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Summary of Contents for Koyker 545
- Page 1 OWNERS MANUAL 2/1/06 MANUAL NO. 669519 LOADER IMPORTANT-KOYKER DEALER BE SURE THIS MANUAL IS GIVEN TO THE PURCHASER FOR FUTURE REFERENCE KOYKER MANUFACTURING CO., P.O. BOX 409 LENNOX, SD 57039 Phone 1-800-456-1107 E-mail koyker@koykermfg.com...
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Page 2: Table Of Contents
Loader Inspection, Service, and Maintenance ..................13 Hydraulic System Parts List ........................14 Hydraulic System Parts Diagram ......................15 “545” Loader Parts Diagram ......................... 16 Parts Identification Schedule ......................17-18 Bucket Parts Diagram ........................... 19 Bucket Parts Identification Schedule ....................20 Hydraulic Cylinder Information ...................... -
Page 3: Introduction
The fast attaching “545” Farm Loader has achieved these goals. With proper care and handling, it will give many years of good service in normal farm operations. -
Page 4: Safety Alert Symbol
SAFETY ALERT SYMBOL The symbol shown below is used to call your attention to instructions concerning your personal safety. Watch for this symbol it points out important safety precautions. It means ATTENTION! Become Alert! Your Personal Safety Is Involved! Read the message that follows and be alert to the possibility of personal injury or death. DANGER: Indicates an imminently hazardous situation that, if not avoided, will result in death or serious injury. -
Page 5: Safety Information
SAFETY Improper use of a loader can cause serious injury or death. The following safety precautions, and those given on the tractor mount installation instructions, should be thoroughly understood before attempting to operate this machine. BEFORE OPERATING: Carefully study and understand this manual, the specific tractor mount instructions, and the attachment(s) manual(s). - Page 6 SAFETY CONTINUED Transport the machine load at the slowest speed possible and with the loader boom at the lowest transport position to avoid tipping or upsetting, which may result in serious injury or death. Be extremely careful when working on inclines or near loose fill, rocks, and holes as they can cause tipping or upsetting which may result in serious injury or death.
- Page 7 1. Move Slowly! 2. Always use care and common sense! 3. Be careful for your own sake and for that of others! 4. Koyker Mfg. Co. includes all reasonable means for accident prevention except a safe and careful operator. FIG. 5-1...
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Page 8: Safety Decals
SAFETY DECALS Page 6... -
Page 9: Tractor & Safety Pointers
TRACTOR & SAFETY POINTERS The use of good judgment and common sense is necessary by the operator in using this loader. The front and rear wheels should be set for the widest wheel tread to assure best stability. Use extra caution when rear wheel weights and tire ballast are added to a loader-equipped tractor. -
Page 10: Attaching Loader
ATTACHING LOADER IMPORTANT: Never attempt loader attachment on grades which are not reasonably level. 1. Check to be sure that the surfaces of the mounts are free of obstructions. (Fig 8-1) 2. Drive the tractor slowly and carefully in between the loader arms only far enough to permit hook-up of the hydraulic system hoses. -
Page 11: Attaching Bucket
ATTACHING THE BUCKET For Fast Attach Buckets, first tilt the bucket adapter forward so the top round pipe slides into the receiver on the bucket (Fig. 9-1). Rotate the bucket back so the two rear pins line up with the holes on the base plates of the bucket (Fig. -
Page 12: Detaching Loader
DETACHING LOADER IMPORTANT: Never attempt loader attachment on grades which are not reasonably level. Raise loader frame slightly to permit loader stand reengagement. (Fig. 10-1) Lower bucket to ground and tip slightly forward to apply pressure to mount connection. Note: This will prevent the loader from inadvertently rocking forward when the mount pins are removed and uprights are disengaged from it’s cradle. -
Page 13: Operation
OPERATION WARNING: Never allow anyone to operate the loader until they have carefully reviewed and understood this owners manual. FILLING THE BUCKET: When manure is piled on a slope, it is best to drive tractor up the slope straight into the pile. Operating sideways on a slope has a tendency to tip the loading unit. -
Page 14: Specifications
*Specifications based on ASAE standards S301.3 (Front-End Agricultural Loader Ratings) The above information is based on testing done by Koyker Mfg. Variations in maximum lift height and other specs for different tractors are due to tire sizes, variations in loader mounting locations and hydraulic system efficiency. -
Page 15: Loader Inspection, Service, And Maintenance
LOADER INSPECTION, SERVICE, AND MAINTENANCE Lower the bucket to the ground, shut off tractor engine, and relieve the pressure in the hydraulic system before adjusting, lubricating, or servicing the loader. Inspect all pins and grease fittings before each use and lubricate with heavy duty grease as indicated in this manual. -
Page 16: Hydraulic System Parts List
HYDRAULIC SYSTEM PARTS LIST PART NUMBER DESCRIPTION QUANTITY 1 ...... 669503 ....3” Lift Cylinder ............2 2 ...... 675502 ....3” Bucket Cylinder ............2 3 ...... 675616 ....1st Oil Line ..............1 4 ...... 675617 ....2nd Oil Line ..............1 5 ...... -
Page 17: Hydraulic System Parts Diagram
HYDRAULIC SYSTEM PARTS DIAGRAM Page 15... -
Page 18: 545" Loader Parts Diagram
KOYKER “545” LOADER PARTS DIAGRAM Page 16... -
Page 19: Parts Identification Schedule
18 ..... 677289 ....31” Hydraulic Hose ............2 19 ..... 654629 ....“American Made” Decal ..........2 20 ..... 654631 ....“Koyker” Decal ............3 21 ..... 669512 ....“545” Decal ..............2 22 ..... 666941 ....Serial Number Decal ............1 23 ..... 666943 ....Warning Decal .............5 24 ..... - Page 20 PARTS IDENTIFICATION CONTINUED Optional Fast Attach Buckets & Bucket Adapter & Cylinder PART NUMBER DESCRIPTION QUANTITY 51 ..... 656757 ....6’ Fast Attach Bucket ...........1 52 ..... 656758 ....7’ Fast Attach Bucket ...........1 53 ..... 656759 ....8’ Fast Attach Bucket ...........1 669599 Bucket Adapter Bundle ..........1 54 .....
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Page 21: Bucket Parts Diagram
BUCKET PARTS DIAGRAM Page 19... -
Page 22: Bucket Parts Identification Schedule
BUCKET PARTS IDENTIFICATION SCHEDULE Optional Fast Attach Buckets with Bolt-on Blade & Clevis PART NUMBER DESCRIPTION QUANTITY 1 ...... 672840 ....6’ Fast Attach Bucket ...........1 2 ...... 672843 ......6’ Fast Attach Bucket Weldment .....1 3 ...... 672846 ......6’ Bolt-on Blade ..........1 4 ...... -
Page 23: Hydraulic Cylinder Information
CYLINDERS IMPORTANT: Read these service tips before beginning assembly of cylinder gland or piston. 1. Keep seals clean from the time they are removed from package until they are installed. 2. Clean the groove or bore into which the seal is to be fitted before installing the seal. 3. -
Page 24: Hydraulics Information
HYDRAULIC SYSTEM The hoses from the tractor valves are attached to the oil lines which are on the inside of the loader main frame. Re-check all joints to prevent leakage after loader is mounted and in operation. KEEP SYSTEM CLEAN - USE ONLY CLEAN OIL CAUTION! It is of utmost importance that the hydraulic system of this loader be kept free from dirt and foreign matter. -
Page 25: 3" Cylinder Service Kit
3” CYLINDER SERVICE KITS WITH 1 3/4” SHAFT KIT NO. 662050: Complete kit with all seals needed to service one (1) 3” Cylinder. Consists of: 1 each 3” Gland “O” Ring 1 each 3” Backup Ring 1 each 1 3/4” U-cup Seal 1 each 1 3/4”... -
Page 26: Hydraulic Cylinder Parts List
HYDRAULIC CYLINDER PARTS LIST LIFT CYLINDER (Part No. 669503) Part No. Description Quantity 1 ...... 669560 ....Tube Weldment .............. 1 2 ...... 661017 ....Locknut ................1 3 ...... 651537 ....Piston Assembly ............. 1 4 ...... 640301 ....“O” Ring Seal ..............1 5 ...... -
Page 27: Hydraulic Cylinder Parts Diagram
HYDRAULIC CYLINDER PARTS DIAGRAM Page 25... -
Page 28: Piston And Gland Diagram
CYLINDER GLAND SERVICE DIAGRAM Note: To install rod wiper and U-cup seal, fold All gland seals shown with a section similar to shape shown below, slip into gland removed to facilitate correct installation. ROD WIPER bore and locate each in its respective groove. Tools are used to fold seals, take care not to damage sealing surfaces. -
Page 29: Limited Warranty Information
(1) year from the sale to the original purchaser. Any defective cylinder reported to Koyker within one (1) year from the sale by the dealer to the original purchaser may be repaired or replaced after Koyker’s inspection and approval. In such case, notify a Koyker dealer for proper instructions. - Page 30 Koyker; rental charges of any substitute equipment; expenses due to lost, damaged, or delayed products or parts resulting from acts beyond the control of Koyker; and personal injury or death of operator or bystanders by misappropriated use of Koyker products or parts.
- Page 31 2. For surface wear, scheduled maintenance parts, and other items that Koyker deems expendable. 3. If products or parts not manufactured by Koyker or approved by Koyker are connected to or used in conjunction with the Koyker products or parts and if Koyker deems the non-Koyker products or parts affect the performance, safety, reliability, or life of the Koyker products or parts.
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Page 32: Torque Specifications
TORQUE SPECIFICATIONS 1. Tightening Bolts & Nuts Check all loader bolts and nuts for tightness every 50 working hours. The movement of the loader over rough terrain may cause bolts to come under pressure and over a long period of time some slight stretching of the bolt may occur.