Barko 495B - SE User manual

Machine
Serial Number
The information and illustrations in this manual have been approved as accurate at the time of printing.
However, the manual may contain information on options not present on your loader. The right is reserved
by Barko Hydraulics,LLC to make changes and improvements in it's product at anytime without notice
or obligation.
NOTE: The operating and safety instructions for a Slasher Saw Attachment or Carrier Lower are not
included in this manual. See Slasher Saw or Carrier manufacturer's information.
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.
Service Manual PN# 800-00412
SERVICE MANUAL
495B - SE (STATIONARY ELECTRIC)
1 Banks Avenue, Superior, WI 54880
phone: [phone] fax: [phone]
website: www.barko.com email: [email protected]


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2
TABLE OF CONTENTS
INTRODUCTION 4
ABBREVIATIONS AND SYMBOLS 5
KNOW YOUR MACHINE 7
SAFETY SUMMARY 8
FIRE PREVENTION 13
INSTALLATION OF FIRE EXTINGUISHER BRACKET 13
MODEL DESCRIPTION 14
SAFETY WHILE SERVICING 16
PREVENTIVE MAINTENANCE 17
SPECIAL NEW-MACHINE INSTRUCTIONS 17
SERVICE SCHEDULE 18
LUBRICATION POINTS 23
FLUID SPECIFICATIONS 24
GENERAL TORQUE SPECIFICATIONS 27
HYDRAULIC DRAWING 29
HYDRAULIC SERVO DRAWING 30
HYDRAULIC SCHEMATIC 31
HYDRAULIC DRAWING TANDEM 32
HYDRAULIC SERVO TANDEM 33
HYDRAULIC SCHEMATIC TANDEM 34
HYDRAULIC PRESSURE SETTINGS (495ML) 35
MACHINE FUNCTION SPEEDS 35
HYDRAULIC PRESSURE ADJUSTMENTS 36
HYDRAULIC RESERVOIR MAINTENANCE 41
HYDRAULIC FILTER MAINTENANCE 42
ELIMINATING AIR FROM THE SYSTEM 44
HYDRAULIC FITTINGS, HOSES & TUBING 45
HYDRAULIC CYLINDER MAINTENANCE 46
HYDRAULIC COLLECTOR MAINTENANCE 48
SWING MOTOR MAINTENANCE (DANFOSS) 52
SWING MOTOR GEARBOX MAINTENANCE (T1/02) 55
ELEC. SCHEMATIC - 460V 3PH 60HZ 100HP 57
ELEC. SCHEMATIC - 575V 3PH 60HZ 100HP 58
ELEC. SCHEMATIC - 380V 3PH 50HZ 125HP 59
ELECTRICAL SYSTEM MAINTENANCE 60
ELECTRIC COLLECTOR MAINTENANCE 65
AIR CONDITIONER MAINTENANCE 67
ENGINE MAINTENANCE 79
PUMP DRIVE MAINTENANCE 80
AIR CLEANER MAINTENANCE 84
TURNTABLE BEARING MAINTENANCE 89

Introduction

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4
INTRODUCTION
Your Barko Loader has been designed and manufactured with high quality materials and care in workmanship. This
manual is intended as a permanent reference to aid professional operator's in their work, and should be available for
use at any time. If the loader is not equipped with this manual, ask your supervisor to obtain one for you.
Understand the correct servicing procedures before servicing the loader. It is important to know the correct operating
and servicing procedures of the loader and all safety precautions to prevent the possibility of property damage and/or
personal injury or death.
As a professional, trained operator, you are responsible for safety, both your own and that of your co-workers. Your
knowledge and use of all safety practices and correct servicing procedures in this manual, and your good judgement,
can be a major factor in preventing some of the thousands of injuries and deaths caused by industrial accidents each
year.
A professional operator should also be familiar with the information contained in other applicable sources such as
American National Standards, SAE, OSHA, etc.
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!
Loader
Model No.
Serial No.
Engine
Model No.
Serial No.
The machine serial number plate is located on the front
of the platform near the ladder.
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.
REFERENCEINFORMATION
All requests for information, service or spare parts
should include loader serial number. For more
information contact:
Barko Hydraulics,LLC
One Banks Avenue
Superior, WI 54880
Phone: [phone]
Fax: [phone]
Website: www.barko.com
Email: [email protected]

Service Manual
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ABBREVIATIONS AND SYMBOLS
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.
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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Raising hydraulic pressure on this
machine above the factory approved
settings may cause death, severe
injury or property damage and will
void the warranty
The consequences of increasing hydraulic pressure are
serious. The function of the relief valves are 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 part fractures cause death, se-
vere injury or property damage. This is an extremely
dangerous practice.
Accordingly, you are advised that the pressure settings of
this machine are limited to the factory approved settings.
Pressures in excess of these settings render each and all
Barko warranties null and void and constitute an obvious
misuse and abuse of our product.
Barko Hydraulics, LLC

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KNOW YOUR MACHINE
The following is a list of ten important safety precautions and warnings you should read through and understand
before operating or servicing your machine.
1. Don't assume that because you know the control functions of other similar machinery, that you can run and/
or service the Barko Loader. All machines differ in some ways, and these differences must be noted and
acknowledged. Read this manual thoroughly and understand all safety, operating, and servicing procedures
before using the loader.
2. Know how to put your machine in a zero energy state for purposes of inspection, maintenance, or repair.
3. Clear operating area of all obstacles and personnel before operating loader.
4. Never approach power lines with any part of the machine or load! Current in a high voltage power line may arc
some distance to jump from the wire to a nearby "ground". KEEP WELL CLEAR!
5. Allow only the operator on the machine. Keep riders off. Riders on machine are subject to injury such as being
struck by foreign objects and being thrown off the machine. Riders also obstruct the operator's view, resulting in
the machine being operated in an unsafe manner.
6. Never use a boom or attachment for a work platform or personnel carrier. Serious injury or death may result.
7. When machine is not operating or when leaving cab, boom and attachment must be lowered to the ground.
Failure to do so may allow boom or attachment to move, causing property damage, injury, or death.
8. Donottamperwithanyhydrauliclinewhenitispressurized.Escapinguidunderpressurecanpenetratethe
skin, causing serious injury. Relieve pressure before unhooking hydraulic or other lines. Tighten all connections
beforeapplyingpressure.Keephandsandbodyawayfrompinholesandnozzleswhichejectuidsunderhigh
pressure. Use a piece of cardboard to search for leaks.
 Ifanyuidisinjectedintotheskin,itmustbesurgicallyremovedwithinafewhoursbyadoctorfamiliarwiththis
type of injury or gangrene may result.
9. UndernocircumstancesshouldanymodicationsbemadetoBarkomachinerywithoutfactoryauthorization.Any
modicationsmayvoidthewarranty.Thismachinewasdesignedtodoaspecicjobandalterationscouldresult
in property damage, injury or death.
10. Replace any safety decals that are faded, torn, missing, illegible, or otherwise damaged. See your machine's
Decals section for decal kits applicable to your machine and for locations of all decals.
Don't stop here - read on.

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SAFETY SUMMARY
Combustibleandammableuidscancausedeathor
severeinjury.Donotsmokeorpermitopenamesnear
fuelsorhydraulicuids.Donotllthetankstocapacity
-allowroomforuidexpansion.Donotremovethe
fuel cap or refuel while engine is hot, running or without
proper ventilation. Never use fuel for cleaning purposes.
Always lower boom to ground and shut down engine be-
fore leaving cab. If necessary to work on machine with
lifted boom, securely support machine and attachment.
Do not move loads over top of truck cab. Do not allow
driver to remain in truck cab while operating. Death,
severe injury or property damage may result.
Safe and stable mounting of this machine on a truck or
trailer bed is the owner's responsibility. See Mounting
Instructions for recommended procedures.
WARNING
When using a Slasher Saw Attachment, be sure to get
proper safety and operating manuals from Slasher
manufacturer. Read and understand those manuals
before using this machine for Slasher purposes.
Never approach power lines with any part of the ma-
chine. Current in a high voltage line may arc some dis-
tance to jump from the wire to a nearby "ground". KEEP
WELL CLEAR!
Do not operate machine during electrical storms.
Failure to fallow 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.
- Indicates an immediate hazard which WILL result in severe personal injury or death.
- Indicates a hazard or unsafe practice which COULD result in severe personal injury or death.
- Indicates a hazard or unsafe practice which could result in minor personal injury or property.

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Do not operate or work on machine until you:
- Read and understand machine manuals, safety
decals, employer work rules, and applicable
government regulations.
- Aretrainedandqualiedinsafemachineoperation
and maintenance.
- Consult supervisor to explain any unclear instructions
and warnings.
- Contact Barko to replace lost manuals.
Moving stabilizers will cause death or severe injury.
Stand clear. Operate stabilizers only when personnel
are clear.
Allow only the operator on the machine. Keep riders off.
Riders on machine are subject to death or injury from
being struck by foreign objects and being thrown from
machine. Riders also obstruct the operator's view, re-
sulting in machine being operated in an unsafe manner.
Never use a boom attachment for a work platform or
personnel carrier.
An unstable machine can cause death, severe injury,
or property damage. Do not operate machine without
loweringstabilizersonrm,levelground.
SAFETY SUMMARY CONTINUED...
Falling boom or load will cause death or severe injury.
Stay clear if boom or load are not grounded.
Clear all persons from area of operation and machine
movement. Never move boom or loads over the heads
of other persons.
Wear required personal protective equipment at all times
tohelppreventpersonalinjury.Donotwearloosetting
clothing or personal articles, loose or uncovered long
hair, or jewelry.
If machine malfunctions during operation, stop machine
motion as quickly as possible, lower boom to the ground
and shut down the machine. Service or repair the ma-
chine as needed before running or operating again.

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Improper load handling and/or hydraulic pressure loss
can cause load to impact cab guard, resulting in death or
severe injury.
- Do not rely on guard alone for personal protection.
Use safe and proper load handling techniques.
- Do not operate machine with damaged or unsecured
guard or cab.
- Do not repair damaged guard. Replace with factory-
authorized guard.
- Do not modify guard without factory authorization.
- Do not operate before conducting Pre-Start
Maintenance Inspection. Check hydraulic
componentsforleaks,loosettingsordamage.
Highpressurehydraulicuidcanpenetrateskincausing
death, gangrene or other severe injury. Seek immediate
medicalhelptoremoveuid.
- Keep hands and body away from areas ejecting
uid.Usepieceofcardboardtocheckforleaks.
Wear proper hand and eye protection.
- Relieve hydraulic pressure before loosening any
hydraulic connections.
- Tighten all hydraulic connections before applying
hydraulic pressure.
Always maintain 3-point contact with handles and steps
when mounting or dismounting. Never jump on or off
machine. Do not rush. Walk, do not run.
Mechanically connected controls will cause movement of
components at all times - even if pump or engine is not
operating. Always be certain that boom and attachment
areproperlysupportedorrestingonrmgroundbefore
stopping engine to minimize chance of
accidental movements of components causing death,
severe injury or property damage.
Grease all boom, cylinder, and turntable bearing/pinion
points daily.
Transparent material such as safety glass must be
replaced when it is cracked or broken, or when vision is
obscured due to scratches.
Loose or overtorqued bolts can cause death, severe
injury, or property damage. Maintain proper bolt torque.
Visually check bolts daily. Check torque every 50 hours.
Remove or secure all personal or maintenance items
such as lunch buckets, chains, shovels, tools, etc., be-
fore moving or operating machine.
Replace any safety decals that are faded, torn, missing,
illegible, or otherwise damaged.
SAFETY SUMMARY CONTINUED...
Make sure that all walking and climbing surfaces of
machine are free of dirt, debris, water, grease, oil, and
snow. Do not leave loose tools or rags on machine.
Replace all non-skid material that is torn, missing or
damaged.