Honda Power Equipment FL6555 Lawn Mower User Manual
Contents
1. 20 5 A Maximum Lift Height 1895mm 74 6in B Clearance with Bucket Dumped 1516mm 59 7 in Reach at Maximum Height 691mm 27 2in D Maximum Dump Angle 36 E Reach with Attachment on Ground 1183mm 46 5in Attachment Rollback Angler 21 G Digging Depth below Grade 113mm 4 4in H Overall Height Carry Position 1280mm 50 5in L Length of Attachment 432mm 17in Lift Capacity to Full Height TN 550 Lbs Breakaway Capacity 950 Lbs Bucket Cylinders 1 5 x 14 Lift Cylinders 1 75 x 13 Relief Valve Pressure Setting Loader 1700 PSI 12 SET UP INSTRUCTIONS SET UP INSTRUCTIONS General Read Set up instruction completely prior to installing loader to familiarize yourself with all mounting and hydraulic system installation procedures Ensure tractor is prepared as described in Tractor Preparation Section The loader operates from the tractor hydraulic system Reference to LH or RH is as viewed from the operators seat A pipe thread sealant must be used on all pipe threads All hardware required for mounting is supplied All loader mount component hardware should be left loose until all mount compo2. Raise the loader off the ground and position bucket cutting edge vertical to ground Lower loader to position bucket cutting edge on the ground and shut tractor off Place parking leg in Park position on the boom and secure with pin Start tractor raise loader and fully retract bucket Lower the loader until the parking leg contacts the ground Tip the bucket until the cutting edge just contacts the ground Shut the tractor OFF remove the hinge assembly clamping capscrews and swing hinges clear of the rear mount 31 LOADER REMOVAL AND INSTALLATION Start the tractor and shift the loader control valve into the Float position Slowly retract the bucket cylinders until the bottom of the bucket rests firmly on the ground Note During this procedure the loader should raise off the rear mount If necessary extend the lift cylinders as required to raise the loader clear of the rear mount Back the tractor slowly until the loader front crosstube is just clear of the Front Mount Observe the hydraulic hoses valve tubelines to ensure they are not caught or stretched during this operation Shift the loader control valve into the neutral position Check to ensure the loader will clear the front tires If additional clearance is required extend the lift cylinders Shut tractor OFF and disconnect the hydraulic hose couplers Secure the hydraulic hoses to ensure they will be clear of the tracto
3. Replace control valve and recheck operation Refer to hydraulic pump Capacity inadequate Check and refill hydraulic system to proper level Check for loose or defective between reservoir and hydraulic pump Refer to tractor owner s manual and replace hydraulic oil using recommended hvdraulic oil Allow hvdraulic fluid to warm up to operating temperature Reduce loads Check relief valve setting as described under relief valve test Check for evidence of restriction in hydraulic oil flow Repair or replace defective component s 47 TROUBLE SHOOTING PROBLEM Loader drops with control valve spool in centered position no external oil leakage evident Note A gradual drop over an extended period is a normal condition Control valve spool s will not return position to centered position External hydraulic fluid leakage 48 POSSIBLE CAUSE Cylinder piston assembly leakage Control valve internal leakage Control lever linkage binding Control valve spool centering spring broken Control valve spool binding in valve bodv spool bore Loose hvdraulic connection Defective hvdraulic hose tubeline adaptor fitting or adaptor fitting O ring Control valve O rings defective Control valve spool or bodv damaged or worn Cvlinder rod packing set leakage CORRECTION Check cylinders for leakage as described under cylinder leakage tests
4. HONDA Power Equipment OPERATOR S MANUAL FRONT LOADER MODEL FL6555 FOR HONDA H6522 A4 COMPACT TRACTOR et LLL EUN NES RER ER A 3 NS LJ d E ELI gt mii ttt ttt tt tT ui EMETRE RENE LLILLLLLLLLLLLLLL HONDA DEALER PLEASE GIVE THIS PUBLICATION TO YOUR CUSTOMER TJ LL D 1991 American Honda motor inc n Rights 3922093 Thank vou for purchasing an HTA FL6555 Front Loader Attachment for vour Honda H6522 A4 Compact Tractor _This manual covers the assembly operation and maintenance of the Model FL6555 Front Loader For vour convenience a repair and parts guide is also included in this publication NOTE The illustrations in this manual are intended to serve as a reference and mav not necessarilv depict the actual model listed above The information in this publication is based on latest product information available at the time of printing American Honda Motor Co Inc reserves the right to make changes any time without notice and without incurring any obligation No part of this publication mav be reproduced without written permission This manual is considered a permanent part of the Front Loa
5. Replace control valve amp recheck Determine origin of binding and repair Replace centering spring Refer to valve service procedure Disassemble valve for inspection and repair Refer to valve service procedure Tighten loose connection Check for origin of oil leak and replace defective part Replace defective O rings Replace control valve Perform cylinder leakage test for rod packing set as described under cylinder leakage tests PROBLEM Hvdraulic pump capacitv inadequate Lift cvlinder rods bend when lift cvlinders extended Bucket cvlinder rods bend when bucket cvlinders extended Bucket cutting edge wear is uneven side to side Bucket cutting edge wear rate is excessive wear rate is even across full width of bucket on concrete Note Extensive use of bucket on concrete asphalt surfaces will accelerate wear rate of bucket cutting edge Fork bucket tine s bend POSSIBLE CAUSE Cold hydraulic fluid Engine RPM too slow Low hydraulic fluid supply Hydraulic hose restriction Hydraulic pump defective Excessive shock load on lift cylinders during transport Back grading or dozing with bucket cylinder extended Bucket is not level to ground Incorrect practices Excessive down pressure placed on bucket when being used on hard abrasive surfaces operation Bucket wear pads worn Excessive loading on individual tine s TROUBLE SHOOTING CORR
6. All parts especially guards and shields should be in good condition and securely fastened in place Do not remove any guards warning labels shields or safety devices they are installed for your safety The tractor roll over protection 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 Always wear sturdy shoes and avoid wearing bulky or loose clothing while operating the tractor or the front loader Never operate the tractor or the front loader when tired or while under the influence of drugs or alcohol In case of emergency know how to stop the engine and thoroughly understand the operation of ALL controls Never permit to operate the tractor or the front loader without proper instructions Children should not be permitted to operate the tractor or the front loader KEEP CHILDREN AND PETS AT A SAFE DISTANCE DURING OPERATION The tractor is an operator oniv vehicle do not allow passengers to ride on the tractor or the front loader Never allow anvone to get under the front loader bucket or reach through the lift arms when the bucket is raised or the tractor engine is running The exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness and may lead to death if the tractor and front loader are operated in an enclosed area SAFETV BEFORE STARTING
7. The use of heavy equipment and or pulling or lifting excessive loads may adversely affect vehicle stability and control To avoid loss of control that can result in severe personal injury Only use 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 Be extra careful when turning or backing up and when on uneven terrain Use counterweights as indicted in this manual and the tractor 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 Rollover Protective 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 that it is snug Be sure that the main transmission lever is in Neutral and the Power Take Off PTO levers are in the OFF position and brake is engaged before starting the engine Operate the tractor and the loader at slow speeds until you become familiar with all of the operating characteristics and controls Do not operate the tractor or the loader until you are sure the area in front and behind is clear of people and pets Sudden stops of the tractor and loader during operation could cause the tractor to overturn Be especially careful during sharp t
8. carriage bolt 1 BUCKET PIVOT PIN 1 00 x 4 25 2 50 x 3 625 clevis pin 1 HYDRAULIC VALVE PACKAGE 4 pivot pin clip 1 plastic tie strap 10 TRACTOR PREPARATION Rear Counterweight DO NOT EXCEED THE RATING FOR MAXIMUM GROSS VEHICLE WEIGHT REFER TO OWNER S MANUAL PROVIDED WITH TRACTOR The use of adequate counterweight for maximum loader capacity is required for proper stability PROPER COUNTERWEIGHT AND BALLAST FOR H6522 4 FL6555 FRONT LOADER ONLY Ag tires _ 99 pounds 45 Kg ballast in each rear tire 75 pound 31 8 Kg wheel weight on each rear wheel Three point hitch mounted with rear weight box containing 583 pounds 265 Kg of sand or High float 236 pounds 107 Kg ballast in each rear tire Three point hitch mounted with rear weight box containing 583 pounds 265 Kg of sand FL6555 FRONT LOADER AND BH6575 BACKHOE Ag tires 99 pounds 45 Kg ballast in each rear tire 75 pound 31 8 Kg wheel weight on each rear tire Turf or High Float 170 Pounds 77 Kg ballast in each rear tire Additional counterweight requirements will vary with loader attachments and equipment applications Certain specific conditions may not permit safe use of loader at loader rating or may require more careful restricted operation at the rated load TRACTOR PREPARATION TIRE TYPES Agricultural Recommended Turf High Flotation TIRE INFLATION AGTIRES TURF TIRES HIGH FLOAT Front 3
9. 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 Service Department of American Honda Motor Co Inc American Honda Motor Co Inc Power Equipment Customer Service Department Duluth Georgia 30136 9421 Telephone 404 497 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 problem 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 dealers 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 Co Inc We want to assist you in every way possible to assure your satisfaction with your purchase 61 ee tt tte tet EE TT Ty bj IE Ie ee ae
10. the skin causing serious personal injury If injured by escaping hydraulic oil consult a physician immediately Oil must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result Before disconnecting hydraulic lines relieve all hydraulic pressure by operating hydraulic control lever through all positions with engine off a WARNING A sudden line burst can cause the mainframe to drop suddeniv causing damage to the tractor or loader or injury to personnel Do not operate the loader if the fittings are leaking or if the hoses are damaged BEFORE OPERATING LUBRICATE ALL MOVING PARTS REFER LUBRICATION SECTION Cold Weather Operation To assure smooth operation in cold weather allow tractor to warm up SLOWLY cycle the loader and attachment several times to warm the fluid in the hydraulic system The loader may operate erratically until the hydraulic fluid has warmed to temperatures 25 OPERATION CONTROLLED RATE of LOADER FUNCTIONS By feathering slightly moving the control lever 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 lt is important to utilize this operational practice when lowering the main frame when the bucket is loaded with material When scraping the Float position should be
11. utilized to maintain the bucket firmiv 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 utu Backfilling Backgrading When Backfilling or Backgrading position the bucket so it is level on the ground Do not dump material from bucket Additional weight CURL 256 UP ct ME MN RE TETE TE TENTE a N TANS 9 MM CSS rel 4 5 a f saba a 4 M 7 SSSI mt es Al ET A SL X TE A of material in bucket will assist in Backgrading and increase loader efficiency during Backfilling sal ip Le ITEM 26 LOADING Drive straight ahead into pile with bucket cutting edge level with the ground In order to prevent possibility of damaging tractor or loader e 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 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 ba
12. 0 psi 22 psi 16 psi Rear 20 psi 20 psi 28 psi Rear tires must be maintained at equal pressure within the recommended tire inflation range Unequal rear tire inflation can prevent loader attachment from contacting the ground across its full width Roll Over Protection Structure ROPS Svstem The tractor ROPS svstem must be in place and used to ensure adequate operator protection Tractor Hydraulic System Tractor operation in a loader application significantly increases demands on the tractor hydraulic system Check the tractor hydraulic system fluid level daily Refer to your tractor owners manual for instructions regarding tractor hydraulic system maintenance Follow recommendations in your Tractor Owner s Manual concerning Hydraulic Fluid and Filter change intervals Refer to tractor owner s manual for hydraulic fluid specifications CAUTION The tractor loader must only be operated with all safety equipment properly installed Front Counterweight Use of front counterweight is not recommended when tractor is being used in a loader application Front counterweight adds unnecessary front axle load in loader applications 11 LOADER SPECIFICATIONS LOADER SPECIFICATIONS Specifications shown are based on ASAE Standards Specifications mav varv with tire size options and tvpe of attachment A B Front tires AG Type 30 PSI ICAP MNCS AG Senet
13. CK SPRING LOAD CHECK POPPET STEEL BALL BALL RETAINER RELIEF SPRING ADJUSTMENT SCREW JAMNUT RELIEF CAP PLUG DETENT SPOOL DETENT END STEEL BALL ORIFICE PARTS LIST VALVE HVDRAULICS 18 HYDRAULIC HOSE 38 HYDRAULIC HOSE DUST PLUG ASSEMBLY DUST CAP ASSEMBLY PARTS LIST BUCKET AND BOOM HVDRAULICS REF 52 DESCRIPTION REQ D TN CYLINDER ASSEMBLY BUCKET 2 2 CYLINDER ASSEMBLY BOOM 2 Erud i HOSE ASSEMBLY bucket cylinder 1 4 x 20 inch 2 PE HOSE ASSEMBLY boom lower 1 4 x 38 inch 2 Das sise HOSE ASSEMBLY boom raise 1 4 x 23 inch 2 CONNECTOR short 9 16 18 flared x 9 16 18 O ring boss shown 6 B soe O ring 15 32 id x 5 64inch 8 TUBE ASSEMBLY front 4 DD A TUBE ASSEMBLY rear 4 STRAP UAR i slm HOSE ASSEMBLY bucket cylinder 1 4 15 inch 2 54 PARTS LIST BUCKET CVLINDER REF DESCRIPTION SEAL piston CYLINDER assy bucket PISTON cylinder BODY assly bucket cyl WIRE retaining FITTING grease 1 GUIDE packing male ROD assy bucket cylinder 1 GUIDE packing female FITTING grease 1 V SEAL rubber NUT hex lock 3 4 in 1 V SEAL fiber END piston WIPER rod O RING piston rod NUT cartridge RING wear piston Indicates
14. ECTION Allow hydraulic fluid to warm up to operating temperature Increase engine R P M Refer to tractor owner s manual for service recommendations Check for evidence of restriction in hydraulic hoses Refer to tractor owner s manual for recommended service procedures Replace hydraulic pump if determined to be defective Replace defective parts Review and observe proper and safe operational practices Replace detective parts Review and observe proper and safe operational practices Check rear tire inflation and adjust pressures to level bucket to ground Refer to operation scraping section for correct operating procedures Utilize float position Replace wear pads Repair replace defective tines Ensure full compliment of tines are under load when breaking out material 49 HVDRAULIC SVSTEM SCHEMATIC HVDRAULIC SVSTEM SCHEMATIC 1 Bucket Cylinder Retract 2 Bucket Cylinder Extend 3 Lift Cylinder Extend 4 Lift Cylinder Retract Quick Disconnect Coupler LH RH Bucket Cylinders Lift Cylinders LH Tractor Hydraulic Pump 432 hL sr mia IN OUT u E Relief Tractor Hvdraulic Svstem 50 PARTS LIST PARTS LIST SINGLE LEVER CONTROL BRACKET Assy CAP SCREW PARTS LIST HYDRAULIC VALVE ASSEMBLY REF DESCRIPTION DETENT SPRING O RING DETENT PLUG O RING LOAD CHECK PLUG GASKET LOAD CHE
15. LT ASTM ASTM ASTM ASTM SIZE mm DIAMETER CLASS CLASS CLASS CLASS 4 6 8 8 9 8 10 9 7 5 fieq 3169 65 85 w 3 870 1308 a 8 738g 2782 34 3 ETES 02 14 SUB FRAME INSTALLATION AND REMOVAL 1 Remove mower deck if installed See mower operator s Manual 2 Ensure tractor is prepared as described in Tractor Preparation section of this manual 3 Remove the front plate and mower front link bracket if installed 4 Loosely install 12mm x 55mm capscrew in the top rearmost holes on each side of tractor frame Engage the bolt threads approximately 10mm These bolts will act as guide bolts to make front bracket installation easier Position the Front Bracket as shown and slip the slotted holes over the guide bolts 5 Loosely install two 12mm x 55mm capscrews 1 2 lockwashers and 1 2 flatwashers in the holes immediately forward of the guide bolts on each side Remove the guide bolts installed in step 4 above WITH OUT MOWER INSTALLATION 6 Loosely install the two Spacer Plates one each side as shown using four 12mm x 45mm capscrews 1 2 lockwashers and 1 2 flatwashers in the four front bolt patterns WITH MOWER INSTALLATION 6 Loosely install the Front Link Bracket supplied with mower as shown using four 12mm x 45mm capscrews 1 2 lockwashers and 1 2 flatwashers in the four front bolt patterns on each side NOTICE If installing mower at
16. T UP INSTRUCTIONS LOADER ASSEMBLY INSTALLATION 1 Install hinge bolts hinge pins and hinges onto loader assembly 2 Open hinges nes 3 Using a suitable overhead hoist alternate safe method of lifting the loader eb assembiv raise the unit and position it into loader mounts 4 Close sub frame hinges and secure bv torquing nuts to 75 foot pounds 102 m 5 Check all pivot points to ensure retaining hardware is in place 6 Route the two 38 hoses on the inside of the loader upright as shown and secure with plastic tie strap Ensure the hoses are positioned to the rear of the muffler fus EE EE exhaust port as shown Fi BEP n 7 Connectthe two 38 hydraulic hoses to the TRA j 5 7 2 tractor hydraulic ports as illustrated A Z J MUFFLER PORT 21 SET UP INSTRUCTIONS Start Up Procedure Ensure tractor meets all requirements as outlined in tractor preparation section of this manual Check to ensure all labels are installed Refer to safety label page for label locations Check tractor hydraulic fluid level Refer to tractor operators manual for fluid specifications Bucket and Lift Cylinders should be fully retracted when checking fluid level Check all hydraulic connections to ensure that they are adequately tightened Lubricate all pivot points that incorporate grease fittings Start tractor and run engine at approximate
17. TO THE LIFT MECHANISM REFER TO OPERATOR S MANUAL FOR ADJUSTMENT INSTRUCTIONS INFORMATION Tractor loader attachments for handling large objects are available from agricultural suppliers TRACTOR OVER CAN CAUSE SERIOUS INJURY OR DEATH i Eom ot E Do 2 2 et counterwelghts for 5 up DO REE AR ZAN WARNING IMPROPER SERVICING CAN CAUSE SERIOUS INJURY OR DEATH Before servicing or adjustment lower loader fo the ground and shut off engine Relieve hydraulic pressure before disconnecting oil lines e Read and understand ail instructions in operators manual before operation A P al f oy LOADS CAN FALL FROM CAUSING SERIOUS INJURY OR DEATH 1 1 1 1 1 1 2 1 DESCRIPTION LABEL MOWER NOTICE LABEL HYDRAULIC OIL NOTICE LABEL TIP OVER WARNING LABEL LOADER OPERATION LABEL ATTACHMENT INFORMATION LABEL SERVICE WARNING LABEL WARRANTV 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 Distributors 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 satisfaction we suggest you take the following action Discuss your problem with a member of the dealership management Often complaints can be
18. ary without notification 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 of this manual and the tractor owners 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 part The serial number is located on the right side of loader sub frame as shown Replacement Parts Genuine Honda replacement parts only should be used to repair this machine Honda replacement parts are available from your Honda Compact 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 xit Serial Number of your machine Serial No Plate SAFETV SAFETV Front Loader Safetv Operation 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 you operate the Tractor or the Front Loader SAFE OPERATING RULES Severe personal injury or equipment damage may result if the operation instructions on pages 5 and 6 are not followed To avoid severe personal injury or equipment damage observe the following precautions
19. ases the bucket position must be adjusted to maintain a level bucket to prevent excessive spillage of material from bucket 28 OPERATION Loader Sub Frame Installed With MM60 Mower You may install your MM60 mower deck with the FL6555 sub frame installed The front loader must be removed from the sub frame If you also have a BH6575 Back Hoe both the back hoe and its sub frame must be removed NOTICE You must use the following procedure to adjust the mower linkage to avoid damage to the deck or linkage 1 Put the hydraulic position control in the DOWN position 2 Adjust the left lift rod as shown With three point hitch installed META Without three point hitch 3 Follow the normal mower installation in mower operators manual up to the point of raising the deck LOADER 0 2 SUB FRAME MOWER DECK STOP 4 Slowly move the hydraulic position control to the UP position to raise the deck Immediately lower the deck at the first indication of resistance 5 Check the clearance between the deck stops and the front loader sub frame Adjust the clearance to 0 20in 5mm by adjusting the left lift rod length shortening the lift rod raises the deck The fully raised position of the deck will be lower with the loader sub frame installed 29 NOTE 30 NOTE LOADER REMOVAL AND INSTALLATION LOADER REMOVAL AND INSTALLATION Loader Removal Select a level place to park the loader
20. cause the load to side p the loader Driving on c 52 eut ot of ono the operator ystanders Read poly 22 instructions In operators manual before operation INFORMATION Tractor loader attachments for handling large objects are available from agricultural suppliers SHIPPING INVENTORV SHIPPING INVENTORV MAJOR COMPONENTS 1 SUB FRAME ASSEMBLV 2 LOADER BOOM ASSEMBLY w stand 3 LOADER BUCKET ASSEMBLY SHIPPING INVENTORV HYDRAULIC VALVE PACKAGE 1 BOLT SACK 1 SINGLE LEVER CONTROL w assy instr 2 25 20 hex nut 1 HYDRAULIC CONTROL VALVE 2 313 18 nut 2 18 HYDRAULIC HOSE ASSEMBLY 2 25 lockwasher 2 20 HYDRAULIC HOSE ASSEMBLY 2 313 lockwasher 2 38 HYDRAULIC HOSE ASSEMBLY 25 20 x 2 00 hex head gr 5 1 1 1 1 LABEL HYDRAULIC FUNCTIONS 313 18 x 1 00 hex head gr 5 375 quick coupler assembly hydraulic hose dust plug hydraulic hose dust cap WOODEN BOX INVENTORY BOLT SACK 2 SWINGING HINGE ASSEMBLY 24 50 13 hex nut 1 REAR MOUNT ASSEMBLY RH 38 50 flat washer 1 REAR MOUNT ASSEMBLY LH 2 50 flat washer wide 2 SPACER PLATE 44 50 lock washer 1 REAR RAIL ASSEMBLY RH 16 50 13 x 2 00 hexhead gr 5 1 REAR RAIL ASSEMBLY LH 4 12mm x 1 25 x 30mm hexhead gr 10 9 1 BUCKET LEVEL INDICATOR TUBE ASSY 8 12mm x 1 25 x 50mm hexhead gr 10 9 1 BUCKET LEVEL INDICATOR ROD 8 12mm x 1 25 x 55mm hexhead gr 10 9 3 BUCKET PIVOT PIN 1 0 x 4 00 2 50 13 x 4 00
21. ck out of pile For maximum loading efficiency minimize angle of turn and distance between the loading and unloading points OPERATION asin Fini iit al ni V rtm et AX NSS SNS NIM ISMI SSS TSS SSS ME 27 OPERATION Transporting Material Transport material to Unloading Point with loader bucket as low as possible to prevent spillage and maintain maximum Tractor Loader stabilitv During transport the loader should not be position that will impair operator s vision Safetv e Avoid any overhead wires or obstacles when loader is raised to avoid damage or possible death bv electrocution Aloadedbucketshouldbe transportedin alow position at slow ground speeds especiallv if the ground is irregular Make turns slowly and use the tractor brakes cautiously A full bucket in the raised position alters the center of grav ity location of the unit and increases the pos sibility of mishaps Do notlift or carry personnel on a loader or attachment a slip or fall could cause serious injury Operate at slow ground speeds especially on 6774 irregular ground to avoid tipping Unloading As the tractor approaches the Unloading Point raise the loader to the height required for clearance to Dump bucket Do not raise loader higher than required for dumping Clearance As Dumping clearance height incre
22. cket and cause 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 turn or stop 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 and equipment damage When descending a slope disengaging the clutch or shifting to neutral can cause loss of control that may result in severe personal injury Never use individual brakes during front loader operation Use of individual brakes during front loader operation can cause abrupt movements of the tractor causing severe personal injury or equipment damage Be sure to follow instructions below whenever applying the tractor differential lock during front loader use Do notapply the tractor differential lock while turning use the differential lock only Wong driving in a straight line Never apply the tractor differential lock on paved surfaces To avoid injury to yourself and others before leaving the front loader unattended ALWAYS Park on level ground Lower the front loader bucket flat to the ground Disengage the front loader drive system Lock the parking brake Stop the engine Remove the key If you find it
23. cted to prevent contamination is recommended that all cvlinder packings be replaced during cvlinder assembiv Order seal repair kit to obtain all sealing components that should be replaced during hvdraulic cvlinder overhaul Cvlinder Disassembiv Refer to illustration for component identification Drain all oil from cvlinder end cap turn counterclockwise Install a plug in base end port of cylinders and pop out rod packing set by applying air pressure to the rod end port of cylinders Do not apply air pressure to base end port of cylinder As rod may extend causing injury Safety glasses should be worn when performing this operation 37 SERVICE Ensure hands and face are kept clear of end of cvlinder With rod packing set out of cvlinder remove the retaining wire located approximatelv 1 1 4 in from end of cvlinder bodv bv pressing on one side to force the retaining wire 90 out of the groove and pull retaining wire out of cvlinder bodv Pull cvlinder rod out of cvlinder bodv Secure the cvlinder rod in a bench vise bv the end eve of the rod Do not clamp on the chromed finish section of the rod Remove piston assembly lock nut and pull piston assembly from rod Remove piston seal and backu ps from piston Clean all parts for inspection Inspection Inspect cylinder body for evidence of scoring and pitting Replace cylinder body if excessive pitting scoring is evident Inspect cylinde
24. der and it must stay with the Loader if resold Safety Messages Your safety and the safety of others are very important We have provided important safety messages in this manual and on the front loader Please read these messages carefully A safety message alerts you to potential hazards that could hurt you or others Each safety message is preceded 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 Vou KILLED or SERIOUSLV HURT WARNING you don t follow Instructions CAUTION You CAN be HURT if you don t follow Instructions Each message tells you what the hazard is what can happen and what you can do to avoid or reduce injury Damage Prevention Messages You will also see other important messages that are preceded 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 may 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 Compact Tractor Dealer TABLE OF CONTENTS ee ee eee eee 4 4 3 ate Operat
25. dy O ring grooves Coat O rings with clean hydraulic oil prior to installation Extreme care must be taken to ensure O rings are not damaged during installation Valve Spools Assemble spool return springs on valve spools if they were removed previously Install detent body on float spool Coat valve spools with clean hydraulic oil and carefully install in valve body Extreme care must be taken during valve spool installations to ensure O damaged Float valve spool is installed in valve body adjacent to return port SERVICE Install end cap on detent body Install detent balls springs and plugs Install support spring spacer and end on valve body bucket cylinder spool Torque hardware to 2 3ft Ibs Relief Valve Install sealing washer seat poppet spring cup and body Screw in relief valve adjustment screw until the spring just begins to compress and install crushwasher hex nut second crushwasher and cap Relief valve adjustment is made following control valve installation as described under Relief Valve Adjustment Control lever and hydraulic connections Install single lever control linkage as illustrated Install adaptor fittings and quick disconnect couplers Inspect adaptor fitting O rings and if required Installation Mount control valve on front loader valve stand and reconnect hydraulic hoses to ports from which they were rem
26. ect hydraulic lines from control valve Cap IN and RETURN lines to prevent contamination of hydraulic system Remove control valve mounting capscrews Disassembly Refer to control valve illustration for component identification Remove quick disconnect couplings and adaptor fittings Plug all ports and thoroughly clean external areas of control valve Remove single lever control components to facilitate spool removal Relief Valve Unscrew relief valve cap followed by adjustment screw Unscrew relief valve body and remove spring cup sealing washer Load Check Valve Service The spring loaded check valve is located adjacent to the bucket cvlinder spool return spring Malfunctioning is most unlikelv but contaminate can prevent free movement or reseating Remove the check valve plug to reveal the spring and poppet Wash free of contaminate and check for free movement of poppet with valve body Replace the poppet if damaged Reassemble in reverse order after valve body is clean and drav Valve Spools Priorto removal mark valve spools to ensure thev can be identified for installation in the same spool bores from which thev were removed Lift Cvlinder Spool Float Remove the detent plugs springs and balls and remove the two detent bodv mounting screws valve spool from valve body pull out from spring end of spool Remove the three valve spool O rings from the valve body and
27. g it to the customer The following checklist is a reminder of points to inspect Check off each item as it is found satisfactory or after proper adjustment is made 24 in fe Check to make sure loader is completely assembled according to assembly instructions Check all bolts to make sure they are tightened to specified torque value Inspect and if necessary lubricate all lubrication points Make sure all fittings are in place and taking grease properly hvdraulic hoses lines and fittings to make sure thev are installed and ng Make sure hydraulic hoses are properly routed and will not be damaged when the loader is raised or lowered Start tractor and lower loader and operate bucket cvlinders and make sure unit is operating properiv Check tractor hvdraulic fluid level Add hvdraulic fluid as required to fill full indicator on dipstick Refer to Tractor Owner s Manual for proper oil to be used Inflate tractor s front tires to maximum recommended pressure OPERATION OPERATION Precautionarv Notes Do not lower the edge of the bucket too low for loading Keep the bottom of the bucket level with the ground when loading NOTICE not use bucket for pushing down material with bucket cvlinders partially extended Damage to the cylinders may result Do not tip bucket cutting edge down fully extend bucket cylinders during backfilling oackgrading operation Operat
28. he fittings are leaking or if the hoses are damaged WARNING Operate the loader fromthe tractor seat only WARNING Accidental movement of control lever or leak in hydraulic system could cause main frame to drop causing Severe injury Do not stand or walk under a raised attachment SET UP INSTRUCTIONS Check the tractor hydraulic system as outlined in the tractor owner s manual When checking hydraulic system oil level the loader should be on the ground and bucket fully retracted All cylinders in retracted position Grease all loader pivot points as indicated in lubrication chart Inspect hydraulic hoses connections control valve and cylinders for leakage If oil seepage past cylinder rod is evident tighten cylinder rod packings by turning cylinder end cap 1 4 turn clockwise Do not over tighten end caps as this will reduce service life of cylinder packings Tractor tire inflation should be checked as listed in the Tractor Preparation section to ensure tire inflation is to specifications Unequal rear tire inflation can result in not being level to the ground Front tires should be maintained at maximum recommended inflation to maintain normal tire profile with added weight of loader material 23 SET UP INSTRUCTIONS Pre Deliverv Checklist After the machine has been completelv assembled and lubricated inspect it thoroughiv to be certain it is operating properly before deliverin
29. her Re check relief pressure Shut tractor OFF remove test gauge and reinstall port plug Start tractor and check for leaks 4000 PSI Test Gauge Fitting 90 Relief Valve Test TROUBLE SHOOTING TROUBLE SHOOTING This trouble shooting chart is provided for reference to possible loader operational problems Determine the problem that best describes the operational problem being experienced and eliminate the possible causes as listed by following the correction procedures For further assistance contact your dealer PROBLEM Lift and Bucket Cylinders inoperative Lift and or bucket cylinders operate in wrong direction relative to control valve lever position POSSIBLE CAUSE Low hydraulic fluid level Hydraulic hoses connected incorrectly Hydraulic hoses to from control valve blocked Loader control valve or tractor main relief valve stuck open Low system pressure supplied from hydraulic pump Control broken valve Quick disconnect coupler s are not fully connected or Flow check Hydraulic hose or tubeline blockage Cylinder piston assembly defective not sealing Control valve blockage Hydraulic hoses connected incorrectly linkage CORRECTION Check and hydraulic fluid replenish Check and correct hydraulic hose connections Check for damaged kinked hoses etc Check system pressure Refer to Hydraulic pump ca
30. ing rules 4 Operation safety 5 Hydraulic valve package installation Dader assembly 21 22 274 92 9 9 9 5 24 DPERATION teen ee ee eee ee be wee 25 dft and des 39 Hydraulic valve 41 PARTSEIST 51 WARRANTV 61 2 General Information General Information Introduction The purpose of this manual is to assist vou in maintaining and operating vour HTA FL6555 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 lilustrations and data used in this manual are current at the time of printing but due to 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 The manufacturer reserves the right to redesign and change the machine as may be necess
31. ion with front tractor wheels off the ground is not recommended Position vehicles to be loaded as near the pile as possible and in such a direction as to minimize the amount of tractor turning required to dump Do not lower the loader with the tractor engine shut off Keep the unit clean and perform regular service Observe safety instructions whenever cleaning servicing or lubricating We urge you to follow this advice Read and understand this manual as well as the Tractor Owner s Manual Remember and observe the Safety Precautions brought to your attention in this manual the tractor manual and on the machinery itself Use good common sense in the everyday operation of this unit Safety recommendations can never be all inclusive You are responsible for watching out for and avoiding unsafe conditions Never exceed the limits of a piece of machinery If its ability to do a job safely is in question Don t 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 When lowering a heavy load ease it downward slowly Never drop a loaded attachment and catch hydraulically Stopping a load after it has gained downward momentum places undue strain on the unit and may cause unnecessary damage to the loader or tractor or even worse personal injury Escaping hydraulic oil under pressure can have sufficient force to penetrate
32. ised loader make sure the loader arms are blocked in the raised position with a safety bar A suitable safety bar can be manufactured following deminsions as illustrated below AS REQUIRED Safetv Label Locations Safetv Label Locations Read all safetv labels and instructions on machine as shown below NOTE Replacement Safetv Labels can be ordered from vour dealer IMPROPER SERVICING CAN CAUSE SERIOUS INJURV OR DEATH TRACTOR TIP OVER CAN CAUSE SERIOUS INJURV OR DEAIH e Before servicing or adjustment lower loader to the ground and shut off engine Relieve hydraulic pressure before disconnecting oil lines e Add recommended wheel ballast and or counterwelghts for stabil T to om proper ievel and prevent damage Drive and tum tractor at slow transporting loads p an incilne or rough terrain e Put loader on ground when parked Read and rr anrang all instructions in operators manual before operation Loader boom must be down and bucket cylinders fully retracted when checking fluid level NORE WHEN MOWER DECK IS INSTALLED WITH FRONT LOADER UFT LINKAGE MUST READJUSTED TO PREVENT DAMAGE THE UFT REFER TO OPERATOR S MANUAL FOR ADJUSTMENT INSTRUCTIONS LOADS CAN FALL FROM BUCKET CAUSING SERIOUS INJURY OR DEATH improperly handling heavy objects can cause the tractor To toll fip ovet or can
33. kage and repair if worn defective Refer to Aeration of hydraulic fluid Check coupler s Repair or replace Check hoses and tubelines for evidence of restriction Check cylinders for leakage described in service section under cylinder leakage tests Check relief valve setting as described under relief valve test Replace control valve and recheck operation Refer to hydraulic pump Capacity inadequate PROBLEM inadequate lifting capacity Aeration of hydraulic fluid generally indicated by foamy appearance of fluid System relief valve squeals POSSIBLE CAUSE Engine RPM too slow Excessive load material weight exceeds specified loader capacity Relief valve setting below specifications Lift cylinder piston assembly leakage Control valve leaking internally Hydraulic pump defective Lower hydraulic fluid level Air leaking into suction side of hydraulic pump Hydraulic fluid foaming due to improper hydraulic oil usage Cold hydraulic fluid Excessive load in bucket Weight exceeds specified loader capacity Relief valve setting below specifications Hydraulic hose tubeline or quick disconnect coupler restriction connections TROUBLE SHOOTING CORRECTION Increase engine RPM Reduce load Check relief valve setting as described under relief valve test Check cylinders for leakage as described in service section under cylinder leakage tests
34. ly 1 200 1 400 R P M for initial cycling of loader Operate all hydraulic cylinders to purge air from loader hydraulic system Re check hydraulic oil level with all hydraulic cylinders fully retracted Add recommended oil as required to return hydraulic oil to proper level as instructed in tractor owner s manual Install loader bucket and bucket level indicator in the second hole from the top NOTE Longest bucket pin is used to attach bucket level indicator Cycle Lift and Bucket Cylinders with bucket empty several times to seat in cylinder components Inspect all hydraulic connections for evidence of leaks Check hydraulic hose routings to ensure adequate clearances exist between hoses and adjacent components Before using loader for the first time cycle lift and bucket cylinders to purge air from cylinders and hydraulic system Air in hydraulic system can cause unexpected fall of loader boom causing injury or damage to loader or tractor The tractor loader should only be operated with all safety equipment properly installed Operate the loader from the tractor seat only NINES Do not stand or walk under a raised attachment Accidental movement of control lever or leak in hydraulic system could cause loader boom to drop causing serious injury Make sure parked loader is on a hard level surface with all safety devices engaged to prevent loader from falling and being damaged or injuring s
35. necessary to park on a grade be sure to lock the parking brake and securely block the wheels MAINTENANCE SAFETV MAINTENANCE SAFETV 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 stop the engine and remove the key Always wear safety goggles when servicing or replacing the front loader cylinder pins Use brass drift and hammer Failure to do so could result in eye injury from possible flying metal fragments Operating 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 by moving the hydraulic control lever through all positions with the engine off Escaping hydraulic fluid under pressure can have sufficient force to penetrate the skin causing serious personal injury If injured by escaping fluid obtain medical treatment immediately Cil must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result Donottamper with relief valve settings The relief valve is factory set to the proper pressure Changing the setting can cause damage to the loader and tractor and lead to severe personal injury Alinuts bolts and fasteners must be properly secured must work beneath a ra
36. nents have been installed Unless otherwise specified refer to Torque Specification Table for torque values of hardware required for assembly Layout and identify all components prior to installation 13 SET UP INSTRUCTIONS TORQUE SPECIFCATIONS PROPER TORQUE FOR FASTENERS TORQUE SPECIFICATIONS AMERICAN Proper torque for American fasteners used on Honda equipment T DIAMETER GRADE 2 GRADE 5 GRADE 8 IN B AND 116 14 2OUNC 6 7 12 16 66 8 3 1408 Bolt Head Markings SS 3820046 2027 3 42 4469 _ AMERICAN s 7ne14UNC 3209 49 60 7065 s 7 6200 3649 5509 78808 3 amp 4 eaw 5509 85 5 120063 No LCR 9793 150 203 212 287 i 110649 170230 240929 144195 2684860 37655 TA UNF 182260 297 402 420559 i2 1 8UNC 25009 6444873 3091282 890 1077 1817 2462 BIN Um _ 1 78 1 1 47UNC 500 678 1120 1518 2013 2728 178 2382 3228 Use 75 of the specified torque value for plated fasteners Use 85 of i the specified torque values for lubricated fasteners Numbers appearing on heads indicate AS TORQUE SPECIFICATIONS METRIC Proper torque Metric fasteners used on Honda equipment Recommended Torque in Foot Pounds Newton Meter WRENCH BO
37. omeone Before disconnecting hydraulic lines relieve all hydraulic pressure by operating hydraulic control lever through all positions with engine off Escaping hydraulic oil under pressure can have sufficient force to penetrate the skin causing serious personal injury Oil must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result LONGEST BUCKET PIN 22 initial Lubrication Do not perform service maintenance Operations with loader raised off ground Lower the loader to the ground and relieve pressure in loader hydraulic lines prior to performing any service maintenance operations on the tractor or loader by operating hydraulic control lever through all positions with engine off Escaping fluid under pressure can have sufficient force to penetrate the skin causing serious injury Oil must be surgically removed within a few hours by a doctor familiar with this type of injury or gangrene may result Before applying pressure to the system be sure all connections are tight and that lines fittings and hoses are not damaged Fluid escaping from avery small hole can be almost invisible Use a piece of cardboard or wood rather than your hands to search for suspected leaks WARNING A sudden line burst could cause the main frame to drop suddenly causing damage to the tractor or loader or injury to personnel Do not operate the loader if t
38. one from the detent body Care must be taken to ensure valve body spool bores are not scratched during O Ring removal Thoroughly clean all parts Inspection Remove any nicks or burrs from valve components and inspect for evidence of excessive wear Inspect valve spools and valve body bores for excessive wear scratches or damage NOTICE If internal leakage with the valve spool s in the spring centered position has been experienced valve body and or valve spool wear damage is indicated If this condition exists the control valve assembly must be replaced Inspect lift cylinder valve spool for excessive wear in the detent area 42 RD GP Hydraulic Valve If spool does not stay in detent position or tends to be difficult to get into detent detent spool wear and or weak detent springs are indicated and suspected parts should be replaced Inspect valve spool return springs for evidence of distortion damage If valve spool s was not centering properly and valve spool slides freely in valve body weak or broken return spring is indicated Inspect relief valve spring for damage or distortion Inspect relief valve poppet and seat for wear or damage Assembly It is recommended that all O rings be replaced during valve service Referto illustration for reference to assembly Thoroughly clean and dry all parts Carefully install the O rings in the valve body spool and detent bo
39. ordered as SEAL KIT only PARTS LIST BOOM CVLINDER REF DESCRIPTION SEAL piston CVLINDER bucket 2 PISTON cvlinder BODY assly bucket cyl 1 WIRE retaining FITTING grease 1 GUIDE packing male ROD assy bucket cylinder 1 GUIDE packing female FITTING grease 1 V SEAL rubber NUT hex lock 3 4 in NF V SEAL fiber END piston WIPER rod O RING piston rod NUT cartridge RING wear piston Indicates ordered as SEAL KIT only 56 PARTS LIST m gt a 7 25 4 e Sal i rs MAIS 4 fe a e 2 PARKING LEG DESCRIPTION LEG parking PIN heading 1 2 x 3 inch Grade 1 PIN hair BUCKET LEVEL INDICATOR INDICATOR ATTACHMENT bucket level TUBE level indicator HOD indicator 57 58 LOADER BOOM ASSEMBLV DESCRIPTION BOOM assembiv GREASE fitting HINGE assembly CARRIAGE BOLT BUCKET cylinder BOOM cylinder PARTS LIST PARTS LIST LOADER SUB FRAME LOADER BRACKET SIDE RAIL SIDE RAIL L REAR BRACKET R REAR BRACKET L 59 PARTS LIST LABELS WHEN MOWER DECK IS INSTALLED WITH FRONT LOADER LIFT LINKAGE MUST BE READJUSTED TO PREVENT DAMAGE
40. osition to retract cvlinders and check for evidence of oil leakage past the rod packing set external leakage On cylinders that have been in service rod packing set leakage is usually indicated accumulation of dirt oil at rod end of cylinder body If oil leakage is evident shut tractor off and turn cylinder end cap 1 4 turn clockwise to tighten gland packing set seals Recheck for cil leakage and repeat tightening procedure until oil leakage stops NOTICE Rod packing set seals should not be over tightened as this will reduce service life If leakage cannot be stopped excessive wear or damage or rod packing set component s is indicated and the cylinder s should be removed and disassembled for inspection and repair Inspect cylinder rod for pitting deterioration or damage to the chrome finish Any excessive damage to the chrome finish reduces the ability of the rod packing set to seal properly rod packing set tests are satisfactory proceed piston seal assembly leakage test 40 Piston Seal Assembly Leakage Test With cylinders in the fully retracted position and tractor shut off disconnect the hydraulic lines from the base end port of cylinders Route a hydraulic hose from the cylinder base end ports to a container to catch oil during leakage test Start tractor and place loader control valve lever in the position to retract cylinders and hold Check for oil leakage from base end
41. oved Referto hydraulic system schematic diagram to check that hydraulic connections are correct Relief valve setting should be adjusted immediately following installation start up as described under relief valve adjustment 43 SERVICE Hvdraulic Valve Installation continued Check for hvdraulic leaks and ensure hose routings do not result in hvdraulic hoses rubbing or catching on adjacent tractor loader components Relief Valve Tes Adjustment Safety glasses should be worn when performing this adjustment Install a 0 4000 PSI test gauge into the unused loader control valve pressure port IN otart tractor and run engine at operating speed to bring hydraulic fluid up to normal operating temperature With engine at governed R P M shift loader control valve bucket cylinder spool to fully retract bucket cylinders and hold in this position to obtain hydraulic system relief pressure Observe pressure reading on test gauge NOTICE Do not maintain hydraulic system at relief pressure for more than 10 second intervals to prevent overheating of hydraulic system Adjust relief pressure to specification by removing relief valve cap loosening locknut and turning adjustment screw IN clockwise to increase relief pressure OUT counter clockwise to decrease relief pressure Refer to Loader Specifications for relief valve setting Re torque locknut and reinstall relief valve cap and crushwas
42. pacity inadequate Check system pressure Refer to Hydraulic pump capacity inadequate Inspect Repair as required Check coupler connections Replace coupler s if necessary Check for evidence of damage to hose or tube lines that would block flow of oil between cylinders and control valve cvlinders for internal leakage as described in service section under cylinder leakage tests Inspect for blockage Disassemble if necessary Correct hydraulic hose connections 45 TROUBLE SHOOTING PROBLEM Slow or erratic Lift 46 POSSIBLE CAUSE Low hydraulic fluid level Cold hydraulic fluid Engine R P M too slow Hydraulic pump R P M too slow Excessive weight in bucket Material weight exceeds maximum specified loader capacity Control valve linkage binding defective Aeration of hydraulic fluid Quick disconnect coupler restriction or coupler flow check Hydraulic hose or tubeline restriction hoses tubeline kinked or pinched Lift cvlinder piston assembiv linkage Relief valve erratic or set below specifications Control valve leaking internally Bypassing fluid within valve Inadequate hydraulic pump Capacity CORRECTION Check replenish hydraulic fluid Allow hydraulic system to warm up to operating temperature Increase engine speed to obtain satisfactory loader operation Reduce material loads Check control valve lin
43. port of cylinder A constant dripping or very slight flow of oil is normal If a steady flow of oil is evident excessive wear or damage of the piston seal is indicated and the cylinder s should be removed and disassembled for inspection and repair If piston seal leakage test in retract position indicates piston seal is satisfactory reinstall hydraulic hoses and dully extend cylinders to perform test in extend position With cylinder in the fully extended position and tractor shut off connect hydraulic lines to base port and disconnect the hydraulic lines from the rod end port of cylinders Route a hydraulic hose from the cylinder rod end ports to a container to catch oil during leakage tests Start tractor and place loader control valve lever in the position to extend cylinders and hold Check for oil leakage from rod end port of cylinders A constant dripping or very slight flow of oil is normal If a steady flow of oil is evident excessive wear or damage of the piston seal Is indicated and the cylinder s should be removed and disassembled for inspection and repair SERVICE Hvdraulic Valve Detent Float Repair Kit Load lt Orifice Plate Repair Kit Relief Valve Repair Kit 41 SERVICE Hydraulic valve Control Vaive Removal Prior to removing control valve ensure loader is on the ground and all hydraulic lines are relieved of oil pressure Label and disconn
44. profile with added weight of loader material CAUTION The tractor loader should only be operated with all safety equipment properly installed 35 LUBRICATION AND MAINTENANCE ITEM Hydraulic System Oil Level Hydraulic System Oil Filter Tire Inflation Loader Pivot Points Loader Hydraulic Lines Hoses Connections Lift and Bucket Cylinder Rod Packings NOTICE Rod Packing Sets should be reset after 10 Hours of operation See Cylinder Assembly Maintenance Section Pivot Pin Clips Subframe Hinge Clamping Bolts Loader Mount Hardware 36 SERVICE Check Replace Check Lubricate Check for leaks wear Check for Seepage Service as described under Lubrication Maintenance Operations Check Replace if missing Check necessary Retorque if Check visually Re torque INTERVAL Daily 10 Hours As specified in Tractor Owners Manual Weekly 50Hours Daily 10 Hours Daily 10 Hours Daily 10 Hours Daily 10 Hours Weekly 50Hours Weekly 50 Hours Every 200 Hours SERVICE Body Assembly Locknut Piston End 69 O ring Wear Ring LI Piston Seal A Retaining Wire Wear Ring 5 Packing Guide 2 Q Male Rod Packing Set N Packing Guide Female kl Rod Wiper End Cap Rod Bushing Insert SERVICE Lift and Bucket Cvlinder General Lift and bucket cvlinder ports should be capped at all times when hvdraulic hoses are disconne
45. r Install dust caps and plugs Start the tractor and carefully back out of the loader 32 ue cm Jl Storage End of Season If loader is to be dismounted from the tractor during storage make sure the parking areais on hard level ground Cap all hydraulic hoses to prevent contamination Store loader in a dry sheltered area if possible Thoroughly clean the loader of all accumulated dirt and grease Completely lubricate the loader as specified in Lubrication section of this manual Using an oil soaked cloth lubricate all hydraulic cylinder rods to protect them from rust and corrosion Repaint any areas where paint is worn or damaged Wear areas on bucket should be coated with grease to prevent rust or corrosion Replace any Safety or Warning Labels that are not readable due to wear or damage Replace any damaged or worn parts MIE To Prevent Accidents do not allow children to play on or around the tractor or loader Remove sub frame if required for other attachments See sub frame installation removal section LOADER REMOVAL AND INSTALLATION Beginning of Season Thoroughly clean the loader of all accumulated dirt and grease If removed from tractor for storage remount loader per procedure in this manual Completely lubricate the loader per Lubrication section of manual Make sure all fittings are taking grease properly Clean with solvent any exposed
46. r rod for evidence of pitting or plating deterioration through the section of the rod that contacts the rod packing set Inspect cylinder rod and body end eyes and bushings for wear The steel bushings should fit snugly in the end eyes Inspect end eye grease fittings and replace if damaged Inspect cylinder packing guides and piston Replace any components that exhibit excessive wear or damage Cylinder Assembly Clean and dry all cylinder components thoroughly Place cylinder end cap on cylinder rod followed bv rod packing set and retaining wire Refer to illustration for reference to component orientation and sequence 38 Assemble piston seal and backups or piston and install piston assembiv on cvlinder rod refer to illustration for reference to component orientation Install Locknut and torque to 225 ft Ibs Coat piston assembly with clean hydraulic oil and with the cylinder body supported in a bench vise carefully install cylinder rod in cylinder body Care must be taken to ensure piston seal is not damaged during installation Install the retaining wire in the cylinder body Coat rod packing set components with clean hydraulic oil and position in cylinder body Install cylinder end cap and tighten until rod packing set components are snug Do not over tighten as rod packing service life will be reduced Rod packing sets should be reset by tightening cylinder end cap 1 4 turn after the initial 10 hour
47. s of cylinder operation Install dust plugs in cylinder ports Lift and Bucket Cvlinder Leakage Test BASE END PORT 8Xx Piston Assembiv General Safetv glasses should be worn when performing cylinder leakage test When performing cylinder leakage tests the tractor engine should be operating at medium R P M to ensure the hydraulic system reaches the relief valve setting During tests the system relief valve governing maximum pressure to the loader cylinders will be open system is at relief valve setting NOTICE Do not maintain hydraulic systemat relief valve setting pressure for more than 20 second intervals to prevent overheating hydraulic system The test procedures outlined enable the cylinders to be checked for rod packing set leakage external leakage and piston seal leakage in both direction internal leakage SERVICE Packing Set Test Procedure Lower loader to the ground shut tractor off and disconnect cvlinders as follows Lift Cvlinder Test Disconnect from Sub frame Rod End Bucket Cvlinder Test Disconnect from bucket rod end Support the cvlinders to prevent excessive strain on hvdraulic hoses in a position that will allow the cvlinders to be completelv extended 39 SERVICE Lift and Bucket Cvlinder Leakage Test Rod Packing Set Leakage Test Start tractor and retract cvlinders completelv Continue to hold control valve leverin p
48. sembly onto the rear mount Shut the tractor OFF and secure the loader assembiv hinges Start the tractor raise the loader off the ground and position bucket cutting edge vertical to ground Lower loader to position bucket cutting edge on ground and shut tractor off Remove the parking leg and place in storage position Lubricate all loader pivot pins 34 LUBRICATION AND MAINTENANCE Do not perform anv Service Maintenance operations with loader raised the off ground For additional access to tractor components remove loader Lower the loader to the ground and relieve pressure in loader hvdraulic lines prior to performing anv service maintenance operations on the tractor or loader 44 WARNING i Escaping fluid under pressure can have sufficient force to penetrate the skin causing serious injurv Before disconnecting lines be sure to relieve all LUBRICATION AND MAINTENANCE accidental movement of control lever or leak in hvdraulic svstem could cause main frame to drop causing serious injurv Do not stand or walk under a raised attachment Check the tractor hvdraulic svstem as outlined in the Tractor Owner s Manual NOTICE When checking hvdraulic svstem oil level the loader should be on the ground and bucket fully retracted All cylinders in retracted position Grease all loader pivot points daily 10 hours Inspect hydraulic hoses connection control valve and c
49. single lever control on the hvdraulic valve assembiv following instructions included with valve 2 Ensure the orifice plate is installed in the hvdraulic valve as illustrated 3 Position the hvdraulic valve assembly onto the valve stand and secure using two 1 4 20 hex nuts 4 Install the valve stand on the right side of the loader sub frame Secure with two 5 16 18 1 capscrews 5 16 lockwashers and 5 16 18 hex nuts 19 SET UP INSTRUCTIONS Connect the two 5 8 38 hoses to the loader hydraulic valve IN and OUT ports as shown Install a quick disconnect coupler female end and dust plug onto the 38 hose connected to the loader hydraulic valve OUT port Install a quick disconnect coupler male end and dust plug onto the 38 hose connected to the loader hydraulic valve IN port Attach two 18 hydraulic hoses and two 20 hydraulic hoses between loader hydraulic valve and steel hydraulic tubes as indicated Note Two 20 hoses install between F H ports 20 and two upper steel tubes Note Installation of hydraulic hoses to steel tubes will be easier if you a Loosen the retainers securing the steel b tubes to the loader arm Install hydraulic hoses to steel tubes beginning with bottom tube and working toward the top Tighten the hoses to the Steel tubes as they are installed Re secure the steel tubes to the loader arm using the retainers SE
50. surfaces which had been coated with grease Wipe dry with a clean cloth then lubricate with an oil soaked cloth Tighten any bolts that have been loosened and make sure all pins and retainers are in place Start tractor and operate loader to make sure it is operating properly and all the hoses are properly connected Check hydraulic fluid level in tractor and fill as required Use oil recommended in tractor owner s manual Make sure hydraulic hoses lines and fittings are in good shape and not leaking Replace or repair as required Review safety precautions and operation sections of this manual 33 LOADER REMOVAL AND INSTALLATION Loader Installation install sub frame if removed See sub frame installation section Carefully drive the tractor into the loader to a position where the hvdraulic hoses can be connected to the tractor control valve Note The tractor front mount should be aligned with the loader front crosstube Shut the tractor OFF and connect the hydraulic couplings to the tractor Start the tractor and drive ahead slowiv to position the loader front crosstube into the tractor front mount Note Activate the bucket cvlinders and lift cvlinders as required to align the loader crosstube front mount and tractor front mount Shift the loader control valve into the Float position With the loader assembly secure in the tractor front mount extend the bucket cylinders to lower the loader as
51. the tractor loosely install each side three 1 2 lockwashers and 1 2 13 hex nuts onto the welded studs no flat washers 14 Secure the Rear Rails to the Loader Bracket as follows in the two rearmost holes of the Loader Bracket each side loosely install from inside to outside two 1 2 13 x 2 capscrews with 1 2 flatwashers Loosely retain each capscrew with 1 2 flatwashers 1 2 lockwasher and 1 2 13 hex nut In the remaining five holes each side loosely install from inside to outside a 1 2 13 x 2 capscrew with 1 2 flatwasher Loosely retain each capscrew with a 1 2 lockwasher and 1 2 13 hex nut 15 Torque bolts and nuts in the following order a Tighten the six 1 2 nuts three each side on the Rear Brackets Torque to 55 foot pounds 7 5 Kgm b Tighten the sixteen 1 2 13 x 2 bolts and 1 2 nuts eight each side that secure the Side Rails to the Loader Bracket Torque to 55 foot pounds 7 5 Kgm c Tighten the eight four each side 12 x 55mm capscrews securing the Loader Bracket to the tractor frame Torque to 55 foot pounds 7 5 Kgm d Tighten the eight four each side 12 x 45mm capscrews securing the Front Bracket to the tractor frame Torque to 55 foot pounds 7 5 Kgm SUB FRAME REMOVAL IS EFFECTIVELY IN REVERSE ORDER OF INSTALLATION 18 SET UP INSTRUCTIONS SET UP INSTRUCTIONS Em E HYDRAULIC VALVE PACKAGE LABEL Ae ORIFICE 1 Install the
52. this time follow instructions in the mower operator s manual and instructions on page 29 of this manual to prevent damage to mower deck and mower linkage SUB FRAME INSTALLATION AND REMOVAL 15 SUB FRAME INSTALLATION AND REMOVAL 7 Install right and left Rear Brackets onto boss of rear axle using two 12mm x 30mm capscrews and 1 2 lockwashers no flatwashers each side Torque to 55 foot pounds 7 5 Kgm 8 Place loader Bracket under tractor as shown 9 Remove the two each side loosely installed 12mm x 55mm bolts installed in step 5 Using two people one each side raise the Loader Bracket into position Align the bolt holes using a drift pin and loosely install four 12mm x 55mm capscrews 1 2 lockwashers and 1 2 flatwashers on each side 16 SUB FRAME INSTALLATION AND REMOVAL 10 Place loader Rear Rails under the transmission area as shown one each side 11 Raise the front of each Rear Rail and align the siotted holes each side with the slotted holes in the Loader Bracket Loosely install from inside to outside a 1 2 13 x 2 capscrew with 1 2 flatwasher Loosely retain the capscrews each side with 1 2 flatwasher 1 2 lockwasher and 1 2 13 hex nut 12 Raise the rear of each Rear Rail and insert the three welded studs into the Rear Brackets on the rear axle 969g o i Ee II 17 SUB FRAME INSTALLATION AND REMOVAL 13 From the rear of
53. urns and when the 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 bales logs or oil drums is not recommended These items can easily shift or roll down the loader arms causing equipment damage or severe personal injury 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 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 of the grade Turning or driving across the face of a slope may cause the tractor to overturn SAFETV Operate the front loader arms gradually by feathering the loader controls to prevent abrupt movements that could cause damage to the front loader or tractor Use added caution when working with shifting or loose loads in the front loader bucket It could cause vehicle instability or fall out of the bu
54. ylinders for evidence of leakage pressure by operating control lever NOTICE NOTICE If oil seepage past cylinder rod is through all positions with engine off Before applying pressure to the system be sure all connections are tight and that lines pipes and hoses are not damaged Fluid escaping from a very small hole can be almost invisible Use a piece of cardboard or wood rather than your hands to search for suspected leaks See a doctor at once if injured by escaping fluid Serious infection or reaction can develop if correct medical treatment is not administered immediately Referto Lubrication and Maintenance Chart for quick reference to maintenance operations CRUEL A sudden line burst could cause the main frame to drop suddenly causing damage to the tractor or loader or injury to personnel Do not operate the loader if the fittings are leaking or if the hoses are damaged Operate the loader from the tractor seat only evident tighten cylinder rod packings by turning cylinder end cap 1 4 clockwise Do not over tighten end caps as this will reduce service life of cylinder packings Tractor tire inflation should be checked at recommended intervals as listed in the tractor owner s manual to ensure tire inflation is to specifications Unequal rear tire inflation can result in bucket not being level to the ground Front tires should be maintained at maximum recommended inflation to maintain normal tire
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