Honda FL5540K0, Operator'S Manual

Page 1: ...40PERATOR S A MANUAL J Front Loader Model FL5540KO for Honda H5518A4 I Multi purposeTractor I ...

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Page 3: ...is manual ond on the front loader Please readthese messagescarefully A safety messagealerts you to potential hazardsthat could hurt you or others Each safety messageis proceded by a safety alert symbol and one of three words DANGER WARNING CAUTION These words mean You WILL be KILLED or SERIOUSLY HURT If you don t follow Instructlons You CAN be KILLED or SERIOUSLY HURT tf you don t follow Instructl...

Page 4: ...SPECIFICATIONS 6 ASSEMBLY INFORMATION Sub frame installation removal Front loader assembly Operational checks 7 OPERATING INSTRUCTIONS 8 LOADER REMOVAL Storage 9 LOADER INSTALLATION 10 TROUBLESHOOTING 11 LUBRICATIONand MAINTENANCE Lubricationand maintenancechart 12 PARTS 13 WARRANTY SERVICE PAGE 1 5 3 4 7 8 9 10 11 12 13 19 25 27 3 1 35 37 41 43 44 45 51 2 ...

Page 5: ...s optional at extra cost The manufacturer reserves the right to redesignand change the machineas may be necessary without notification NOTE Illustrationsusedinthis manualmaynotshowa l l safetyequipmentthat isrecommended to ensuresafeoperationof tractorAoader RefertoSafetySectionof this manualandtheTractor Owner s Manual for informationconcerning safety equipment Consult your dealer for further inf...

Page 6: ...ot been modifiedor structurallydamaged Know how to stop the engine quickly Thoroughly understandoperation of all controls Never permit anyone to operate the tractor or front loaderwithout properinstructions The tractor is an operatoronly vehicle do not allow passengersto ride on the tractor orfront loader Keepchildren andpets at a safe distance during operation Never allow anyone to get under the ...

Page 7: ...lever is in Neutral and the front and rear PowerTake Off PTO leversare inthe Off positionbefore startingthe engine Operate the tractor andthe front loaderat slow speeds untilyou become familiar with all of the operatingcharacteristicsandcontrols Do not operate the tractor or front loader untilyou are sure the area in front and behind is clear of people and pets Sudden stops of the tractor or front...

Page 8: ...ting the front loader on sloping or unevensurfaces Operate loader controls only from the operator s seat to preventpossiblesevere personalinjury Attempting to change gears while operating the front loader on a slope may adversely affect vehicle stability and control and severe personalinjurycouldresult Do notback down or rapidly accelerateup a sloping surface To avoid loss of control or overturnin...

Page 9: ...possibleflying metal objects Operatingthe front loader or the tractor with damaged worn or brokenparts may resultin severe personalinjury Beforedisconnectingany hydrauliclines relieveall hydraulicpressure Keep hands and body from pressurized lines Use paper orcardboard not body parts to check for leaks Hydraulic oil under pressurewill penetratethe skin causingserious injury Makesure that all opera...

Page 10: ...DS CAN FALL FROM BUCKET CAUSING SERIOUS INJURY OR DEATH MCTOR TIP OVER CAN CAUSE SERIOUS INJURY O R DEATH a Add recommended wheel ballast and or oounterwelghts for rtablllly Ddve and turn tractor a t slow speed Place loader low when transpomng kads especially on an lncllne or rough tenaln e Put M e r on ground when parked Read and understand all lnstructlons In operator s manual before operation i...

Page 11: ...PACKAGINGINVENTORY PACKAGINGINVENTORY I3 I 12 Required 37 5Ibs each j 1 WEIGHTS SECUREDTO CRATE B O O M I CIC c I l l l l l l i LARGE CARTON SMALL CARTON 1 ...

Page 12: ...actor Weight addedto the rearof thetractor providesbettertraction andeasier moreefficient loader operation The tractor must be counterweightedby installation of rearweights Additional counterweight requirements will vary with loader attachments and equipment applications Certain specificconditionsmaynotpermitsafeuseof loaderatloaderrating or may requiremorecarefullyrestrictedOperationat the rated ...

Page 13: ...ach Maximum Height Reachwhucket on ground Maximum Dumpangle Digging Depth Below Grade Tractor Type H55 Maximum Lift Height Bucket roll back angle A FL5540 400lb 180kg 42in 1050mm Double acting Suit casetype 37 5lb x 12 17 0kgx 12 Frame mounttype Front PTOcoupled 18A4 only Ag tires recommended 5501b 250kg A 72 1in 1837mm B 16 4in 409 3mm C 47 9in 1195 2mm D 17 36 E 47 31 F 3 02in 80 5mm 11 ...

Page 14: ...lues of hardware requiredfor assembly Lay out and identify all components prior to installation TORQUE SPECIFICATIONS AMERICAN Bolt HeadMarkings SA Grade2 NoDashes1 SAE Grade5 3Dashes1 METRIC 6 4 d 2 Numbersappearingon bolt heads indicateASTM class Proper torque for American fasteners used on Honda equipment RecommendedTorque inFootPounds NewtonMeters Use 75 of the specified torque value for plate...

Page 15: ...L H W W IOU 29 8 09 Hn TopouD 3 WHEN UNDBnDE MOUmNC KHTr 29 ft 0 9 hT O p o u O NEW LOWER FRONTCOVER m M E I p A m FRAME CAN BE DAMACED F M E lpAcrop ISMOVEDWHLEMHL1COMRISOCFORWIJSAB3 NOT lWITWE0 I o M E mofmTopOK Note A second label is included with this operator s manual Installthis label onto the original frame lower cover 2 Remove the drawbar and replace it with the bottom bracket usingthe two...

Page 16: ...or in line with the sub frameandtireguideondriveonplate allowing a clearance of approximately 60mm 2 4in betweensub frameandthe innerwall of the left front tire 5 Drive the tractor fomvarc om the rear oIf the sub frame over the drive on plate keeping it parallelwith the sub frame SUB FRAME GUIDE SUB FRAME Page 14 ...

Page 17: ...MOVAL 6 Stop the tractor when the mastfixing 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 shapedchannel of the bottom bracket NOTE Use two peopleto lift sub frame ...

Page 18: ... 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 pointingdown 9 Insert two mounting pins 3 4 x 3 19inj from insidethe bottombracketthroughthe sub frame Slip a washer over each pin and retain with a clip pin as shown NOTE Mounting pins have a flat side that must be pointingdown MOUNTING PIN FLAT SIDE ...

Page 19: ...ligning 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 1x 12inch mountingpin in rearlower hole Secure with linchpins 11 Install the twelve counterweights Insert the countetweight fixing pins through the bracket and secure with linchpins NOTE For sub frame removal use reverse procedures COUNTERWEIGHT BRACKET 17 ...

Page 20: ... FL5540SUB FRAMEandCOUNTERWEIGHTINSTALLATlON REMOVAL ...

Page 21: ...ating of grease to tractor front PTO at this time Mount hydraulicpumpto tractor bysliding splined pump drive joint onto front PTO shaft with mounting bracketsinside main frame and attachingwith four 5 lsx 4i inch bolts and 5 16 lockwashers Tighten all pump mounting bolts NOTE The masts and main frame come assembled All cylinders and hoses have been attached to the frame except the two hoses from t...

Page 22: ...on the pump Attach with hose clamps and tighten securely 5 Attach the front guard on the front of the sub frame using two each l h x l inch and 1 2x15 16 inch bolts and four each 112 inch nuts and washers Do not tighten bolts at this time AlTACHlNG LOADINGMASTS 6 Move the tractor until the masts are positioned over the upright pads on the sub frame use two people to lower the masts onto the pads a...

Page 23: ...e left brace arm with metal loops Ensure that the high pressure hose smaller diameter is positionedon top of the suction hose large diameter Install the nylon tie strap to bind the two hosestogetherat front cornerof hoodline 9 Install valve handles to the hydraulic control valve mounted on the left mast The A handleattachesto the spool used for loader operation and the B handle attachestothe spool...

Page 24: ...utomatictransmission fluid 11 Remove filler plug and oil checkscrew on back of left mast Fill with 4 quarts of hydraulicfluid Start tractor engine and set speed at 1 2 throttle Engage tractor front PTO and operate loader lift and bucketcylindersat leastfive or six times to purge the system of air Lower the loader to the ground Retract bucket cylinders by pulling back on handle B Add 21 2 morequart...

Page 25: ...emove the stands 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 andthrough the stand Repeatthe above steps for the other side Lowerthe loader to the ground Front Loaderis readyto becomeoperational MOUNTINGHOOK I 23 ...

Page 26: ...FRONT LOADER ASSEMBLY NOTES 24 ...

Page 27: ... meets all requirements in Tractor PreparationSection Checkfront loaderhydraulicfluid level Refer to front loaderoperator s manual Note Bucketand liftcylindersshouldbefully retractedwhen checking hydraulicfluid level Check all hydraulic hose connections to ensurethat they are not leaking Lubricate all pivot points that incorporate grease fittings Starttractor and run engine at approximately 1200 1...

Page 28: ...he limits of a piece of machinery Ifitsability to do ajob or to do so safely is in question Don t try it Don t hurry the learning process or take the unit for granted Ease into it and becomefamiliar with your newloaderand tractor 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 downward momentum places undue...

Page 29: ...ITION A Right handle pushed all the way forward thisisfloat position Handlewill stay untilpulled back POSITION B Right handlepushedhalfway forward bucket will lower POSITION C Neutral position POSITION D Right handle pulled back bucket will raise Note In float position there is no hydraulic pressure going to the lift cylinders If the loader frame i s up off the ground it will lower to the ground b...

Page 30: ...Float Position B Loader Down C Neutral D Loader Up 8 Neutral C Bucket Back SCRAPING When scraping the float positionshouldbe utilized to maintain the bucket firmly on the groundandat the sametime allow the bucket to follow groundcontours The bucket should be positioned levelto the ground during scraping operations BACKFILLING BACKGRADING When backfilling or backgrading position the bucketso it isl...

Page 31: ... fill capacity This procedure also resultsinthe materialbeingremovedinlayers from the top for maximumloading efficiency When thle bucket is full raise loade rso that the bucketisclearof materialandslowlyback out of pile For maximum loading efficiency minimize angle of turn and distance between the loadingand unloading points 29 ...

Page 32: ... ground is irregular Make turns slowly and usethe tractor brakes cautiously Afull bucketInthe raisedposition alters the center of gravity of the unit and Increasesthe possibility of mishaps 1 do not lift or carry personnel on a loaderor attachment aslip or fall could cause seriousInjury UNLOADING As the tractor approaches the unloading point raise the loader to the height required for clearance to...

Page 33: ...moval Lower bucket to the ground and remove the stands from the loader mainframe 2 Raise the loader until the stands can be inserted into the loader arms Installthe clip pins intothe stand ends 3 Lowerthe loader until the stands rest on the ground Dumpthe bucket untilthe edge of bucket touches the ground 31 ...

Page 34: ... bucket operation to make fixing pin removaleasier 5 Remove the clip pins and mounting pins from the mastsandthe front guard Remove the hydraulic hoses from the left brace loops Remove the brace arms 6 Roll backthe bucketto detachloaderfrom sub frame Operate the bucket slowly to avoid loaderto tractor interference 32 ...

Page 35: ...e the front guard from sub frame 8 Removethe hydraulicpump by removing the four bolts holding the mounting bracketsto the tractor frame Removethe pump from the PTO shaft NOTE Do not disconnect hoses Loader is now parked and readyfor storage Forsub frame removalsee pages 13thru 17 33 ...

Page 36: ...LOADER REMOVAL FROMTRACTOR NOTES 34 ...

Page 37: ...lay on or around the tractor or loader PROCEDURES BEGINNINGOF SEASON 1 Review safety precautionsand operation sections of manual 2 Thoroughly clean loader of all accumulateddirt and grease 3 If removed from tractor for storage remountloaderper LoaderInstallation section of this manual 4 Completely lubricate the loader per the lubrication section of this manual Make sure allfittings aretaking greas...

Page 38: ...STORAGE NOTES 36 ...

Page 39: ... Move the tractor centrally between the masts 2 Mount hydraulic pumpto tractor bysliding 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 Attach the front guard on the front of the sub frame usingtwo each 1 2x 1inchand 1 2 x 1 5 16 inch bolts and four each 1 2 inch nutsandwashers Tighten boltsand nuts Torque 76 f...

Page 40: ...sts onto the pads 5 Use bucket movementto shake maststo align pin holes Insert the fixing pins through the masts and pads Install clip pinsthrough holes 6 Attach bracearmsto mastandfrontguard as shown with clevis pins and clips NOTE Route hydraulic hoses along left brace arm through hose holder loops Ensure high pressure hose smaller of two is positionedon top of larger suction hose ...

Page 41: ...om the stands and 9 Align the hole in the bottom of the stand with the mounting ho ok at rear of mainframe Slide the stand over the mounting hook and then insert the fixing pin previously removed through main frame andthrough the stand Repeatthe above steps for the other side Lowerthe loaderto the ground Front Loader is ready for operational check Page 25 ...

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Page 43: ... Cold oil Oil viscosity may be too high at start Beforeoperating allow oil to warm up Components sticking or binding Check for dirt or gummy deposits Pumpdamaged Checkfor worn orbroken parts SYSTEM RUNS OR WORKS SLOWLY Cold oil Allow to warm up before operating Oil viscosity too heavy See specificationson properoil Not enough engine speed Increase engine speed Low oil supply Check reservoir and ad...

Page 44: ... WITH CONTROL VALVE IN NEUTRALPOSITION Leaking or broken oil lines from control valves to cylinder Check for leaks Tighten or replace lines Oil leaking past cylinder packing or 0 rings Replace worn parts If wear is caused by contamination clean hydraulic system and determine source of dirt Oil leaking past control valve Clean or replace valve Wear may be caused by contamination Cleansystem and det...

Page 45: ...akage Note If oil seepage past cylinder rod is evident look for scoring on rod Tractor tire inflation should be checked as listedintractor owner s manualto ensuretire inflation isto specification Unequal inflation can result in bucket not being levelto the ground Fronttires shouldbe maintainedat maximum recommended inflation to maintain normal tire profile with added loader weight and material A m...

Page 46: ...ion Check Weekly SO Hrs Loader pivot points Lubricate Daily l0 Hrs Hydraulic lines hoses Checkfor leakage Daily lo Hrs andconnections wear and damage Lift and bucket cylinders Checkfor seepage Daily l0 Hrs Mounting pins Clip pins Check Daily lO Hrs Sub framemounting Check Weekly 50Hr and hardware Re torque Fixing pins replaceif missing I 44 ...

Page 47: ...16x 1 KEY 1 2x 2 PIPE NIPPLE 1 2x 45 PIPE ELBOW 1 2 PIPE END 3 8 9 0 ST ELBOW 318 x 3 PIPE NIPPLE 3 8 90 PIPE ELBOW 3 4 SUCTION HOSE 16 HOSE CLAMP 1 2 3 8 HEX REDUCER BUSHING 3 8 X 60 HYDRAULICHOSE9 16 18 ORB X 3 8MS 5 16 18 X 13 4 HEX HEADCAPSCREW 5 16 18 X 1 HEX HEADCAPSCREW 5 16 18 X 1 2 SOCKET HEAD SETSCREW 5 16 FLATWASHER 5 16 LOCK WASHER 5 16 18 HEX NUT 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 48 2 2 8...

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Page 49: ... 90 ELBOW 1 4X 24 HYDRAULIC HOSE 9 16 18 ORB x3 8 MJlC 3 8 x 20 HYDRAULIC HOSE 9 16 18 ORB x 3 8MS 1 4 x 16 HYDRAULIC HOSE 1 4 MP x 318 MJIC 1 2 x 90 ST ELBOW 1 2 VENT PLUG 1 2 PIPE END 3 8 x 90 ST ELBOW 1 4 x 90 ST ELBOW 10 X 1 2 HEX HEAD SELF TAPPINGSCREW 1 4 28 UNF ST GREASEZERK 1 4 20 X 2 HEX HEAD CAPSCREW 1 4 LOCK WASHER 1 4 20 HEX NUT DECAL VALVE OPERATION DECAL HONDA DECAL WARNING IMPROPER ...

Page 50: ...ACKETA 2 PIN COUNTERWEIGHTBRACKET B PIN COUNTERWEIGHTBRACKETC 2 1 PIN D WITH FLAT Mounting Pin 4 PIN E Fixing Pin 4 5 4 x 1 114 CLEVIS PIN 4 7 1 16 LYNCH PIN 5 11 CLIP PIN 12 1 114 314 x l O g a MACHINERYBUSHING 4 12x 25mm HEX HEADCAPSCREW 2 10x 30mm HEX HEADCAPSCREW 2 1 2 13X 1 314 HEX HEADCAPSCREW 2 1 2 13X 1 1M H f 3 HEADCAPSCREW 2 112 FLATWASHER 4 1R LOCKWASHER 6 1 2 13 HEX NUT 2 7 16 14X 1 11...

Page 51: ... 2 9 SPACER 1 10 DETENTSPOOL 1 11 RETURNSPRING 1 12 DETENTPLUG 2 13 DETENTSPRING 2 14 STEEL B A U 2 15 DETENTENDCAP 1 16 LOADCHECK POPPET 1 17 LOAD MCHECK PLUG 2 18 LOADCHECK SPRING 1 19 TAMPER PROOFCAP 1 20 JAMNUT 1 21 GASKET 2 22 ADJUSTMENTSCREW 1 23 RELIEFSPRING 1 24 B A URETAINER 1 25 STEEL BALL 1 26 HANDLE STRAIGHT 1 27 C HOOK 2 28 PIN 2 29 COlTER PIN 4 30 HANDLE BENT 1 ...

Page 52: ...NOTES ...

Page 53: ...sfaction contact the Power Equipment Customer Relations Departmentof American Honda Motor Co Inc American Honda Motor Co Inc Power EquipmentCustomer Relations Department P O Box 10021 Duluth Georgia 30136 9421 Telephone 770 497 6400 We will need the following informationto assist you Your name address and telephone number Product model and serial number Date of purchase Dealer name and address Nat...

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