Honda FL5540KO Operator's Manual
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Honda FL5540KO Operator's Manual

Honda FL5540KO Operator's Manual

Front loader for honda h5518a4 multi-purpose tractor
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MANUAL
Front Loader
Model FL5540KO
for Honda H5518A4
I
Multi-purpose Tractor

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Table of Contents
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Summary of Contents for Honda FL5540KO

  • Page 1 40PERATOR'S MANUAL Front Loader Model FL5540KO for Honda H5518A4 Multi-purpose Tractor...

  • Page 3: Table Of Contents

    TOPIC 1 .GENERAL ... 1 INTRODUCTION ... 3 Front loader safety Maintenance safety ... 7 Safety label locations ... 8 PACKAGING INVENTORY TRACTOR PREPARATION LOADER SPECIFICATIONS 6 . ASSEMBLY INFORMATION Sub-frame installation/removal ... 13 Front loader assembly Operational checks ... 25 OPERATING INSTRUCTIONS ...

  • Page 4: General

    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 5: 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.
  • Page 7 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 8: 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;...

  • Page 9: 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 to the ground and shut off engine. Rolleve hydraulic disconnecting oil lines. LOADS CAN FALL FROM BUCKET CAUSING SERIOUS INJURY OR DEATH INFORMATION Special loader attachments for...

  • Page 10: Packaging Inventory

    ............................. SECURED T O C RATE BOTTOM .

  • Page 11: Tractor Preparation

    TRACTOR PREPARATION HARDWARE BAG CONTENTS QNT'Y DESCRIPTION 7/16" lynchpin 10mm x 30mm hex hd capscrew 12mm x 25mm hex hd capscrew 1/2-13x11/2" hex hd capscrew #11 clip pin 3/4 x 11/4 x 10 ga. machine bushing 1/2-13x13/4" hex hd capscrew 3/8"...

  • Page 12: Loader Specifications

    ITEM ....Rated Lift Capacity ....Bucket Size (width) ....Hydraulic cylinder .

  • Page 13: 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 14 FL5540 SUB-FRAME and COUNTERWEIGHT INSTALLATION/REMOVAL Remove the existing frame lower cover and replace with the new lower cover using existing mounting bolts and collar washers. 1 - d - Never operate the tractor without the lower cover. INSTALLATION INSTRUCTIONS 1. CLEAN THE CONTACT SURFACES BETWEEN BRACKET AND FRAME. 2.
  • Page 15 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.
  • Page 16 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.
  • Page 17 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.
  • Page 18 COUNTERWEIGHT BRACKET INSTALLATION 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.

  • Page 19: Front Loader Assembly

    FRONT LOADER ASSEMBLY HY DRAULIC 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 5/16x2 inch bolts and 5/16" flatwashers. The right bracket is shorter than the left.
  • Page 20 FRONT LOADER ASSEMBLY PRESSURE 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.
  • Page 21 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.
  • Page 22 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.
  • Page 23 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. 14. Align the hole in the bottom of the stand with the mounting hook at rear of mainframe.

  • Page 24: 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 25 OPERATIONAL CHECK OPERATING TIPS NOTICE -Do 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) during backfilling/backgrading operation. Cylinder and rod may be damaged.

  • Page 26: 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 27 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 28 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 the bucket is clear of material and slowly back out of pile.
  • Page 29 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. During transport the loader should be in a position that will not impair operators vision, Observe the following safety messages.

  • Page 30: Loader Removal

    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.
  • Page 31 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.
  • Page 32 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.

  • Page 33: Storage

    STORAGE END OF SEASON 1. If loader is to be dismounted from the tractor during storage, make sure parking area is on hard, level ground. 2. Store in a dry, sheltered area, if possible. Note: All hydraulic cylinders should be in the retracted position.

  • Page 34: Loader Installation

    LOADER INSTALLATION 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.
  • Page 35 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.
  • Page 36 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.

  • Page 37: Troubleshooting

    TROUBLE SHOOTING 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 —...
  • Page 38 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.

  • Page 39: Lubrication And Maintenance

    LUBRICATION and MAINTENANCE Do not perform any service/maintenance operations with front loader raised off the ground. Note: 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 40: Lubrication And Maintenance Chart

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

  • Page 41: Parts

    REPAIR PARTS REFERENCE NUMBER 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 3/8 HEX REDUCER BUSHING 3/8 90" ST ELBOW 3/8 x 3"...

  • Page 43: Repair Parts

    REPAIR PARTS REFERENCE NUMBER MAIN FRAME UPRIGHT UPRIGHT STAND BUCKET PIN - A x 1" COTTER PIN 5/32 #11 CLIP PIN 3/8 x 2 1/4" LYNCH PIN 1 1/4 x 3/4" LIFT CYLINDER LIFT CYLINDER BUCKET CYLINDER VALVE FEEDLINE -TOP FEEDLINE FEEDLINE - 3rd FEEDLINE...
  • Page 44 PARTS REPAIR PARTS REFERENCE NUMBER SUB FRAME FRONT BRACKET LOWER FRONT COVER, FRAME BOTTOM BRACKET WEIGHT BRACKET, COUNTERWEIGHTS PUMP GUARD BRACE ARM, RH BRACE ARM, LH PIN, COUNTERWEIGHT BRACKET A PIN, COUNTERWEIGHT BRACKET B PIN, COUNTERWEIGHT BRACKET C PIN D, WITH FLAT (Mounting Pin) PINE (Fixing Pin) 5/8 x 1 1/4"...
  • Page 45 REPAIR P A RT S EFERENCE DESCRIPTION UMBER O-RING O-RING SCREW END CAP RETURN SPRING SPACER WASHER SCREW w/LOCKWASHER SPACER DETENT SPOOL RETURN SPRING DETENTPLUG DETENT SPRING STEEL BALL DETENT END CAP LOAD CHECK POPPET LOAD MCHECK PLUG LOAD CHECK SPRING TAMPER PROOF CAP JAM NUT GASKET...

  • Page 46: 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.
  • Page 47 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.

This manual is also suitable for:

H5518a4

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