

starting aids can explode and injure

bystanders.bystanders.

bystanders.

WARNINGWARNING

WARNING

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

Before doing welding of any kind,

clean machine and disconnect batteryclean machine and disconnect battery

clean machine and disconnect battery

cables. Cover rubber hoses, battery,cables. Cover rubber hoses, battery,

cables. Cover rubber hoses, battery,

and other flammable parts. Neverand other flammable parts. Never

and other flammable parts. Never

ground an arc welder or electricalground an arc welder or electrical

ground an arc welder or electrical

accessories through turntable or boomaccessories through turntable or boom

accessories through turntable or boom

bearings as arcing may occur causingbearings as arcing may occur causing

bearings as arcing may occur causing

bearing damage.bearing damage.

bearing damage.

Do not weld on any structural memberDo not weld on any structural member

Do not weld on any structural member

unless specifically authorized by Barkounless specifically authorized by Barko

unless specifically authorized by Barko

Hydraulics. Any unauthorized weldingHydraulics. Any unauthorized welding

Hydraulics. Any unauthorized welding

or welding procedures will void theor welding procedures will void the

or welding procedures will void the

warranty, and may cause structuralwarranty, and may cause structural

warranty, and may cause structural

damage.damage.

damage.

WARNINGWARNING

WARNING

Read the Engine Manual that comesRead the Engine Manual that comes

Read the Engine Manual that comes

with every machine for completewith every machine for complete

with every machine for complete

engine operating and engine safetyengine operating and engine safety

engine operating and engine safety

instructions.instructions.

instructions.

page 15page 15

page 15

240 Harvester Feller/

Buncher

Make sure you have the proper fire extinguisher that is labeled A (wood, trash), B (gas, grease, oil, paint)

and C (electrical).

In case of Fire

1. Hold upright and pull ring pin.

2. Stand back ten feet and aim at base of fire.

3. Squeeze lever and sweep side to side.

Recharge (bring to authorized server) fire extinguisher immediately after any use. Partial discharge

may cause the fire extinguisher to leak. Inspect monthly for possible damage.

Check the plastic seal wire to be intact. Make sure the label instructions are clean (visible).

Check the needle indicator for designated pressure levels.

NOTE: The green area is the "charged zone". During cold temperatures the indicator may read on

the low side of the green. During hot temperatures it may read high in the green. A true reading

may be checked by placing the fire extinguisher in a normal room temperature of 70 degrees for

several hours.

FIRE PREVENTIONFIRE PREVENTION

FIRE PREVENTION

Fire ExtinguisherFire Extinguisher

Fire Extinguisher

page 16page 16

page 16

240 Harvester Feller/

Buncher

MODEL DESCRIPTIONMODEL DESCRIPTION

MODEL DESCRIPTION

page 17page 17

page 17

240 Harvester Feller/

Buncher

MaintenanceMaintenance

Maintenance

A. PREVENTIVEA. PREVENTIVE

A. PREVENTIVE

MAINTENANCEMAINTENANCE

MAINTENANCE

MaintenanceMaintenance

Maintenance

page 18page 18

page 18

240 Harvester Feller/

Buncher

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 before working onAlways shut down the machine before working on

Always shut down the machine before working on

the machine.the machine.

the machine.

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 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.specifically authorized by Barko Hydraulics.

specifically authorized by Barko Hydraulics.

Any unauthorized welding or welding proceduresAny unauthorized welding or welding procedures

Any unauthorized welding or welding procedures

will void the warranty, and may cause death,will void the warranty, and may cause death,

will void the warranty, and may cause death,

severe injury, property damage or structuralsevere injury, property damage or structural

severe injury, property damage or structural

damage to the machine.damage to the machine.

damage to the 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 determineCheck the Hour Meter regularly to determine

Check the Hour Meter regularly to determine

when the machine needs periodic maintenance.when the machine needs periodic maintenance.

when the machine needs periodic maintenance.

Use the intervals on the Service ScheduleUse the intervals on the Service Schedule

Use the intervals on the Service Schedule

except when operating in extreme conditions;except when operating in extreme conditions;

except when operating in extreme conditions;

then shorter intervals must be used.then shorter intervals must be used.

then shorter intervals must be used.

WARNINGWARNING

WARNING

Under no circumstances should anyUnder no circumstances should any

Under no circumstances should any

modifications be made to Barko machinerymodifications be made to Barko machinery

modifications be made to Barko machinery

without factory authorization. Any modificationswithout factory authorization. Any modifications

without factory authorization. Any modifications

may void the warranty. This machine wasmay void the warranty. This machine was

may void the warranty. This machine was

designed to do a specific job and alterationsdesigned to do a specific job and alterations

designed to do a specific job and alterations

could result in death, severe injury or propertycould result in death, severe injury or property

could result in death, severe injury or property

damage.damage.

damage.

WARNINGWARNING

WARNING

Relieve all hydraulic pressure before breakingRelieve all hydraulic pressure before breaking

Relieve all hydraulic pressure before breaking

any hydraulic connection, opening the reservoirany hydraulic connection, opening the reservoir

any hydraulic connection, opening the reservoir

access cover, or performing any maintenance onaccess cover, or performing any maintenance on

access cover, or performing any maintenance on

the machine.the machine.

the machine.

- Shut down machine to a zero energy state.

- Remove key from ignition.

- Disengage servo lever.

- Allow machine to cool.

- Relieve all hydraulic pressure.

- Disconnect battery using battery disconnect switch.

- Remove, block or guard against body contact with all

other sources of hazardous pressure, temperature,

electricity, or machine motion.

BEFORE INSPECTION OR MAINTENANCE:BEFORE INSPECTION OR MAINTENANCE:

BEFORE INSPECTION OR MAINTENANCE:

page 19page 19

page 19

240 Harvester Feller/

Buncher

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 100 HOURS OF OPERATION OF A NEW MACHINEAFTER THE FIRST 100 HOURS OF OPERATION OF A NEW MACHINE

AFTER THE FIRST 100 HOURS OF OPERATION OF A NEW MACHINE

A new machine needs a special maintenance procedure after the first 100 hours of operation.

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

2. Check torque (retorque if necessary):

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

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

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

4. Change all filter elements.

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 onInstructions are necessary before doing service on

Instructions are necessary before doing service on

loader. See warnings and instructions both at theloader. See warnings and instructions both at the

loader. See warnings and instructions both at the

beginning and throughout this manual. After doingbeginning and throughout this manual. After doing

beginning and throughout this manual. After doing

service or making repairs or adjustments always checkservice or making repairs or adjustments always check

service or making repairs or adjustments always check

function of loader.function of loader.

function of loader.

Safety glasses or goggles are always needed for eyeSafety glasses or goggles are always needed for eye

Safety glasses or goggles are always needed for eye

protection from electric arcs, from shorts or welding,protection from electric arcs, from shorts or welding,

protection from electric arcs, from shorts or welding,

battery acid, compressed springs, fluids under pressure,battery acid, compressed springs, fluids under pressure,

battery acid, compressed springs, fluids under pressure,

and flying debris or loose material when engines areand flying debris or loose material when engines are

and flying debris or loose material when engines are

running or tools are used. Use eye protection approvedrunning or tools are used. Use eye protection approved

running or tools are used. Use eye protection approved

for type of welding. Failure to obey warnings can causefor type of welding. Failure to obey warnings can cause

for type of welding. Failure to obey warnings can cause

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

death, severe injury or property damage.

page 20page 20

page 20

240 Harvester Feller/

Buncher

Routine component replacement part numbers -

Engine:

Oil Filter - 535-04320

Air Filter (Primary) - 535-02437

Air Filter (Safety Element) - 535-02438

Fuel Filter - 535-02439

Fuel Water Separator Filter - 535-04321

Hydraulics:

Main Return Filter - 565-01724

Case Return Filter - 565-01728

Preventative Maintenance ChartPreventative Maintenance Chart

Preventative Maintenance Chart

The following charts states the maintenance checks that the operator of the machine should perform to

make sure the machine is in a safe and proper working condition. If any major problems are noted during

the inspection and maintenance of the machine, inform the approprriate personal within your company.

COMMON REPLACEMENT PARTSCOMMON REPLACEMENT PARTS

COMMON REPLACEMENT PARTS

Barko 6025 User manual

Popular Chipper manuals by other brands