Barko Hydraulics 595ML User manual

OPERATORS: 800-00050 PARTS: 800-00111 SERVICE: 800-00177
The information and illustrations in this manual have
been approved as accurate at the time of printing.
However, the manual may contain information on
optionsnotpresentonyourloader. Therightisreserved
by Barko Hydraulics,LLC to make changes and
improvementsinitsproductatanytimewithoutnotice
or obligation.
BARKO
LOADERS
SERVICEMANUAL
Machine
Serial Number
081413
NOTE: The operating, service and safety instructions for a Slasher Saw, Delimber or Topping Saw are
not included in this manual. See 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.
BARKO
HYDRAULICS,LLC
mailing:POBox16227,Duluth,MN 55816 shipping:1BanksAvenue,Superior,WI 54880
phone:[phone] fax:[phone]
website:www.barko.com email:[email protected]
595ML MAGNUM CRAWLER

TABLE OF CONTENTS
INTRODUCTION ........................................................ 3
Introduction .........................................................4
AbbreviationsandSymbols .................................5
HydraulicPressureWarningSheet ......................6
Warranty..............................................................7
KnowYourMachine.............................................8
Safety Summary .................................................9
FirePrevention ....................................................14
ModelDescription................................................15
MAINTENANCE......................................................... 16
A.PreventiveMaintenance.................................... 16
Safety While Servicing ........................................17
PreventiveMaintenance ......................................18
SpecialNew-MachineInstructions .......................18
ServiceSchedule ................................................19
LubricationPoints................................................22
Fluid Specifications .............................................23
SpecialTorqueSpecifications .............................25
GeneralTorqueSpecifications.............................26
B. Hydraulic System .............................................. 27
HydraulicPressureSettings (595 ML CRL)..........28
MachineFunctionSpeeds ...................................28
HydraulicPressureAdjustment ...........................29
PumpAdjustmentCRL(SauerTandem) ..............30
Sauer-DanfossPlus1Module ..............................31
K170Upper Valve Adjustments........................32
HydraulicReservoirMaintenance.........................35
HydraulicFilterMaintenance................................36
Eliminating Air From The System ........................38
Hydraulic Fittings, Hoses & Tubing......................39
HydraulicCylinderMaintenance...........................40
SwingMotorGearboxMaintenance(1010D) ........42
AttachingSlasher Saw ........................................43
C. Electrical System Maintenance ........................ 44
Electrical System Maintenance ...........................45
Electrical System Description ..........................45
Electrical System Inspection............................45
Battery Disconnect Switch ...............................45
Using an Extra Battery to Start Machine ..........46
Installing a New Battery....................................47
AlternatorDrive Belt Adjustment ......................47
AlternatorMaintenance.....................................47
Trouble Shooting the Electrical System............49
ElectricCollectorMaintenance ............................50
AirConditionerMaintenance ................................53
Refrigerant........................................................53
Checking/AddingRefrigerant ............................54
AirConditionerTroubleShooting ......................55
AirConditionerCharging ...................................63
D. Power Unit Maintenance ................................... 67
EngineMaintenance ............................................68
PumpDriveMaintenance.....................................69
Two,Three and Four PadPump Drives ............69
Single Pad Pump Drives ..................................72
DisconnectClutch(optional).............................72
AirCleanerMaintenance......................................73
E. Structural Maintenance ..................................... 77
TurntableBearingMaintenance ...........................78
CrawlerMaintenance ...........................................82
TROUBLESHOOTING .............................................. 84
Engine..............................................................85
Hydraulic System .............................................86
Electrical System .............................................87
MachineOperations .........................................88
DECALS .................................................................... 89

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595MLCRL(S)
800-00177
Introduction
Marker

page4
595MLCRL(S)
800-00177
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
informationcontact:
Barko Hydraulics,LLC
P.O. Box 16227
One Banks Avenue
Duluth, MN 55816
Phone: [phone]
Fax: [phone]
Website: www.barko.com

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595MLCRL(S)
800-00177
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.
SYMBOLS USED ON MACHINE
Ignition
Key Switch
Power On
(Accessory)
Power Off
Power On
Horn
Starter
Engine RPM
Faster
Slower
Air
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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595MLCRL(S)
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WARNING
BARKO HYDRAULICS, LLC
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 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 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.
HYDRAULIC PRESSURE WARNING SHEET

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BARKOHYDRAULICS,LLC
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
warrantywillbe 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(excludingseals).
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 repairsmadein an unauthorized mannerorinstallation of componentsoralterations 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. Overtimelaborpremiums.
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
componentsshallapply.
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

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595MLCRL(S)
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KNOWYOURMACHINE
The following is a list of ten important safety precautions and warnings you should read through and
understand before operating or servicing your machine.
1. Don't assume that because you know the control functions of other similar machinery, that you
can run and/or service the Barko Loader. All machines differ in some ways, and these
differences must be noted and acknowledged. Read this manual thoroughly and understand all
safety, operating, and servicing procedures before using the loader.
2. Know how to put your machine in a zero energy state for purposes of inspection, maintenance,
or repair.
3. Clear operating area of all obstacles and personnel before operating loader.
4. Never approach power lines with any part of the machine or load! Current in a high voltage
power line may arc some distance to jump from the wire to a nearby "ground". KEEP WELL
CLEAR!
5. Allow only the operator on the machine. Keep riders off. Riders on machine are subject to injury
such as being struck by foreign objects and being thrown off the machine. Riders also obstruct
the operator's view, resulting in the machine being operated in an unsafe manner.
6. Never use a boom or attachment for a work platform or personnel carrier. Serious injury or death
may result.
7. When machine is not operating or when leaving cab, boom and attachment must be lowered to
the ground. Failure to do so may allow boom or attachment to move, causing property damage,
injury, or death.
8. Do not tamper with any hydraulic line when it is pressurized. Escaping fluid under pressure can
penetrate the skin, causing serious injury. Relieve pressure before unhooking hydraulic or other
lines. Tighten all connections before applying pressure. Keep hands and body away from
pinholes and nozzles which eject fluids under high pressure. Use a piece of cardboard to search
for leaks.
If any fluid is injected into the skin, it must be surgically removed within a few hours by a doctor
familiar with this type of injury or gangrene may result.
9. Under no circumstances should any modifications be made to Barko machinery without factory
authorization. Any modifications may void the warranty. This machine was designed to do a
specific job and alterations could result in property damage, injury or death.
10. Replace any safety decals that are faded, torn, missing, illegible, or otherwise damaged. See your
machine's Parts Manual for decal kits applicable to your machine and for locations of all decals.
Don't stop here - read on.

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595MLCRL(S)
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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.
DANGER - Indicates an immediate hazard which WILL result in severe personal injury or death.
WARNING - Indicates a hazard or unsafe practice which COULD result in severe personal injury or death.
CAUTION - Indicates a hazard or unsafe practice which could result in minor personal injury or property
damage.
WARNING
Combustible and flammable fluids can cause
death or severe injury. Do not smoke or permit
open flames near fuels or hydraulic fluids. Do
not fill the tanks to capacity - allow room for fluid
expansion. Do not remove the fuel cap or refuel
while engine is hot, running or without proper
ventilation. Never use fuel for cleaning
purposes. Clean up any fluid spills immediately.
WARNING
Always lower boom to ground and shut down
engine before leaving cab. If necessary to work
on machine with lifted boom, securely support
machine and attachment.
WARNING
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.
WARNING
Safe and stable mounting of this machine on a
truck or trailer bed is the owner's responsibility.
See Mounting Instructions for recommended
procedures.
WARNING
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.
DANGER
Never approach power lines with any part of the
machine. Current in a high voltage line may arc
some distance to jump from the wire to a nearby
"ground". KEEP WELL CLEAR!
DANGER
Do not operate machine during electrical storms.

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595MLCRL(S)
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WARNING
Do not operate or work on machine until you:
- Read and understand machine manuals,
safety decals, employer work rules, and
applicable government regulations.
- Are trained and qualified in safe machine
operation and maintenance.
- Consult supervisor to explain any unclear
instructions and warnings.
- Contact Barko to replace lost manuals.
DANGER
Moving stabilizers will cause death or severe
injury. Stand clear. Operate stabilizers only
when personnel are clear.
WARNING
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, resulting in
machine being operated in an unsafe manner.
Never use a boom attachment for a work
platform or personnel carrier.
WARNING
An unstable machine can cause death, severe
injury, or property damage. Do not operate
machine without lowering stabilizers on firm,
level ground.
SAFETY SUMMARY CONTINUED...
DANGER
Falling boom or load will cause death or severe
injury. Stay clear if boom or load are not
grounded.
Clear all persons from area of operation and
machine movement. Never move boom or loads
over the heads of other persons.
WARNING
Wear required personal protective equipment at
all times to help prevent personal injury. Do not
wear loose fitting clothing or personal articles,
loose or uncovered long hair, or jewelry.
WARNING
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 machine as needed before
running or operating again.

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595MLCRL(S)
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WARNING
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 fittings or
damage.
WARNING
High pressure hydraulic fluid can penetrate skin
causing death, gangrene or other severe injury.
Seek immediate medical help to remove fluid.
- Keep hands and body away from areas
ejecting fluid. 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.
WARNING
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.
WARNING
Mechanically connected controls will cause
movement of components at all times - even if
pump or engine is not operating. Always be
certain that boom and attachment are properly
supported or resting on firm ground before
stopping engine to minimize chance of
accidental movements of components causing
death, severe injury or property damage.
WARNING
Grease all boom, cylinder, and turntable bearing/
pinion points daily.
WARNING
Transparent material such as safety glass must
be replaced when it is cracked or broken, or
when vision is obscured due to scratches.
WARNING
Loose or overtorqued bolts can cause death,
severe injury, or property damage. Maintain
proper bolt torque. Visually check bolts daily.
Check torque every 50 hours.
WARNING
Remove or secure all personal or maintenance
items such as lunch buckets, chains, shovels,
tools, etc., before moving or operating machine.
WARNING
Replace any safety decals that are faded, torn,
missing, illegible, or otherwise damaged.
SAFETY SUMMARY CONTINUED...
WARNING
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.

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595MLCRL(S)
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WARNING
Any unauthorized welding, alterations, additions
or modifications made to Barko machinery will
void warranty. This machine was designed to do
a specific job and alterations could result in
death, severe injury or property damage.
If Barko-authorized welding must be done, first
disconnect battery, electronic throttle, and radio,
or electrical and structural damage may occur.
WARNING
Hot and pressurized fluid can cause severe
burns. Let system cool before removing any
caps. Then remove caps slowly.
WARNING
If this machine is equipped with electric motor
driven Auxiliary Oil Cooler, be sure battery is
disconnected before going near cooler fan. If
battery is not disconnected, fan may come on at
any time causing severe injury.
WARNING
Hot exhaust pipe can cause severe burns. Do
not touch exhaust pipe when hot, or when engine
is running.
CAUTION
Use only hydraulic fluid in hydraulic oil reservoir.
Use only diesel fuel in fuel reservoir.
Other fluids will cause machine damage.
SAFETY SUMMARY CONTINUED...
DANGER
Improper electrical connections will cause
battery explosion, combustion or electrical
component damage, and may result in death or
severe injury.
This is a 12 volt negative ground electrical
system.
WARNING
Always wear seat belt when operating or running
machine.
CAUTION
Check the Air Cleaner Assembly daily for cracks,
loose clamps, or any other damage. If debris is
able to bypass the Air Cleaner for any reason, it
can damage the engine.
WARNING
Maintain all components of Muffler Assembly to
meet noise and exhaust standards.
WARNING
Improper machine transport can cause death,
severe injury or property damage.
Before transporting:
- Lower and secure boom/attachment to truck/
trailer bed.
- Raise stabilizers.
- Shut down machine to a zero energy state.

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595MLCRL(S)
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WARNING
Use caution when checking items beyond your
reach. Use an approved safety ladder.
SAFETY SUMMARY CONTINUED...
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
WARNING
Do not exceed 15 PSI nozzle pressure when
drying parts with compressed air. Do not direct
compressed air against human skin. Serious
injury could result.
WARNING
Older air conditioning equipment may contain R-
12, a substance which harms public health and
environment by destroying ozone in the upper
atmosphere. To remove R-12 from the air
conditioning system, use service equipment
certified to meet the requirements of S.A.E.
J2209 or J1990.
WARNING
On machines equipped with an accumulator,
release all pressure before working on the
system. After service work is done, repressurize
the accumulator(s) to the proper specification.

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595MLCRL(S)
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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:
WARNING
Always keep a fire extinguisher
and first aid kit where they can be
easily reached in case of fire and
keep these items properly
maintained.
Operating personnel should be
instructed on what to do in case
of fire and be required to
demonstrate how to use fire
extinguisher and fire suppression
equipment.
Any portable fire extinguisher or
fire suppression system carried
on the machine that has been
used, should be recharged or
replaced before the machine
resumes operating. Fire
extinguisher manufacturers
recommended service intervals
should be followed.
WARNING
Allow machine to cool down by
idling the engine for a while
before shut-down. Many engine
and transmission fires start after
shut-down.
WARNING
Before adding fuel, shut down
the engine and allow it to cool.
Never smoke while handling fuel
or working on either the fuel or
the hydraulic system.
WARNING
Do not use the machine in areas
with explosive dust or gases that
can be ignited by arcs, sparks,
hot components, or exhaust
fumes.
WARNING
Daily inspect the machine for
flammable debris, removing any
twigs, leaves, straw, rags, fluid
spills or leaks, dirt or grime. Pay
special attention to areas such as
the engine, engine cooling
system, exhaust system, battery,
electrical connections, brake
systems,transmission/drivetrain,
fuel system and hydraulic system.
Clean as often as necessary to
help prevent overheating and
combustion.
WARNING
The electrical system (battery,
electrical connections, etc.) can
be a source of arcs or sparks if
damaged or incorrectly
maintained. Daily inspect all
electrical wiring and connections
for damage. Keep the battery
terminals clean and tight. Replace
or repair any damaged part. Use
proper battery connection and
disconnection procedures.
WARNING
Daily inspect all fuel and
hydraulic oil tubes, hoses, and
fittings for damage and leakage.
Tighten or replace as necessary.
Always clean fluid spills.
WARNING
Do not use ether or starting fluids
on diesel engines with glow
plugs. These starting aids can
explode and injure bystanders.
WARNING
Before doing welding of any kind,
clean machine and disconnect
battery cables. Cover rubber
hoses, battery, and other
flammable parts. Never ground
an arc welder or electrical
accessories through turntable or
boom bearings as arcing may
occur causing bearing damage.
Do not weld on any structural
member unless specifically
authorized by Barko
Hydraulics. Any unauthorized
welding or welding procedures
will void the warranty, and may
cause structural damage.
WARNING
Read the Engine Manual that
comes with every machine for
complete engine operating and
engine safety instructions.

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595MLCRL(S)
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MODEL DESCRIPTION
Exhaust
Pipe
Hydraulic Reservoir
Shrouding
Power Unit &
Pumps
Air Cleaner
Hood Cab
Platform/Control Deck
Head
Assembly
Main
Boom
Stick Boom
Grapple
Hanger
Grapple
Rotator
Grapple Cylinders
Main Boom
Cylinder
Grapple
Arms
Counterweight
Electrical Enclosure
(under platform frame)
Swing Moor
& Gearbox
Turntable Bearing
Lower
(carbody &
sideframes)
Stick Boom
Cylinder

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595MLCRL(S)
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Maintenance
A. PREVENTIVE MAINTENANCE
Maintenance

page17
595MLCRL(S)
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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 SERVICING
REMEMBER: SAFETY FIRST!
WARNING
Always shut down the machine and lower the
boom and attachment to the ground before
working on the machine. If necessary to work on a
lifted boom or attachment, securely support the
boom and attachment so that they cannot move or
fall in any way.
WARNING
Don't leave loose tools and rags on the
machine. Ensure that all walking and climbing
surfaces are clean.
WARNING
Handle fuel carefully. Do not smoke while filling
fuel tank or working near fuel.
Refer to Fluid Specifications whenever
replacing oils, fluids, or filling fuel tank.
WARNING
Do not weld on any structural member unless
specifically authorized by Barko Hydraulics. Any
unauthorized welding or welding procedures will
void the warranty, and may cause death, severe
injury, property damage or structural damage to
the machine.
WARNING
Do not support the machine on cinder blocks,
hollow tiles, or props that may crumble under a
load. Do not work under a machine that is
supported solely by a jack.
CAUTION
Check the Hour Meter regularly to determine when
the machine needs periodic maintenance. Use the
intervals on the Service Schedule except when
operating in extreme conditions; then shorter
intervals must be used.
WARNING
Under no circumstances should any modifications
be made to Barko machinery without factory
authorization. Any modifications may void the
warranty. This machine was designed to do a
specific job and alterations could result in death,
severe injury or property damage.
WARNING
Relieve all hydraulic pressure before breaking any
hydraulic connection, opening the reservoir access
cover, or performing any maintenance on the
machine.
- Lower boom to ground.
- 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.
- Ensure machine, boom or attachment are not
supported on props that may collapse. Ensure boom
and attachment are grounded.
BEFORE INSPECTION OR MAINTENANCE:

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595MLCRL(S)
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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 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 gearboxes.
Resume the normal maintenance intervals after this. See the Service Schedule for more information.
SPECIAL NEW-MACHINE INSTRUCTIONS
PREVENTIVE MAINTENANCE
WARNING
Instructions are necessary before doing service on loader.
See warnings and instructions both at the beginning and
throughout this manual. After doing service or making repairs
or adjustments always check function of loader.
Safety glasses or goggles are always needed for eye
protection from electric arcs, from shorts or welding, battery
acid, compressed springs, fluids under pressure, and flying
debris or loose material when engines are running or tools are
used. Use eye protection approved for type of welding.
Failure to obey warnings can cause death, severe injury or
property damage.

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595MLCRL(S)
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8 hours
Daily
SERVICEREQUIRED
Fan and Drivebelts -Check for loosenessandwear.
Tightenorreplaceasneeded.
Operator's Platform -Cleanareaof debris, tools,
rags, water, ice, and snow.
Fuel Tank - Check level and fill if necessary.
Engine Crankcase Oil - Check level.
Engine Radiator - Check coolant level and fill if
necessary. Inspect exterior for dirt and debris and
clean if necessary.
Hoses, Connections, Cylinders -Inspect for leaks
and damage. Tighten, repair, or replace parts if
necessary.
Swing Motor Gearboxes - Check fluid levels.
Engine Air Cleaner - Inspect & replace element,if
needed.
Hydraulic Reservoir - check level and quality of oil.
Engine Shrouding - Clean and inspect.
SERVICE SCHEDULE
Fittings - Lubricate as shown on Lubrication Points.
Useamulti-purposegrease.
Bolts/Nuts -Visually inspect for wearordamage.
50 hours
Weekly 100 hours Monthly 400 hours 2 Months 1000 hrs 6 Months Yearly
ControlLever Linkage-Lubricate.
Bolts/Nuts-Checkforpropertorque every100hours.
Retorqueifnecessary.
Safetytreads,safetysigns, seat belt -Checkfor
damaged of missing items and replace.
Pump Drive - Check fluid level.

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595MLCRL(S)
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SERVICE SCHEDULE CONTINUED...
8 hours
Daily
SERVICEREQUIRED 50 hours
Weekly 100 hours Monthly 400 hours 2 Months 1000 hrs 6 Months Yearly
Battery - Clean and coat posts with grease. Check
electrolyte level and fill if necessary.
Engine Oil Filter - Replace.
Followenginemanufacturersguidelines.
Hydraulic Oil Cooler and Radiator -Clean.
HydraulicOilReservoirBreather-Replace.
Accumulators-Checkpressureandmaintainat1200
PSI.
Hydraulic Collector -Checkmountingbolts.
Pump Drive - Replace fluid.
Hydraulic Oil Filters - Replace elements every 400
hours, after initial change at 100 hours on a new
machine.
HydraulicOilReservoir -Changefluid.
Entire Loader - Steam clean, inspect for stress, wear,
cracks, damage, and loose parts.
Pilot Filters in Valve Banks - Remove, inspect and
clean.
SwingMotorGearboxes -Changefluid.
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.
Air Conditioner Air Intake Filter -Replace.
Hydraulic Oil Filter - On new machines the filter
element should be replaced first at 100hrs. and
then at 400 hrs. thereafter.