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Honda FL5540K1 Operator's Manual

Front loader for honda h5518a4 multi-purpose tractor.
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   Summary of Contents for Honda FL5540K1

  • Page 3: General

    Thank you for purchasing an HTA Front Loader attachment for your tractor. This manual covers the assembly, operation and maintenance of the HTA FL5540K1 front loader for the H5518 A4 Multi-purpose Tractor. For your convenience, guide, troubleshooting section and warranty service information.

  • Page 4: Table Of Contents

    ... . . : ....TOPIC ....... 1 .GENERAL .

  • Page 5: 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.

  • Page 6: Front Loader Safety

    FRONT LOADER SAFETY Operating the tractor front loader requires 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.

  • Page 7

    Before leaving the tractor unattended, always lower the front loader, shift the transmission to neutral, set the parking brake, stop the engine and remove the key from the ignition switch to prevent children or unauthorized persons from starting the engine. Prolonged exposure to loud noise can cause permanent impairment or loss of hearing.

  • Page 8

    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.

  • Page 9: Maintenance Safety

    Maintenance the tractor safety the safety of others. Know these requirements before perfoming maintenance on loader. the tractor front 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. -move the front PTO to the off position -stop the engine and remove the key.

  • Page 10: Safety Label Locations

    SAFETY LABEL LOCATIONS SAFETY LABEL LOCATIONS Read these SAFETY LABELS before you operate the front loader. IMPROPER SERVICING CAN CAUSE SERIOUS INJURY OR DEATH Before lower loader shut Relieve hydraulic pressure disconnecting oil lines. FALL LOADS CAN FROM BUCKET CAUSING SERIOUS INJURY OR DEATH Impropefiy hrndlhg heavy o bJe cts can c a m...

  • Page 11: Packaging Inventory

    ..........................SECURED TO CRATE BOlTOM LARGE CARTON SMALL CARTON--i...

  • Page 12: Tractor Preparation

    'RACTOR PREPARATION HARDWARE BAG CONTENTS QNT'Y DESCRIPTION VI S " lynchpin 10rnrn 30mm hex hd capscrew 25mrn hex hd capscrew 12mm x hex hd capscrew l/2-13xl lh" clipxpin ga. machine bushing hex hd capscrew lh-13x13/4" Va" flat washer V16-14~1 hex hd capscrew l/4"...

  • Page 13: Loader Specifications

    ....... . ITEM ......Rated Lift Capacity .

  • Page 14: 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.

  • Page 15: Sub-frame Installation/removal

    12 x 25mm hex head bolts with washers and two x 30mm hex head bolts with washers. 3/8" FL5540K1 SUB-FRAME INSTALLATION/REMOVAL FRAME LOWER 7/16" DRAWBAR / - - o - & - . BOLTS...

  • Page 16

    FL5540K1 SUB-FRAME INSTALLATION/REMOVAL Scribe the position of the two 14mm (9/16") holes in the bottom bracket onto the 3-point hitch box. 4. Remove the hitch box. Drill the two 14mm (9/16") holes as illustrated. 5. Install the hitch box and bottom bracket and...

  • Page 17

    60mm (2.4in) between sub-frame and the inner wall of the left front tire. 8. Drive the tractor forward from the rear of the sub-frame, over the drive-on plate keeping it parallel with the sub-frame. FL5540K1 SUB-FRAME INSTALLATION/REMOVAL area. solid SUB-FRAME...

  • Page 18

    FL5540K1 SUB-FRAME INSTALLATION/REMOVAL Stop the tractor when the mast fixing pad is even with the floor board of the tractor. Use a hydraulic jack to lift the front of the subframe. insert support blocks under the subframe in front of the mast fixing pad.

  • Page 19

    Remove the jack from the front. Push down on the front of the subframe while pushing back. Slide the subframe into the U-shaped channel. Place blocks un- der the rear of the subframe. Lift the front of the subframe with a jack and slip it into the channel of the lower cover.

  • Page 20

    FL5540K1 SUB-FRAME and COUNTERWEIGHT INSTALLATION/REMOVAL 11. Insert two mounting pins (3/4 x 3.1 gin) from inside the bottom bracket through the sub- frame. Slip a washer over each pin and retain with a clip as shown. Mounting pins have a flat side that must be pointing down.

  • Page 21: Front Loader Assembly

    FRONT LOADER ASSEMBLY HYDRAULIC PUMP MOUNTING Pump mounting plate and pump drive joint are installed on pump. Ensure bolts and set screw are tight. Attach the pump brackets to the pump mounting plate using two each bolts and flatwashers. The right 5/16"...

  • Page 22

    FRONT LOADER ASSEMBLY PRESSURE and SUCTION HYDRAULIC HOSE CONNECTION Remove the pipe plug from thevalve 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.

  • Page 23

    Attach brace arms to masts with clevis pins and clip pin. Tighten front guard bolts installed in step 5. Torque: 76 ft-lb (103 Nm). Bring the two hoses along the left side brace arm to the left mast. Route hoses on the left brace arm with metal loops.

  • Page 24

    FRONT LOADER ASSEMBLY BUCKET ATTACHING Using the bottom holes on the bucket, attach both sides of bucket to loader frame. Use two each clip pins. Attach both cylinders to top holes on bucket. Use two each and clip pins. The loader is now ready for hydraulic fluid. BUCKET LEVEL INDICATOR INSTALLATION 1 1.

  • Page 25

    HYDRAULIC FLUID SERVICING You will need 1/2 quarts of a good grade hydraulic fluid or ATF automatic transmission fluid. Remove filler plug and oil check screw on back of left mast. Fill with 4 quarts of hydraulic fluid. Start tractor engine and set speed at 1/2 throttle.

  • Page 26

    FRONT LOADER ASSEMBLY LOADER STAND REMOVAL Raise the loader with the loader control until the stands clear the ground. Remove latch pin from the stands and remove the stands. Align the hole in the bottom with the mounting hook at rear mainframe.

  • Page 27: Operational Checks

    OPERATIONAL CHECK Check all pivot points on the loader. Lubricate as necessary. (See lubrication chart.) on page number 44 Check loader hydraulic fluid. Note: Check fluid level with loader arms down and bucket flat on the ground. Remove oil check screw and see if oil will run out hole.

  • Page 28

    OPERATIONAL CHECK OPERATING TIPS f m L D o not use the bucket for pushing down material with bucket cylinders partially extended. Cylinder and rod may be damaged. Do not tip bucket cutting edge down (fully extend bucket cylinders) backfilling/backgrading operation. Cylinder and rod may be damaged.

  • Page 29: 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.

  • Page 30

    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"...

  • Page 31

    LOADING Drive straight ahead into pile with bucket cutting edge level with the ground. In order to prevent possibility of damaging tractor or loader; Do not ram into pile at high speed. not attempt turn tractor As bucket begins to fill with material, gradually roll the bucket back and raise the loader to increase "fill"...

  • Page 32

    OPERATING INSTRUCTIONS TRANSPORTING MATERIAL Transport material to “unloading point” with loader bucket as low as possible to prevent spillage maintain tractor/loader stability. - 1 - During transport the loader should be in position that will not impair operator‘s vision. Observe the following safety messages. -Avoid any overhead wires or obstacles when loader is raised, to avoid damage or possible death by electrocution.

  • Page 33: Loader Removal

    LOADER REMOVAL FROM TRACTOR Select a level, safe, and solid place for loader removal. Lower bucket to the ground and remove the stands from the loader main frame. Raise the loader until the stands can be inserted into the loader arms. Install the clip pins into the stand ends.

  • Page 34

    LOADER REMOVAL FROM TRACTOR Using the bucket to support the loader main frame, remove loader mast fixing pins. Use bucket operation to make fixing pin removal easier. Remove the clip pins and mounting pins from the masts and the front guard. Remove the hydraulic hoses from the left brace loops.

  • Page 35

    Put the tractor in reverse and drive it back 2 feet. Remove the front guard from su b-f rame. Remove the hydraulic pump by removing the four bolts holding the mounting brackets to the tractor frame. Remove the pump from the PTO shaft. To presewe system integrity and to prevent fluid contamination, do not disconnect hoses.

  • Page 36

    LOADER REMOVAL FROM TRACTOR NOTES:...

  • Page 37: Storage

    STORAGE SEASON If loader is to be dismounted from the tractor during storage, make sure parking area is on hard, level ground. Store in a dry, sheltered area, if possible. Note: hydraulic cylinders should be in retracted position. 3. Thoroughly clean the loader of all accumulated dirt and grease.

  • Page 39: Loader Installation

    LOADER INSTALLATION Install the sub-frame and rear weight box. (pages 1 The sub-frame, masts and main frame are assembled. All cylinders and hoses are attached to the loader frame and hydraulic Pump. Move the tractor centrally between the masts. 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...

  • Page 40

    LOADER INSTALLATION ATTACHING LOADER MASTS Move the tractor until the masts are positioned in line with upright pads on the sub-frame. Operate the bucket control lever to roll the bucket down to push the masts down onto the pads. Use bucket movement to shake masts to align pin holes.

  • Page 41

    LOADER STAND REMOVAL 7 . Raise the loader with the loader control until the stands clear the ground. Remove fixing pin from the stands and remove the stands. Align the hole in the bottom of the stand with the mounting hook at rear of mainframe.

  • Page 43: Troubleshooting

    TROUBLE SHOOTING SYSTEM DOES NOT WORK AT ALL "OFF" position Put to 'ON'. No oil in system Fill to proper level. Check system for leaks. Oil low 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.

  • Page 44

    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 used specifications on proper oil. Air leak in line from reservoir to Tighten or replace suction line. Kink in oil suction line Replace oil line.

  • Page 45: Lubrication And Maintenance

    LUBRICATION MAINTENANCE Do not perform any service/maintenance operations with front loader raised off the ground. Lower front loader to the ground and relieve pressure in loader hydraulic lines prior to performing any service / maintenance operations on tractor or loader. -Keep hands and body from pressurized lines.

  • Page 46: Lubrication And Maintenance Chart

    LUBRICATION AND MAINTENANCE LUBRICATION AND MAINTENANCE CHART LUBRICATION AND MAINTENANCE CHART ..Hydraulic oil level ..Tire inflation ..Loader pivot points .

  • Page 47: Parts

    IEFERENCE UMBER ANGLE ANGLE PUMP COUPLER PUMP PLATE RUBBER BUSHING 304 PUMP 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 3/8 x 3"...

  • Page 48

    PARTS...

  • Page 49

    REPAIR PARTS - MAIN FRAME ASSEMBLY 3EFERENCE WMBER MAIN FRAME UPRIGHT UPRIGHT - LH STAND BUCKET 42" BUCKET LEVEL INDICATOR 5/32 x 1" COTTER PIN #11 CLIP PIN 3/8 x 2 1/4" LYNCH PIN 1 1/4x 3/4"x 10ga. MACHINERY BUSHING LIFT CYLINDER LIFT CYLINDER BUCKET CYLINDER...

  • Page 50

    REPAIR PARTS REFERNCE NUMBER SUB FRAME FRONT BRACKET LOWER FRONT COVER, FRAME BOTTOM BRACKET PUMP GUARD BRACE ARM, RH BRACE ARM, LH PIN D, WITH FLAT (Mounting Pin) PIN E (Fixing Pin) #11 CLIP PIN 1-114" 1/2- 112- 13 112" FLATWASHER 112"...

  • Page 51

    REPAIR PARTS REFERENCE DESCRIPTION NUMBER O-RING O-RING SCREW END CAP RETURN SPRING SPACER WASHER SCREW w/LOCKWASHER SPACER DETENT SPOOL RETURN SPRING DETENT PLUG DETENT SPRING STEEL BALL DETENT END CAP LOAD CHECK POPPET LOAD MCHECK PLUG LOAD CHECK SPRING TAMPER PROOF CAP JAM NUT GASKET ADJUSTMENT SCREW...

  • Page 52

    NOTES:...

  • Page 53: 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. I f you have a warranty problem that has not been handled to your satisfaction, we suggest you take the following action: Discuss your problem with a member of the dealership management.

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