Honda FL5540KO User's Manual
Contents
1. 9 1 E FE am INS Eu M e 22 REPAIR PARTS HYDRAULIC VALVE DESCRIPTION QUANITY REQ SPOOL RETURN SPRING DETENTPLUG DETENT END CAP LOAD CHECK POPPET 49 WARRANTY SERVICE 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 Often complaints can be quickly resolved at that level If the problem has already been reviewed with the Service Manager contact the owner of the dealership or the General Manager If your problem still has not been resolved to your satisfaction contact the Power Equipment Customer Relations Department of American Honda Motor Co Inc American Honda Motor Co Inc Power Equipment Customer Relations Department P O Box 10021 Duluth Georgia 30136 9421 Telephone 770 497 6400 We will need the following information to assist you Your name address and telephone number Product model and serial number Date of purchase Dealer name and address Nature of p2. 72 1 1837mm Reach Maximum Height rr 16 4in 409 3nm Reachwhucket on ground 47 9 1195 2mm Bucket roll D 17 36 Maximum Dumpangle 4731 Digging Depth Below Grade F 3 02in 80 5mm 11 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 All hardware required for mounting loader is supplied Loader mount component hardware should be left loose until all mount components have been installed Unless otherwise specified refer to torque specification table for torque values of hardware required for assembly Lay out and identify all components prior to installation TORQUE SPECIFICATIONS Proper torque for American fasteners used on Honda equipment AMERICAN Recommended Torque in Foot Pounds Newton Meters e Bolt Head Markings 7 16 1 4 20 60 1206 SAE Grade2 7 16 1 4 280n 6m 1003 14 18 No Dashes 1 2 5 6 18ec 1195 17 23 25 33 1 2 5 16 24we 13417 9060 27 037 9 16 3 8 16wc 20 27 31 42 44660
3. 4 Maintenance safety 7 21 1 147422191 11 9 6 110 3 8 OM atta cCiliuizmelil 9 4 TRACTOR PREPARATION 10 5 LOADER SPECIFICATIONS 11 6 ASSEMBLY INFORMATION 12 Sub frame installation removal 1 1 1 a aaa 13 Front loader assembly 19 Operational checks sseeeesssssseseeeeeenenn nennen nnne 25 27 31 SAGE 37 41 43 Lubricationand maintenance chart 45 tnt 5 INTRODUCTION 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 However through experience and these instructions you should be able to develop operating procedures suitable to your particular situation Right and Left as used throughout this manual are determined by facing the direction the machine will travel when in use The illustrations and data used in this manual are current at time of printing but due to
4. Limit loads to those within tractor and front loader limitations as stated in this manual and in the tractor owner s manual Be extra careful when turning or backing up and when on uneven terrain Use counterweights as indicated in this manual and the tractor s owner s manual Before installing or using the front loader carefully read all instructions and precautions OPERATION Be sure to fasten the seat belt whenever driving the tractor with the Roll Over Protection Structure ROPS attached Use of either device seat belt or ROPS without the other will increase the chance of injury in a rollover Adjust the seat belt so it is snug Be sure that the main transmission lever is in Neutral and the front and rear Power Take Off PTO levers are in the Off position before starting the engine Operate the tractor and the front loader at slow speeds until you become familiar with all of the operating characteristics and controls Do not operate the tractor or front loader until you are sure the area in front and behind is clear of people and pets Sudden stops of the tractor or front loader during operation could cause the tractor to overturn Be especially careful during sharp turns and when front loader bucket has material in it Carry the front loader arms at a low position during transport This will enhance vehicle stability and front vision Using the front loader for handling large objects such as round hay bal
5. 9 16 3 8 240 23 31 35407 49666 SAE Grade5 5 8 7 16 14wc 3283 49 6 7049 5 8 7 16 20 36 49 55 75 78 106 3 4 106 144 e 3 4 1 2 20 55060 85 115 120 163 7 8 153 207 Usa T 7 8 9 16 18uw 79 107 122 165 172 233 Sira A SAE Grade B t 6 Dashes Use 75 of the specified torque value for plated fasteners Use 8596 of the specified torque values for lubricated fasteners Proper torque for metric fasteners used on Honda equipment Recommended Torque in Foot Pounds Newton Meters Numbers appearing on bolt heads indicate ASTM class 12 FL5540 SUB FRAME COUNTERWEIGHT INSTALLATION REMOVAL 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 Never operate the tractor without the lower cover FRAME LOWER COVER INSTALLATION INSTRUCTIONS 1 CLEAN THE CONTACT SURFACES BETWEEN BRACKET AND FRAME NEW LOWER 2 MOUNT THE BRACKET BY INSTALLING THE 8 BOLTS FINGER TIGHT 3 TIGHTEN UNDERSIDE MOUNTING BOLTS 29 ft lbs 39 Nm TORQUE FRONT COVER 4 TIGHTEN SIDE MOUNTING BOLTS 29 ft Ibs 39 Nm TORQUE THE TRACTOR FRAME CAN BE DAMAGED IF THE TRACTOR IS MOVED WHILE THIS COVER IS OFF OR BOLTS ARE NOT TIGHTENED TO THE PROPER TORQUE Note A second label is included with this oper
6. a grade be sure to lock the parking brake and securely block the wheels MAINTENANCE SAFETY MAINTENANCE SAFETY Maintenance of the tractor and front loader requires special efforts on your part to ensure your safety andthe 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 lower the front loader bucket flat to the ground move the front PTO to the off position stop the engine and remove the key Always wear safety glasses when servicing or replacing the front loader cylinder pins Use a brass drift and hammer Failure to do so could result in eye injuries from possible flying metal objects Operating the front loader or the tractor with damaged worn or broken parts may result in severe personal injury Before disconnecting any hydraulic lines relieve all hydraulic pressure Keep hands and body from pressurized lines Use paper or cardboard not body parts to check for leaks Hydraulic oil under pressure will penetrate the skin causing serious injury Make sure that all operating and service personnel know that in the event hydraulic fluid penetrates the skin it must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result nuts bolts and fasteners must be properly sec
7. REPAIR PARTS SUB FRAME REFERENCE DESCRIPTION QUANTITY 1 SUB FRAME 2 FRONT BRACKET 3 LOWER FRONT COVER FRAME 4 BOTTOM BRACKET x WEIGHT BRACKET COUNTERWEIGHTS f 8 9 10 PUMP GUARD BRACE ARM RH BRACE ARM LH PIN COUNTERWEIGHTBRACKETA PIN COUNTERWEIGHT BRACKET B COUNTERWEIGHT PIN D WITH FLAT Mounting Pin PINE Fixing Pin 5 8 x 1 1 4 LEVIS PIN 7 1 6 LYNCH PIN 11 CLIP PIN 1 1 4 x 314 x 10ga MACHINERY BUSHING 12x 25mm HEX HEAD CAPSCREW 10 x 30mm HEX HEAD CAPSCREW 1 2 13x 1 3 4 HEX HEAD CAPSCREW 1 2 13x 1 1 2 HEX HEAD CAPSCREW 1 2 FLATWASHER 1 2 LOCKWASHER 1 2 13 HEX NUT 7 16 14 X 1 1 4 HEX HEAD CAPSCREW 7 16 FLAT WASHER 7 16 LOCKWASHER 7 16 14 HEX NUT 3 8 FLATWASHER DECAL INSTALLATION 48 REFERENC z c UU m J O RING O RING SCREW END CAP RETURN SPRING SPACER WASHER SCREW w LOCKWASHER SPACER DETENT SPRING STEEL BALL LOAD MCHECK PLUG LOAD CHECK SPRING TAMPER PROOF CAP JAM NUT GASKET ADJUSTMENT SCREW RELIEF SPRING BALL RETAINER STEEL BALL HANDLE STRAIGHT C HOOK PIN COITER PIN HANDLE BENT PARTS a OER Se emmy GOL p 5 5 iun Et is 3 Sa 212 4 855 pos D S DENIS _ E A olo 1 1 So es IS gt gt _ NNa DB NEST NES INS ae ZEN EA NER TH 1 i
8. 3 8 x 3 PIPE NIPPLE 11 12 13 14 3 8 90 PIPE ELBOW 15 3 8 x 60 HYDRAULIC HOSE 9 16 18 ORB x 3 8MS 16 3 4 SUCTION HOSE 17 16 HOSE CLAMP 5 16 18x 1 3 4 HEX HEAD CAPSCREW 5 16 18x 1 HEX HEAD CAPSCREW 5 16 18 x 1 2 SOCKET HEAD SETSCREW 5 16 FLAT WASHER 5 16 LOCK WASHER 5 16 18 HEX NUT 18 PARTS 46 REPAIR PARTS MAIN FRAME ASSEMBLY REFERENCE NUMBER DESCRIPTION MAIN FRAME UPRIGHT RH UPRIGHT LH STAND BUCKET 42 PIN A 5 32 1 COTTER PIN 811 CLIP PIN 3 8 x 2 1 4 LYNCH PIN 1 1 4x 3 4 x 10ga MACHINERY BUSHING LIFT CYLINDER RH LIFT CYLINDER LH BUCKET CYLINDER VALVE FEEDLINE TOP FEEDLINE 2nd FEEDLINE 3rd FEEDLINE BOTTOM 9 16 18 SWIVEL NUT 90 ELBOW 1 4x 24 HYDRAULIC HOSE 9 16 18 ORB x3 8 3 8 x 20 HYDRAULIC HOSE 9 16 18 ORB x3 8MS 1 4x 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 TAPPING SCREW 1 4 28 UNF ST GREASE ZERK 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 SERVICE DECAL WARNING TRACTOR OVER DECAL WARNING LOADS CAN FALL DECAL NOTICE LOADER HYDRAULIC SYSTEM DECAL SERVICE INFORMATION SPECIALATTACHMENTS QUANTITY 2 m o 5 I2 N N PARTS
9. TRACTOR PREPARATION HARDWARE BAG CONTENTS QNT Y DESCRIPTION 7116 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 flat washer 7 16 14x11 4 hex hd capscrew TRACTOR PREPARATION 7116 14 hex nut 7 16 lockwasher 1 2 13 hex nut 1 2 flat washer 1 2 lock washer 9 16 18 x 1 hex hd capscrews 5 16 lockwasher 7 16 flatwasher 5 16 18 13 4 hex hd capscrew 5 16 flatwasher 2 hose clamp nylon tie NN N amp A O R gt nN 5 2 2 2 6 2 2 2 2 This loader is not intended to be used with any other attachments mounted on tractor REAR COUNTER WEIGHT WARNING DO NOT EXCEED THE RATING FOR MAXIMUM GROSS VEHICLE WEIGHT REFER TO OWNER S MANUAL PROVIDED WITH TRACTOR The use of adequate rear counterweight is required for proper loader stability Refer to Tractor Owner s Manual for specific recommendations on counterweighting tractor Weight added to the rear of the tractor provides better traction and easier more efficient loader operation The tractor must be counterweighted by installation of rear weights Additional counterweight requirements will vary with loader attachments and equipment applications FW TITO Certaln specific conditions may not permit safe use of loader at loader rating or may require more carefully restricted Operation at
10. loader pivot points as indicated on lubrication chart LUBRICATION and MAINTENANCE Inspect hydraulic hoses connections control valve and cylinders for evidence of leakage Note If oil seepage past cylinder rod is evident look for scoring on rod Tractor tire inflation should be checked as listed in tractor owner s manual to ensure tire inflation is to specification Unequal inflation can result in bucket not being level to the ground Front tires should be maintained at maximum recommended inflation to maintain normal tire profile with added loader weight and material 43 LUBRICATION AND MAINTENANCE LUBRICATIONAND MAINTENANCE CHART LUBRICATION AND MAINTENANCE CHART Hydraulic oil level Tire inflation Loader pivot points Hydraulic lines hoses and connections Lift and bucket cylinders Mounting pins Clip pins Fixing pins Sub frame mounting and hardware 44 CHECK areng 6 260 Daily 10 Hrs Sl app Weekly 50 Hrs bomo Daily 10 Hrs Check for leakage Daily 10 Hrs wear and damage Checkforseepage Daily 10 Hrs a CHECK TOT Daily 10 Hrs replace if missing Check Re torque Weekly 50 Hr 5 ANGLE RH ANGLE LH PUMP COUPLER PUMP PLATE RUBBER BUSHING 304 PUMP 3 16 x 3 16 x 1 KEY 1 2x 2 PIPE NIPPLE 1 2x 45 PIPEELBOW 1 2 PIPE END 1 2 3 8 HEX REDUCER BUSHING 3 8 90 ST ELBOW
11. pivot points that incorporate grease fittings Start tractor and run engine at approximately 1200 1400 RPM for initial cycling of loader Push PTO lever forward to ON Before using front loader for the first time cycle lift and bucket cylinders to purge air from cylinder Air in the hydraulic system can cause unexpected fall of main frame causing Injury or damage to loader or tractor Cycle lift and bucket cylinders with bucket empty several times to seat in cylinder components Check all hydraulic hose routings to ensure adequate clearances exist between hoses and adjacent components WARNING he tractor front loader should only be operated with all safety equipment properly installed Operate loader from the tractor seat only Engine will not run with PTO engaged unless operator s seat is occupied 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 Position vehicles to be loaded as near the pile as possible and in such a direction as to minimize the amount of tractor turning requiredto dump Do not use the spill guard to push objects as It will deform and become damaged Keep the unit clean and perform regular service Observ
12. results in the material being removed in layers from the top for maximum loading efficiency When the bucket is full raise loader so that the bucket is clear of material and slowly back out of pile For maximum loading efficiency minimize angle of turn and distance between the loading and unloading points TEST SITE TRE TE E OPERATINGINSTRUCTIONS H a Dy F xd x tan el a or Iss n T w U A lt TEXTES I 1 4 d Ky T d AY nat 5 rk 4 DO tm ac 2 2 T Sa 29 OPERATINGINSTRUCTIONS TRANSPORTING MATERIAL Transport material to unloading point with loader bucket as low as possible to prevent spillage and maintain maximum tractor floader stability NOTICE During transport the loader 5 should be in a position that will not impair operators vision Observe the following safety messages DANGER Avoid overhead wires obstacles when loader is raised to avoid damage or possible death by electrocution A loaded bucket should be transported In a low position at slow ground speeds especially if the ground is irregular Make turns slowly and use the tractor brakes cautiously A full bucket in the raised position alters t
13. the left brace loops Remove the brace arms 6 Rolback the bucket to detach loader from sub frame Operate the bucket slowly to avoid loader to tractor interference 32 Putthe 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 NOTE Do not disconnect hoses Loader isnow parked and for storage For sub frame removal see pages 13 thru 17 LOADER REMOVAL FROMTRACTOR 33 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 5 retracted position Thoroughly clean the loader of all accumulated dirt and grease 4 Completely lubricate the loader as specified in lubrication section of manual 5 Using an oil soaked cloth lubricate all hydraulic cylinder rods to protect them from rust and corrosion 6 Repaint any areas where paint is worn or damaged 7 Wear areas on buckets or other attachments should be coated with grease to prevent rust or corrosion 8 any safety or warning labels that are not readable due to wear or damage _ notallow childrento on or around the trac
14. the rated load ROLL OVER PROTECTIONSTRUCTURE ROPS SYSTEM The tractor ROPS system must be in place and used properly to ensure adequate operator protection LOADER HYDRAULIC SYSTEM Follow recommendations in this operator s manual for hydraulic fluid specifications TRACTOR TIRES Selection of tires should be restricted to tire recommendations as specified by your Tractor owner s manual Ag tires are recommended when using the front loader TIRE INFLATION Front tires must be maintained at the maximum recommended inflation with the added weight of loader and material Ag Tire pressure 34 psi Rear tires must be maintained at equal pressure within the recommended tire inflation range Ag Tire pressure 24 psi 10 LOADER SPECIFICATIONS LOADER SPECIFICATIONS 1 Ai p a A Hu METTE FL5540 Rated Lift Capacity 400lb 180kg x x s s 42in 1050mm Hydrauliccylinder aos a ee a w w w w Wm w w maa a Double acting COUNTGIWEIGNIS ih ee eee xen Suit case type 37 5lb x 12 rm 17 0kg x 12 SUDNING ok A Frame mount type Hydraulic PUMO gt eee ee Sac sasawa khana C Front PTO coupled Tractor Type s Ree m m H5518 A4 only Ag tires recommended Weight w subframe 5500 250kg Maximum Lift Height
15. Equipment OPERATOR S MANUAL Front Loader Model FL5540KO for Honda H5518A4 Multi purpose Tractor 44 44444 manual to your computer LL LLL LL LLL LL E LLL LLLLLLL LLL LL LE LE LE LLLI LI ILI LLL LL LI LLL tt te te ett tt 11 sms 211111 11111111111111 1 111111111 ee 2009610 1996 American Honda Motor Co Inc Rights Reserved EE Printed in U S A E Thank you for purchasing an Front Loader attachment for your tractor This manual covers the assembly operation and maintenance of the FL5540 front loader for the H5518 A4 Multi purpose Tractor For your convenience it also provides a parts guide 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 NOTE The information in this publication is based on the latest product information available at the time of printing American Honda Motor Inc reserves the right to make changes any time without notice and without incurring any obligation No part of this publication may be reproduced without written permission This manual should be considered a permanent part of the front loader and should remain with it if resold Safety Messages Your safety and the safety of others are very important We have provided important safety messages in this manual ond on the front loader Plea
16. 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 Oil suction line could be collapsing to cut off oil supply Replace line Air leaks in pump suction line Check hose clamps or replace hose Dirt in pump Clean and repair pump If needed drain and flush hydraulic system Badly worn pump Check for problems Causing pump wear Oil leak in pressure lines Tighten fittings or replace defective lines Hoses attached improperly Attach properly and tighten securely Control Valve Defective Replace SYSTEM RUNS WITH STOPS AND STARTS Air in system Examine suction side of system for leaks Make sure oil level is correct To get air out of system after oil level is correct and leaks fixed use bucket and loader cylinders 5 to 6 times to purge the system of air Cold oil Oil viscosity may be too high at start Before operating allow oil to warm up Components sticking or binding Check for dirt or gummy deposits Pump damaged Check for worn or broken parts TROUBLESHOOTING SYSTEM RUNS OR WORKS SLOWLY Cold oil Allow to warm up before operating viscosity too heavy See specifications on proper Not enough engine speed Increase engine speed Low oil supply Check reservoir and add oil if needed Chec
17. alert Do not operate the front loader when you are tired ill or under the influence of alcohol or drugs Work with the equipment only in daylight or good artificial light Watch out for and avoid rocks roots holes and other objects If you hit an object stop and inspect for damage repair any damage before you operate the equipment again Replace damaged worn or broken parts immediately The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may lead to death if the front loader is operated in an enclosed place FRONT LOADER SAFETY 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 Wear suitable protective device such as an external hearing protector earmuffs or ear plugs to protect against loud or otherwise objectionable noise Use extreme caution when crossing a gravel drive walkway or road Stay alert for the hidden hazards of traffic BEFORE STARTING The use of heavy equipment and or 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
18. ator s manual Install this label onto the original frame lower cover 2 Remove the drawbar and replace it with the bottom bracket using the two 12 x 25 mm hex hd capscrews with 7 16 washers and two 10 x 30mm hex hd capscrews with 3 8 washers Torque front cover and rear bracket bolts as follows 10mm Bolts 29 ft Ibs 29 Nm 12mm Bolts 43 ft lbs 60 Nm 10 x 30mm DRAWBAR BOLTS BOTTOM BRACKET 13 55405 COUNTERWEIGHT INSTALLATION 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 60mm 2 4in DRIVE ON PLATE 5 Drive the tractiforward from the rear of the sub frame over the drive on plate keeping it parallel with the sub frame UP P T 14 5540 SUB FRAME COUNTERWEIGHT INSTALLATION REMOVAL 6 Stop the tractor when the mast fixing comes even with the floor board ofthe tractor MAST FIXING PAD 7 Using two people lift the sub frame and engage pipe of sub frame into the 9 U shaped channel of the bottom bracket NA NOTE Use two people to lift sub frame 2 E U CHANNEL zx e
19. e E Ss c 9 15 5540 SUB FRAME COUNTERWEIGHT INSTALLATION REMOVAL 8 Lift the front ofthe sub frame and slip it into the channel ofthe 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 NOTE Mounting pins have a flat side that must be pointing down 46 i MOUNTING PIN 97 d FLAT SIDE DOWN 9 Insert two mounting pins 3 4 x 3 19in from inside the bottom bracket through the 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 pointing down ri CLIP PIN BOTTOM BRACKET 16 5540 SUB FRAME COUNTERWEIGHT INSTALLATION REMOVAL 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 Secure with linchpins 11 Install the twelve counterweights Insert the counterweight fixing pins through the bracket and secure with linchpins NOTE For sub frame removal use reverse procedures 17 FRONT LOADER ASSEMBLY FRONT LOADER ASSEMBLY PUMP HY DRAULIC PUMP MOUNTING MOUNTING LEFT BRACKET PLATE 1 Pu
20. e front of the sub frame usingtwo each 1 2x1 inch and 1 2 x 1 5 16 inch bolts and four each 1 2 inch nuts and washers Tighten bolts and nuts Torque 76 ft lb 103 Nm LOADERINSTALLATION 37 LOADERINSTALLATION ATTACHING 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 1 align pin holes Insert the fixing pins through the masts and pads Install clip pins through holes ui 6 Attach brace arms to mast and front guard 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 positioned on top of larger suction hose 38 LOADER STAND REMOVAL f 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 Slide the stand over the mounting hook and then insert the fixing pin previously removed through main frame and through the stand Repeat the above steps for the other side Lower the loader to the ground Front Loader is ready for operational check Page 25 LOADER INSTALLATION 39 TROUBLE SHOOTING SYSTEM DOES NOT WORK AT ALL PTO in
21. e safety instructions whenever cleaning servicing or lubricating Weurge you to follow this advice 1 Head and understand this manual as well as the tractor owner s manual 2 Remember and observe the Safety Precautions brought to your attention in this manual the tractor manual and on the loader itself 3 Use good common sense in the everyday operation of this unit Safety instructions can never be all inclusive You are responsible for watching out for and avoiding unsafe conditions 4 Never exceed the limits of a piece of machinery If its ability to do a job or to do so safely is in question Dont try it Don t hurry the learning process or take the unit for granted Ease into it and become familiar with your new loader and tractor 26 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 strain on the unit and may cause damage to the loader or tractor nS _ Before disconnecting hydraullc lines relieve all hydraullc pressure Escaping hydraulic oil under pressure can have sufficient force to penetrate the skin causing serious personal injury If injured by escaping hydraulic oil consult a physician immediately 44 WARNING Do not operate the loader if the hydraulic fittings or hoses are leaking or damaged A sudden line burst can cause the main frame to drop sudden
22. es logs or oil drums is not recommended These items can easily shift or roll down the front loader arms causing equipment damage or severe personal injury This tractor utilizes Four Wheel Steering 4WS The feel of 4WS is slightly different from other tractors and will affect front loader operation Practice use of the front loader in a wide safe area 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 The front loader is intended for relatively flat terrain useage Avoid overhead wires and obstacles when the front loader is in the raised position Contacting electric wires can cause electrocution Allow for the added length of the front loader attachment when making turns to prevent striking people or objects When operating the front loader on a slope always drive up and down the face ofthe grade Turning or driving across the face of the slope may cause the tractor to overturn Operate the front loader arms gradually by feathering the loader controls to prevent abrupt movements that could cause damage to the front loader and tractor Use added caution when working with shifting or loose loads in the loader bucket could cause vehicle instability or fall out ofthe bucket and cause personal inju
23. ghten parts Piston rod damaged Check rod for nicks or scratches that could cause seal damage or allow oil leakage Replace defective cylinder 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 Use paper or cardboard not body parts to check for leaks Hydraulic oil under pressure will penetrate the skin causing serious injury Make sure that all operating and service personnel know that in the event hydraulic fluid penetrates the skin it must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result Do not operate the front loader If the fittings or the hoses are leaking or damaged A sudden line burst could cause the main frame to drop suddenly causing damage to the tractor or loader or injury to personnel movement of control lever or leak in the hydraulic system could cause main frame to drop causing serious Injury Do not stand or walk under a raised attachment Note When checking hydraulic system oil level the loader should be on the ground and bucket fully retracted all cylinders in the retracted position Grease all
24. he center of gravity of the unit and increases the possibility of mishaps Do not lift or carry personnel on a loader or attachment a slip or fall could cause serious injury UNLOADING As the tractor approaches the unloading point raise the loader to the height required for clearance to dump bucket Drive slowly to position bucket above unloading point stop tractor and dump bucket NOTE Do not raise loader higher than required for dumping clearance As dumping clearance height increases the bucket position must be adjusted to maintain a level bucket to prevent excessive spillage of material from bucket 30 LOADER REMOVAL FROMTRACTOR LOADER REMOVAL FROM TRACTOR and solid place for Select a level safe 1 loader removal Lower bucket to the ground and remove the stands from the loader main frame 2 Haise the loader until the stands can be inserted into the loader arms Install the clip pins into the stand ends 3 Lower the loader until the stands rest on 22 the ground P ae Dump the bucket until the edge of bucket touches the ground 31 LOADER REMOVAL FROMTRACTOR 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 Hemove the hydraulic hoses from
25. inched Clean or replace line between reservoir and pump Reservoir air vent plugged Remove vent plug flush and clean air vent Air in oil Tighten or replace suction line Check system for leaks Check pump shaft seal Worn or scored pump bearings or shafts Replace pump PUMPLEAKS OIL Damaged seal around pump shaft Heplace seal 42 LOAD DROPS WITH CONTROL VALVE IN NEUTRAL POSITION Leaking or broken oil lines from control valves to cylinder Check for leaks Tighten or replace lines Oil leaking past cylinder packing or O 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 Clean system and determine source of dirt CONTROL VALVE STICKS OR WORKS HARD Valve broken or scored internally Replace valve CONTROL VALVE LEAKS OIL Worn or damaged rings Replace O rings If contamination has caused O rings to wear clean system and look for source Broken valve parts Replace parts or valve CYLINDER LEAKS OIL Damaged cylinder bowl Replace cylinder Correct cause of damage Rod seal leaking Replace seal If contamination caused seal to wear look for source Wear may be caused by external as well as internal contaminants Check piston rod for scratches or misalignment Loose parts Ti
26. k system for leaks that could cause low oll Air in system Check suction side of system for leaks Badly worn pump Repair or replace pump Check for problems causing pump wear such as contaminated oil Restriction in suction line Suction line could be dirty or have inner walls that are collapsing to cut off oil supply Clean or replace suction line Cil leaks in pressure lines Tighten fittings or replace defective lines OVERHEATING OF OIL IN SYSTEM Using incorrect oil See specifications on proper oll Low oil level Fill reservoir Look for leaks Engine running too fast Reduce throttle Restriction in hydraulic line Clean or replace Controls stuck in partially or full open position Free both handles so they return to neutral 41 TROUBLE SHOOTING FOAMING OF OIL IN SYSTEM Low oil level Fill reservoir Look for leaks Water in oil Drain and replace oll Wrong kind of oil being use See specifications on proper oil Air leak in line from reservoir to pump Tighten or replace suction line Kink in oil suction line Replace oil line Worn seal around pump shaft Clean sealing area and replace seal Check oil for contamination PUMP MAKES NOISE Low oil level Fill reservoir Check system for leaks Cil viscosity too high See specifications on proper oll Cold oil Allow oil to warm up before operating Suction line plugged or p
27. ly causing damage to the tractor or loader or injury to personnel BEFORE OPERATING LUBRICATE ALL MOVING PARTS Refer to lubrication section COLD WEATHER OPERATION To assure smooth operation in cold weather allow the tractor to warm up Slowly cycle the loader and bucket several times to warm the fluid in the hydraulic system The loader may operate erratically until the hydraulic fluid has warmed to operating temperatures 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 HYDRAULICCONTROL VALVE Your loader control valve has two handles The right handle operates the lift cylinders the loader and has a float position The left handle operates the bucket cylinders Both handles will return to neutral except from float position when released 4 RIGHT HANDLE 7 LOADER A Float Position B Loader Down LEFT HANDLE 7 BUCKET A Bucket Dump B Neutral C Neutral Bucket Back D Loader Up 17 3 2 d e 22011 HANDLE USE BUCKET POSITION A Left handle pushed forward bucket will dump POSITION B Neutral position POSITION C Left handle pulled back bucket will roll back OPERATING INSTRUCTIONS LOADER POSITION A Right handle
28. ment to you Name and address of the dealer who services your equipment Date of purchase e Your name address and telephone number Adetailed description of the problem _ 3752490 L IL L lt 21111 11 111111111 1 11111111 1 PTT TT
29. mp mounting plate and pump drive joint installed on pump Ensure bolts and set screw are tight SUR Attach the pump brackets to the pump TT s Z mounting plate using two each 5 16 2 inch M bolts and 5 16 flatwashers The right BS ri bracket is shorter than the left Do not tighten the bolts at this time d RIGHT BRACKET Apply a light coating of grease to tractor front PTO atthis time 2 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 16x7 8 inch bolts and 5 16 lockwashers Tighten all pump mounting bolts LOADER INSTALLATION NOTE The masts and main frame come assembled All cylinders and hoses have been attached to the frame except the two hoses from the hydraulic pump Set the loader on its stands and move the tractor centrally between the masts 19 FRONT LOADER ASSEMBLY PRESSURE and SUCTION HYDRAULIC HOSE CONNECTION 4 9 pipe plug from the valve body and clean the threads and then install the pressure hose Remove the plastic caps from the pump outlets Usesealer on threads and screw the other end swivel connector end into the threaded pipe fitting on the pump Slide the suction hose large hose over the pipe end at the bottom of mastkeservoir and pipe end on the pump Attach with hose clamps and tighten secu
30. peat the above steps for the other side Lower the loader to the ground Front Loader is ready to become operational 23 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 oil check screw and see if oil will run out hole Do not overfill If oil level is low remove fill plug and add hydraulic fluid until it runs out of oil check hole Re install and tighten the oil check screw and oil fill plug Operate the loader up and down several times and recheck oil level Replenish as necessary Operate and check the loader main frame and bucket for interference noise and bending of parts MEL _ Before using loader double check e Tractor Owner s Manual for recommended tire pressure That all bolts and hoses have been tight ened and that all tools have been removed from tractor and loader Counterweights are Installed and correct START UP PROCEDURE Ensure tractor meets all requirements in Tractor Preparation Section Check front loader hydraulic fluid level Refer to front loader operator s manual OPERATIONAL CHECK Note Bucket and lift cylinders should be fully retracted when checking hydraulic fluid level Check all hydraulic hose connections to ensure that they are not leaking Lubricate all
31. possible in line production changes your machine may vary slightly in detail Extra equipment that may be shown on the machine is optional at extra cost manufacturer reserves the right to redesign and change the machine as may be necessary without notification NOTE Illustrations used in this manual may not show all safety equipment that is recommended to ensure safe operation of tractor loader Refer to Safety Section ofthis manual and the Tractor Owner s Manual for information concerning safety equipment Consult your dealer for further information SERIAL NUMBER and LOCATION The serial number is important information about the machine and it may be necessary to know It before obtaining the correct replacement parts The serial number is located on the right side mast as shown REPLACEMENT PARTS Use only Genuine Honda Replacement parts to repair this machine Honda replacement parts are available from your Honda Multi purpose Tractor Dealer To obtain prompt efficient service always remember to give the dealer the following information Correct part description or part number Model number of your machine Serial number of your machine w Sy pasi FRONTLOADER 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 fron
32. pushed all the way forward this is float position Handle will stay until pulled back POSITION B Right handle pushed half way 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 is up off the ground it will lower to the ground by gravity When the bucket is on the ground and the valve is still in float the bucket will follow the shape of the ground even when the tractor is moving This allows hydraulic oil to flow back and forth in the hydraulic system as the loader is raised and lowered by the ground contour HW 6S Do not allow bucket lip to dig into ground when tractor is moving forward in float The bucket bottom should be level with the ground or slightly rolled back NOTE The float position is most commonly used with attachments in snow removal Tractor should be run at slow ground speed and the lift and bucket cylinders used to work material loose and fill the bucket 27 OPERATING INSTRUCTIONS CONTROLLED RATE of LOADER FUNCTIONS B 5 By feathering slightly moving the control levers precise operational speeds can be obtained This action controls the position of LEFT HANDLE BUCKET HANDLE 522 OADER the valve spools in the control valve and Bucket Dump Bad edi DOW regulates flow of oil from to cylinders Neut
33. r attachments for handling large objects are available from agricultural suppliers PACKAGINGINVENTORY 37 5 lbs each 2 2 y EE E x 3 3 i P 5 i WEIGHTS 1 x H H 2 eese ERE sit Ri pa S 8 D TP m Z a aa Ph e i a ea ie uat Tea at ea a Ie Ea a a ua ua an I nan eT Sua mw Ce n Seat ra ee o IU 7 anaana n eats i PAAA A ne DOG T e GIN PAGE GIN Se PABA ESM EAN hh AA A ISI TRENT TS Te TAAA 1 trt LR RUP LRL UD p ata ee Mar a ee r aa h r T a IR 5 FA P PSI T LARGE CARTON SMALL CARTON aq ar pipa a taru tw aa a a a a a a a 4 a a a a a aa a ri p aa a
34. ral C Neutral Bucket Back D Loader Up It is important to utilize this operational practice when lowering the main frame when the bucket is loaded with material N 221 C53 CHEER SCRAPING When scraping the float position should be utilized to maintain the bucket firmly on the ground and at the same time allow the bucket to follow ground contours The bucket should be positioned level to the ground during scraping operations TS lU LLLA UL ESTER TT ESTERI u BACKFILLING BACKGRADING When backfilling or backgrading position the bucket so it is level on the ground Do not dump material from the bucket Additional ACA a ex SNR weight of material in bucket will assist in NN backgrading and increases loaderefficiency ring backfilling Pe during backfilling amie FIERE 28 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 Do not attempt to turn tractor while loading As bucket begins to fill with material gradually roll the bucket back and raise the loader to increase fill capacity This procedure also
35. rely Attach the front guard on the front of the sub frame using two each 1 2 x 1 inch and 1 2 x 15 16 inch bolts and four each 1 2 inch nuts and washers Do not tighten bolts at this time AITACHING LOADING MASTS 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 and insert the fixing pins through the masts and pads Install clip pins to retain fixing pins NOTE Masts may have to be shaken to align fixing pin holes 20 VALVE BODY FIXING PIN 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 9 Bring the two hoses along the left side brace arm to the left mast Route hoses on the left brace arm with metal loops Ensure that the high pressure hose smaller diameter is positioned on top of the suction hose large diameter Install the nylon tie strap to bind the two hoses together at front corner of hoodline Install valve handles to the hydraulic control valve mounted on the left mast The A handle attaches to the spool used for loader operation and the B handle attaches to the spool for bucket operation FRONT LOADER ASSEMBLY LEFT BRACE ARM HANDLEB HANDLEA COTTER COTTERPIN C HOOK 21 FRONT LOADER ASSEMBLY BUCKET ATTACHING SPILL GUARD 10 Using the bottom holes on the bucke
36. roblem After reviewing all the facts involved you will be advised of what action can be taken Please bear in mind that your problem will likely be resolved at the dealership using the dealer s facilities equipment and personnel so it is very important that your initial contact be with the dealer Your purchase of a Honda product is greatly appreciated by both your dealer and American Honda Motor We want to assist you in every way possible to assure your satisfaction with your purchase Page 51 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 The Service Manager or General Manager can help Almost all problems are solved in this way If you are dissatisfied with the decision made by the dealership s management contact the Honda Power Equipment Customer Relations Office You can write American Honda Motor Co Inc Power Equipment Division Customer Relations Office 4900 Marconi Drive Alpharetta GA 30005 8847 Or telephone 770 497 6400 M F 8 30 am 5 00 pm EST When you write or call please provide the following information e Model and serial numbers e Name of the dealer who sold the Honda power equip
37. ry To avoid loss of control or overturning always reduce speed and exercise extreme caution when operating the front loader on sloping or uneven surfaces Operate loader controls only from the operator s seat to prevent possible severe personal injury Attempting to change gears while operating the front loader on a slope may adversely affect vehicle stability and control and severe personal injury could result Do not back down or rapidly accelerate up a sloping surface To avoid loss of control or overturning do not stop or turn on sloping surfaces Do not operate the front loader near the edge of a ditch or an embankment Slipping off the edge could lead to severe personal injury or equipment damage When descending a slope disengaging the clutch or shifting into neutral can cause loss of control that may result in severe personal injury Be sure to follow instructions below whenever applying the tractor differential lock during front loader use Do not apply the tractor differential lock while turning use the differential lock only while driving in a straight line Never apply the differential lock on paved surfaces To avoid injury to yourself and others before leaving the front loader unattended ALWAYS park on level ground and lock the parking brake ower the front bucket flat to the ground disengage the front loader drive system stop the engine and remove the key If you find it necessary to park
38. se read these messages carefully safety message alerts you to potential hazards that could hurt you or others Each safety message is proceded by a safety alert symbol and one of three words DANGER WARNING CAUTION These words mean DANGER You WILL be KILLED or SERIOUSLY HURT DANGER If you don t follow Instructions WARNING You be KILLED or SERIOUSLY HURT H you don t follow Instructions CAUTION You be HURT you don t follow Instructions Each message tells you what the hazard is what can happen and what you can do to avoid reduce injury Damage Prevention Messages You will also see other important messages that are proceded by the word NOTICE This word means NOTICE Your equipment or other property can be damaged if you don t follow Instructions Using this product for a purpose not Intended can cause injury or property damage Read and understand this Operator s Manual before operating the front loader failure to do so could result In personal Injury or equipment damage if a problem should arise or if you have any questions about your front loader consult an authorized Honda Multi purpose Tractor dealer 1 NERO G FON 3
39. t loader SAFE OPERATING RULES oevere personal injury or equipment damage may result if the operating instructions on pages 25 thru 30 jare not followed Always make pre operationchecks page 25 before you start the engine You may preventan accident or equipmentdamage To avoid severe personalinjury or equipment damage observe the following precautions All parts especially guards and shields should be in good condition and securely fastened in place e Be sure all nuts bolts and screws are tight Do not remove any guards warning labels shields or safety devices they are installedfor your Safety The tractor roll over protective structure ROPS will only protect you from injury if you are also wearing the seat belt the ROPS is securely attached and has not been modified or structurally damaged Know how to stop the engine quickly Thoroughly understandoperation of all controls Never permit anyone to operate the tractor or front loader without proper instructions The tractor is an operator only vehicle do not allow passengers to ride on the tractor orfront loader Keep children and pets at a safe distance during operation Never allow anyone to get under the front loader bucket or reachthrough the lift arms when the bucketis raised or tractor engine is running Always wear sturdy shoes or boots and avoid wearing bulky or loose clothing while operating the tractor or the front loader Be
40. t 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 e BUCKET and clip pins b The loader is now ready for hydraulic fluid 3 4 x 3in PINS HYDRAULIC FLUID SERVICING You will need 6 1 2 quarts of a good grade hydraulic fluid or ATF automatic transmission fluid 11 Remove filler plug and oil check screw on back of left mast Fill with 4 quarts of hydraulic fluid VALVE otart tractor engine and set speed at 1 2 throttle Engage tractor front PTO and operate loader lift and bucket cylinders at least five 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 2 1 2 more quarts of hydraulic fluid or until oil runs out of check hole Replace oil fill plug and oil check screw NOTE When lowering loader DO NOT push loader handle A all the way forward into FLOAT 22 FRONT LOADER ASSEMBLY LOADER STAND REMOVAL i 12 Raise the loader with the loader control untilthe stands clear the ground lt 13 Remove latch pin from the stands and A remove the stands MOUNTING HOOK 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 and through the stand Re
41. tor or loader STORAGE PROCEDURES BEGINNING OF SEASON 1 Heview safety precautions and operation sections of manual Thoroughly clean loader of all accumulated dirt and grease If removed from tractor for storage remount loader per Loader Installation section of this manual Completely lubricate the loader per the lubrication section of this manual Make sure all fittings are taking grease properly Clean with solvent any exposed surfaces which had been coated with grease Wipe dry with a clean cloth then lubricate with an oil soaked cloth Tighten any bolts that may have been loosened and make sure all pins are in place otart tractor and operate loader to make sure it is operating properly and all hoses are properly connected Check hyaraulic fluid level in loader mast and fill if required Use oil recommended in this manual Make sure hydraulic hoses lines and fittings are in good shape and are not leaking Repair or replace as needed 35 LOADER INSTALLATION NOTE Install sub frame and weights Page 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 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 inch bolts 3 Attach the front guard on th
42. ured If you must work underneath a raised loader make sure the arms are blocked in the raised position with a safety bar A suitable steel safety bar can be manufactured following the dimensions as illustrated below es EN lt AS SAFETY LABEL LOCATIONS SAFETY LABEL LOCATIONS Read these SAFETY LABELS before you operate the front loader W 2 IMPROPER SERVICING CAN CAUSE SERIOUS INJURY OR DEATH Before servicing or adjustment lower loader to the ground and shut off engine e HRolleve hydraulic pressure before disconnecting oil lines TRACTOR TIP OVER CAN CAUSE SERIOUS INJURY OR DEATH e Add recommended wheel ballast and or counterweights for stability e Drive and turn tractor at slow speed e Place loader low when transporting loads especially on an incline or rough terrain Put loader on ground when parked Read and understand all i ons in operators manual before operation M Ta T m Ex 5 a ERGO SIE URBAN AID DARE C UCKET CAUSING SERIOUS INJURY OR DEATH ropery handi la heavy objects 8 cause the toll or can cause the load to roll or Mide down the bode ami ento the operator ting on uneven terah can cduse the tip out of bucket onto the operator or bystanden Read and undentand ol instructions Operdtors manual before operation INFORMATION Special loade
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