40PERATOR'S MANUAL A J Front Loader Model FL5540KO for Honda H5518A4 Multi-purpose Tractor I
CONTENTS TOPIC PAGE 1.GENERAL ................................................................................................... 1 2 . INTRODUCTION ........................................................................................................ 3 Front loader safety ........................................................................................... 4 Maintenance safety ............................................................................................ 7 Safety label locations ...
~ INTRODUCTION INTRODUCTION The purpose of this manual is to instruct you in maintaining and operating your HTA Front Loader. Read it carefully; it furnishes information and instructions that will help you achieve years of dependable performance. Some information may be general in nature due to unknown and varying conditions. However, through experience and these instructions, you should be able to develop operating procedures suitable to your particular situation.
FRONT LOADER SAFETY FRONT LOADER SAFETY Operating the tractor and front loader requires special efforts on your part to ensure your safety and the safety of others. Know these requirements before you operate the tractor or front loader. SAFE OPERATING RULES Severe personal injury or equipment damage may result if the operating instructions on ( pages 25 thru 30 ) are not followed. Always make pre-operation checks ( page 25 ) before you start the engine. You may prevent an accident or equipment damage.
FRONT LOADER SAFETY Never operate the tractor or front loader when visibility is diminished by darkness or by bad weather; your ability to see obstacles will become impaired. Avoid loose fill, rocks and holes. They may cause vehicle instability or cause the vehicle to overturn. The front loader is intended for relatively flat terrain useage. Avoid overhead wires and obstacles when the front loader is in the raised position. Contacting electric wires can cause electrocution.
MAINTENANCE SAFETY MAINTENANCE SAFETY Maintenance of the tractor and front loader requires special efforts on your part to ensure your safety and the safety of others. Know these requirements before perfoming maintenance on the tractor or front loader. Before performing maintenance/inspections,read the instructions thoroughly. Before cleaning, inspecting or servicing the loader be sure to; - lower the front loader bucket flat to the ground.
SAFETY LABEL LOCATIONS SAFETY LABEL LOCATIONS Read these SAFETY LABELS before you operate the front loader. IMPROPER SERVICING CAN CAUSE SERIOUS INJURY OR DEATH 0 Before servicing or adjustment lower loader to the ground and shut off engine. Rolleve hydraulic pressure before disconnecting oil lines. TRACTOR TIP-OVER CAN CAUSE SERIOUS INJURY OR DEATH Add recommended wheel ballast and/or counterweights for stability. • Drive and turn tractor at slow speed.
PACKAGING INVENTORY PACKAGING INVENTORY ....................................................................... 12 Required 37.5 Ibs. each I3 j WEIGHTS 1 ................................ ..................................................................................... I SECURED TO CRATE BOTTOM ........~..,.~...........~..~.~~........~..~..........................,....,. ................................................................................................... I. ........ .........
HARDWARE BAG CONTENTS -2 QNT'Y DESCRIPTION 7/16" lynchpin 5 2 10mm x 30mm hex hd capscrew 2 12mm x 25mm hex hd capscrew 2 1/2-13x11/2" hex hd capscrew 16 #11 clip pin 12 3/4 x 11/4 x 10 ga.
LOADER SPECIFICATIONS LOADER SPECIFICATIONS A- - LOADER SPECIFICATIONS ........................ ITEM Rated Lift Capacity Bucket Size (width) Hydraulic cylinder Counterweights . . . . . . . . . FL5540 ................ ........ 400lb (180kg) . . . . . . . . . . . . . . . . . . . . . . . . 42in (1050mm ) . . . . . . . . . . . . . . . . . . . . . . . . . Double acting . . . . . . . . . . . . . . . . . . . . . . . . . . Suit case type 37.5lb x 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY INFORMATION ASSEMBLY INFORMATION GENERAL Read assembly instructions completely prior to installing loader to familiarize yourself with all mounting and hydraulic system installation procedures. The loader operates from its self contained hydraulic system with the pump driven from the tractor front PTO. A pipe thread sealant must be used on all pipe threads. All hardware required for mounting loader is supplied.
FL5540 SUB-FRAME and COUNTERWEIGHT INSTALLATION/REMOVAL - - FL5540 SUB-FRAME and COUNTERWEIGHT INSTALLATION/REMOVAL 1. Remove the existing frame lower cover and replace with the new lower cover using existing mounting bolts and collar washers. d--1 Never operate the tractor without the lower cover. INSTALLATION INSTRUCTIONS NEW LOWER FRONT COVER 1. CLEAN THE CONTACT SURFACES BETWEEN BRACKET AND FRAME. 2. MOUNT THE BRACKET BY INSTALLING THE (8) BOLTS FINGER TIGHT. 3.
FL5540 SUB-FRAME and COUNTERWEIGHT INSTALLATlON/REMOVAL 3. Lay the sub-frame on a level, solid area. 4. Position the tractor in line with the sub-frame and tire guide on drive on plate, allowing a clearance of approximately 60mm (2.4in) between sub-frame and the inner wall of the left front tire. SUB-FRAME GUIDE forward from the rear of 5. D rive the tractor the sub-frame, over the drive on plate keeping it parallel with the sub-frame.
FL5540 SUB-FRAME and COUNTERWEIGHT INSTALLATION/REMOVAL 6. Stop the tractor when the mast fixing pad comes even with the floor board of the tractor. 7. Using two people, lift the sub-frame and engage the pipe of sub-frame into the U-shaped channel of the bottom bracket. NOTE: Use two people to lift sub-frame.
FL5540 SUB-FRAME and COUNTERWEIGHT INSTALLATION/REMOVAL 8. Lift the front of the sub-frame and slip it into the channel of the lower cover. Insert two mounting pins (3/4 x 3.19in) from inside sub-frame through frame lower cover. Slip a 3/4in washer over each mounting pin and insert the clip pins through the holes. NOTE: Mounting pins have a flat side that must be pointing down. MOUNTING PIN FLAT SIDE DOWN 9. Insert two mounting pins (3/4 x 3.19in) from inside the bottom bracket through the sub-frame.
FL5540 SUB-FRAME and COUNTERWEIGHT INSTALLATlON/REMOVAL COUNTERWEIGHT BRACKET INSTALLATION - LINCHPIN MOUNTINGPINS - FIXING PINS 10. Place the rear counterweight bracket on the rear of the sub-frame aligning the mounting holes of the bracket with those of the sub-frame. Insert two 1 x 3.5 inch mounting pins in the forward holes and one 1 x 12 inch mounting pin in rear lower hole. Secure with linchpins. COUNTERWEIGHT BRACKET 11. Install the twelve counterweights.
FRONT LOADER ASSEMBLY FRONT LOADER ASSEMBLY HY DRAULIC PUMP MOUNTING 1. Pump mounting plate and pump drive joint are installed on pump. Ensure bolts and set screw are tight. LEFT BRACKET PUMP MOUNTING PLATE Attach the pump brackets to the pump mounting plate using two each 5/16x2 inch bolts and 5/16" flatwashers. The right bracket is shorter than the left. Do not tighten the bolts at this time. - Apply a light coating of grease to tractor front PTO at this time. RIGHT BRACKET 2.
FRONT LOADER ASSEMBLY PRESSURE and SUCTION HYDRAULIC HOSE CONNECTION 4. Remove the pipe plug from the valve body and clean the threads and then install the pressure hose. Remove the plastic caps from the pump outlets. Use sealer on threads and screw the other end (swivel connector end) into the threaded pipe fitting on the pump. Slide the suction hose (large hose) over the pipe end at the bottom of mastkeservoir and pipe end on the pump. Attach with hose clamps and tighten securely.
~ ~ ~~ ~ FRONT LOADER ASSEMBLY 7. Attach brace arms to masts with clevis pins and clip pin. Tighten front guard bolts installed in step 5. Torque: 76 ft-lb (1 03 Nm). 8. Bring the two hoses along the left side brace arm to the left mast. Route hoses on the left brace arm with metal loops. Ensure that the high pressure hose (smaller diameter) is positioned on top of the suction hose (large diameter). Install the nylon tie strap to bind the two hoses together at front corner of hoodline. 9.
FRONT LOADER ASSEMBLY BUCKET ATTACHlNG 10. Using the bottom holes on the bucket, attach both sides of bucket to loader frame. Use two each 3/4 x 3 inch pins and clip pins. Attach both cylinders to top holes on bucket. Use two each 3/4 x 3 inch pins and clip pins. The loader is now ready for hydraulic fluid. 3/4 x 3in PINS HYDRAULIC FLUID SERVICING You will need 6 1/2 quarts of a good grade hydraulic fluid or ATF automatic transmission fluid. 11.
~~ ~ ~~~~ ~ FRONT LOADER ASSEMBLY LOADER STAND REMOVAL 12. Raise the loader with the loader control until the stands clear the ground. 13. Remove latch pin from the stands and remove the stands. MOUNTING HOOK 14. Align the hole in the bottom of the stand with the mounting hook at rear of mainframe. Slide the stand over the mounting hook and then insert the latch pin previously removed through main frame and through the stand. Repeat the above steps for the other side.
OPERATIONAL CHECK OPERATIONAL CHECK Note: Bucket and lift cylinders should be fully retracted when checking hydraulic fluid level: Check all pivot points on the loader. Lubricate as necessary. (See lubrication chart.) on page number 44 Check all hydraulic hose connections to ensure that they are not leaking. Check loader hydraulic fluid. Lubricate all pivot points that incorporate grease fittings. Note: Check fluid level with loader arms down and bucket flat on the ground.
~_____ OPERATIONAL CHECK 6. When lowering a heavy load, ease it downward slowly. Never drop a loaded .. bucket and “catch” hydraulically. Stopping a load after it has gained NOTICE -Do not use the bucket for pushing downward momentum places undue down material with bucket cylinders partially strain on the unit and may cause damage extended. Cylinder and rod may be to the loader or tractor. damaged.
OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS Main, lift and bucket cylinders are double acting type (both push and pull under hydraulic power). This means that the loader can be forced down as well as up. It means that the bucket can be tilted down or up with hydraulic pressure. HYDRAULIC CONTROL VALVE Your loader control valve has two handles. The right handle operates the lift cylinders (the loader) and has a float position. The left handle operates the bucket cylinders.
OPERATING INSTRUCTIONS CONTROLLED RATE of LOADER FUNCTIONS By feathering (slightly moving) the control levers, precise operational speeds can be obtained. This action controls the position of the valve spools in the control valve and regulates flow of oil from/to cylinders. It is important to utilize this operational SCRAPING When scraping, the "float" position should be utilized to maintain the bucket firmly on the ground and at the same time allow the bucket to follow ground contours.
OPERATING INSTRUCTIONS LOADING .-. . . As bucket begins to fill with material, gradually roll the bucket back and raise the loader to increase "fill" capacity. This procedure also results in the material being removed in layers from the top for maximum loading efficiency. When the bucket is full, raise loader so that the bucket is clear of material and slowly back out of pile. For maximum loading efficiency, minimize angle of turn and distance between the loading and unloading points.
OPERATING INSTRUCTIONS TRANSPORTING MATERIAL Transport material to "unloading point" with loader bucket as low as possible to prevent spillage and maintain maximum tractor floader stability. - -1 During transport the loader should be in a position that will not impair operators vision, Observe the following safety messages. B h . —Avoid any overhead wires or obstacles when loader is raised, to avoid damage or possible death by electrocution. .
LOADER REMOVAL FROM TRACTOR LOADER REMOVAL FROM TRACTOR 1. Select a level, safe, and solid place for loader removal. Lower bucket to the ground and remove the stands from the loader main frame. 2. Raise the loader until the stands can be inserted into the loader arms. Install the clip pins into the stand ends. 3. Lower the loader until the stands rest on the ground. Dump the bucket until the edge of bucket touches the ground.
LOADER REMOVAL FROM TRACTOR 4. Using the bucket to support the loader main frame, remove loader mast fixing pins. Note: Use bucket operation to make fixing pin removal easier. 5. Remove the clip pins and mounting pins from the masts and the front guard. Remove the hydraulic hoses from the left brace loops. Remove the brace arms. 6. Roll back the bucket to detach loader from sub-frame. Operate the bucket slowly to avoid loader to tractor interference.
LOADER REMOVAL FROM TRACTOR 7. Put the tractor in reverse and drive it back 2 feet. Remove the front guard from sub-frame. 8. Remove the hydraulic pump by removing the four bolts holding the mounting brackets to the tractor frame. Remove the pump from the PTO shaft. NOTE: Do not disconnect hoses. Loader is now parked and ready for storage. For sub-frame removal see pages 13 thru 17.
STORAGE STORAGE PROCEDURES END OF SEASON BEGINNING OF SEASON 1. If loader is to be dismounted from the tractor during storage, make sure parking area is on hard, level ground. 1. Review safety precautions and operation sections of manual. 2. Store in a dry, sheltered area, if possible. 2. Thoroughly clean loader of all accumulated dirt and grease. Note: All hydraulic cylinders should be in the retracted position. 3.
LOADER INSTALLATION LOADER INSTALLATION I NOTE: Install sub-frame and weights (Page 13 - 17). The sub-frame, masts and main frame are assembled. All cylinders and hoses are attached to the loader frame and hydraulic pump. 1. Move the tractor centrally between the masts. 2. Mount hydraulic pump to tractor by sliding splined pump drive joint onto front PTO shaft with mounting brackets inside main frame and attaching with four 5/16 x 7/8 inch bolts. 3.
LOADER INSTALLATION ATTACHlNG LOADER MASTS 4. Move the tractor until the masts are. positioned in line with upright pads on the sub-frame, use two people and the bucket to lower and guide the masts onto the pads. 5. Use bucket movement to shake masts to align pin holes. Insert the fixing pins through the masts and pads. Install clip pins through holes. 6. Attach brace arms to mast and front guard as shown with clevis pins and clips.
LOADER INSTALLATION LOADER STAND REMOVAL 7. Raise the loader with the loader control until the stands clear the ground. 8. Remove fixing pin from the stands and remove the stands. 9. Align the hole in the bottom of the stand with the mounting hook at rear of mainframe. Slide the stand over the mounting hook and then insert the fixing pin previously removed through main frame and through the stand. Repeat the above steps for the other side. Lower the loader to the ground.
TROUBLE SHOOTING TROUBLE SHOOTING SYSTEM RUNS OR WORKS SLOWLY SYSTEM DOES NOT WORK AT ALL PTO in 'OFF' position — Put to 'ON'. No oil in system — Fill to proper level. Check system for leaks. Oil low in reservoir — Check and fill to proper level. Check system for leaks. Restriction in system — Oil suction line could be collapsing to cut off oil supply. Replace line. Air leaks in pump suction line — Check hose clamps or replace hose. Dirt in pump — Clean and repair pump.
TROUBLE SHOOTING FOAMING OF OIL IN SYSTEM Low oil level — Fill reservoir. Look for leaks. Water in oil — Drain and replace oil. Wrong kind of oil being use — See specifications on proper oil. Air leak in line from reservoir to pump — Tighten or replace suction line. Kink in oil suction line — Replace oil line. LOAD DROPS WITH CONTROL VALVE IN NEUTRAL POSITION Leaking or broken oil lines from control valves to cylinder — Check for leaks. Tighten or replace lines.
LUBRICATION and MAINTENANCE LUBRICATION and MAINTENANCE Do not perform any service/maintenance operations with front loader raised off the ground. Inspect hydraulic hoses, connections, control valve and cylinders for evidence of leakage Note: If oil seepage past cylinder rod is evident, look for scoring on rod.
LUBRICATION AND MAINTENANCE LUBRICATION AND MAINTENANCE CHART LUBRICATION AND MAINTENANCE CHART . . . . . . Check . . . . . . . . . . . . . . . . . . . . . . . Check . . . . . . . . . . . . . Hydraulic oil level Daily/10 Hrs Tire inflation Weekly/50 Hrs . . . . . . Lubricate . . . . . . . . . . . . Daily/10 Hrs Loader pivot points Hydraulic lines hoses and connections ..... Check for leakage. wear and damage ....... Daily/10 Hrs . . . Check for seepage. . . . . . . .
PARTS REPAIR PARTS REFERENCE NUMBER 1 - PUMP ASSEMBLY DESCRIPTION ANGLE - RH QUANTITY REQ'D 1 2 3 4 5 6 ANGLE - LH PUMP COUPLER PUMP PLATE RUBBER BUSHING 304 PUMP 1 1 1 2 1 7 8 9 11 12 3/16 x 3/16 x 1 KEY 1/2 x 2" PIPE NIPPLE 1/2 x 45" PIPE ELBOW 1/2" PIPE END 1/2 3/8 HEX REDUCER BUSHING 3/8 90" ST ELBOW 1 1 1 1 1 1 13 14 15 16 17 18 3/8 x 3" PIPE NIPPLE 3/8 90" PIPE ELBOW 3/8 x 60" HYDRAULIC HOSE 9/16 - 18 ORB x 3/8MS 3/4" SUCTION HOSE # 16 HOSE CLAMP 5/16 - 18 x 1 3/4" HEX HEAD CAPSCREW 1 1 1
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PARTS REPAIR PARTS REFERENCE NUMBER - MAIN FRAME ASSEMBLY IUANTlTY QUANTITY IEQ'D REQ'D DESCRIPTION MAIN FRAME UPRIGHT - RH UPRIGHT - LH STAND BUCKET - 42" PIN - A 5/32 x 1" COTTER PIN #11 CLIP PIN 1 1 1 2 1 12 8 4 9 10 11 12 13 14 15 16 3/8 x 2 1/4" LYNCH PIN 1 1/4 x 3/4" x 10ga.
PARTS REPAIR PARTS REFERENCE NUMBER 1 2 3 4 5 6 - SUB-FRAME DESCRIPTION QUANTITY REQ'D SUB FRAME FRONT BRACKET LOWER FRONT COVER, FRAME BOTTOM BRACKET WEIGHT BRACKET, COUNTERWEIGHTS PUMP GUARD 1 1 1 1 1 1 7 8 9 10 11 12 BRACE ARM, RH BRACE ARM, LH PIN, COUNTERWEIGHT BRACKET A PIN, COUNTERWEIGHT BRACKET B PIN, COUNTERWEIGHT BRACKET C PIN D, WITH FLAT (Mounting Pin) 1 1 2 1 2 4 13 14 15 16 17 18 PINE (Fixing Pin) 5/8 x 1 1/4" LEVIS PIN 7 1/6" LYNCH PIN #11 CLIP PIN 1 1/4" x 314" x 10ga MACHINERY BU
PARTS REPAIR PARTS .- HYDRAKIC VALVE EFERENCE UMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 DESCRIPTION O-RING O-RING SCREW END CAP RETURN SPRING SPACER WASHER SCREW w/LOCKWASHER SPACER DETENT SPOOL RETURN SPRING DETENTPLUG .
WARRANTY SERVICE WARRANTY SERVICE OWNER SATISFACTION Your satisfaction and good will are important to your dealer and to us. All Honda warranty details are explained in the Distributor's Limited Warranty. Normally any problems concerning the product will be handled by your dealer's service department. If you have a warranty problem that has not been handled to your satifaction, we suggest you take the following action: Discuss your problem with a member of the dealership management.
Current customer service contact information: United States, Puerto Rico, and U.S. Virgin Islands: Honda Power Equipment dealership personnel are trained professionals. They should be able to answer any question you may have. If you encounter a problem that your dealer does not solve to your satisfaction, please discuss it with the dealership's management. The Service Manager or General Manager can help. Almost all problems are solved in this way.
