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Honda FL5540K0 Operator's Manual

Front loader for honda h5518a4 multi-purpose tractor.
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40PERATOR'S
A
J
I
MANUAL
Front Loader
Model FL5540KO
for Honda H5518A4
I
Multi-purpose Tractor

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   Summary of Contents for Honda FL5540K0

  • Page 1

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

  • 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 FL5540 front loader for the H5518 A4 Multi-purpose Tractor. For your convenience, troubleshooting section and warranty service information. Read this manual and the owner’s manual forthe Honda H5518 A4 Multi-purpose Tractor before you operate the front loader.

  • 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 the safety of others. Know these requirements before you operate the tractor 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.

  • Page 7

    The use of heavy equipment andor pulling or lifting excessive loads may adversely affect vehicle stability or control. To avoid loss of control that can result in severe personal injury: Use only recommended tractor hitch attachment points. -Limit loads to those within tractor and front loader limitations as stated in this manual and in the tractor owner’s manual.

  • Page 8

    FRONT LOADER SAFETY Never operate the tractor or front loader when visibility is diminished by darkness weather; your ability to see obstacles will become impaired. Avoid loose rocks and holes. They may cause vehicle instability or cause the vehicle to fill, overturn.

  • Page 9: Maintenance Safety

    tractor and Maintenance of the safety the safety of others. Know these requirements before perfoming maintenance on 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. - m o v e 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 Before lower loader to fho ground and shut off engine. Rolleve hydraulic dlreonnecHng oil lines. LOADS CAN FALL FROM BUCKET CAUSING SERIOUS INJURY OR DEATH INFORMATION Special loader attachments for...

  • Page 11: Packaging Inventory

    ............................. SECURED T O C RATE B O ~ O M .

  • Page 12: Tractor Preparation

    TRACTOR PREPARATION HARDWARE BAG CONTENTS QNT'Y DESCRIPTION lynchpin h " x 30mm hex capscrew 1Omm capscrew 12mm x 25mm hex hd capscrew lh" hex hd % ! - 1 3 X l clipxpin 0 ga. machine bushing 3/4xl'/4 hd capscrew V2-13xl3AW flat washer 98"...

  • Page 13: Loader Specifications

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

  • 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

    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. 1 - d - Never operate the tractor without the lower cover. INSTALLATION INSTRUCTIONS 1 C(M#ECO)IUCISWFACESBEIWEENBUWMrPrJllL M O W M E BRAcILl DY I N S W I N G WE W H E N...

  • Page 16

    Lay the sub-frame on a level, solid area. 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. Drive the tractor fomvarc ,,om the rear o the sub-frame, over the drive on plate keeping it parallel with the sub-frame.

  • Page 17

    Stop the tractor when the mast fixing pad comes even with the floor board of the tractor. 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...

  • Page 18

    FL5540 SUB-FRAME and COUNTERWEIGHT INSTALLATION/REMOVAL 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 Slip a 3/4in washer over each cover.

  • Page 19

    COUNTERWEIGHT BRACKET INSTALLATION 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 20

    FL5540 SUB-FRAME and COUNTERWEIGHT INSTALLATlON/REMOVAL...

  • Page 21: Front Loader Assembly

    FRONT LOADER ASSEMBLY '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 %6x2 inch bolts and flatwashers.

  • Page 22

    FRONT LOADER ASSEMBLY PRESSURE SUCTION HYDRAULIC HOSE CONNECTION 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. 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 (1 03 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 AlTACHlNG 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. HYDRAULIC FLUID SERVICING You will need 6 1/2 quarts of a good grade hydraulic fluid or ATF automatic transmission...

  • Page 25

    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 of the stand with the mounting hook at rear of mainframe.

  • Page 26

    FRONT LOADER ASSEMBLY NOTES...

  • Page 27: Operational Checks

    OPERATIONAL CHECK Check all pivot points on the loader. Lubricate as necessary. (See lubrication chart.) on page number 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

    CHECK OPERATIONAL OPERATING TIPS NOTICE- Do not use the bucket for pushing down material with bucket cylinders partially extended. Cylinder and rod may be damaged. tip bucket cutting edge down (fully extend bucket cylinders) backfillinghackgrading operation. Cylinder and rod may be damaged. Position vehicles to be loaded as near the pile as possible and in such a direction minimize the amount of tractor turning...

  • 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 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 fromho cylinders. It is important to utilize this operational SCRAPING When scraping, the "float"...

  • Page 31

    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 th le bucket is full, rais e loade the bucket is clear material and slowly back pile.

  • Page 32

    OPERATING INSTRUCTIONS TRANSPORTING MATERIAL Transport material to "unloading point" with loader bucket as low as possible to prevent spillage maintain tractorfloader stability. -1 - During transport the loader should be in a position that will not impair operatots 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. 2 . 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. Note: 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 feet. Remove the front guard from sub-frame. 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.

  • 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. All hydraulic cylinders should be in the Note: retracted position. Thoroughly clean the loader of all accumulated dirt and grease.

  • Page 38

    STORAGE NOTES...

  • Page 39: Loader Installation

    LOADER INSTALLATION NOTE: Install sub-frame and weights (Page 17). 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 AlTACHlNG LOADER MASTS 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. Use bucket movement to shake masts to align pin holes.

  • Page 41

    LOADER STAND REMOVAL 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 ho.ok at rear of mainframe.

  • Page 43: Troubleshooting

    TROUBLE SHOOTING SYSTEM DOES NOT WORK AT ALL PTO in 'OFF' position Put to 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.

  • 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 pump Tighten or replace suction line.

  • Page 45: Lubrication And Maintenance

    LUBRICATION and MAINTENANCE 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 46: Lubrication And Maintenance Chart

    LUBRICATION AND MAINTENANCE LUBRICATION AND MAINTENANCE CHART LUBRICATION AND MAINTENANCE CHART ..Hydraulic oil level ..Tire inflation ..Loader pivot points Hydraulic lines hoses and connections Lift and bucket cylinders...

  • Page 47: Parts

    REPAIR PARTS IEFERENCE SUMBER ANGLE ANGLE PUMP COUPLER PUMP PLATE RUBBER BUSHING 304 PUMP 3/16x3/16x 1 KEY 1/2 x 2" PIPE NIPPLE 1/2 x 45' PIPE ELBOW 1/2" PIPE END 3/8 HEX REDUCER BUSHING 9 0 ' ST ELBOW 318 x 3" PIPE NIPPLE 3/8 90' PIPE ELBOW 60"...

  • Page 49: Main Frame Assembly

    REPAIR PARTS IEFERENCE IUMBER MAIN FRAME UPRIGHT UPRIGHT STAND BUCKET 42" 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" x 10ga. MACHINERY BUSHING LIFT CYLINDER LIFT CYLINDER BUCKET CYLINDER VALVE FEEDLINE -TOP...

  • Page 50

    PARTS REPAIR PARTS IEFERENCE 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) PIN E (Fixing Pin) x 1 114' CLEVIS PIN 7 1 1 6 '...

  • Page 51

    REPAIR P A RT S EFERENCE DESCRIPTION UMBER O-RING O-RING SCREW ENDCAP RETURN SPRING SPACER WASHER SCREW wROCKWASHER SPACER DETENT SPOOL RETURN SPRING DETENTPLUG DETENT SPRING STEEL B A U DETENT END CAP LOAD CHECK POPPET LOAD MCHECK PLUG LOAD CHECK SPRING TAMPER PROOF CAP JAMNUT GASKET...

  • 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 satifaction, we suggest you take the following action: Discuss your problem with a member of the dealership management.

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