HONDA FL5540K0 User Manual

40PERATOR'S

A

MANUAL

J

Front Loader

Model

for

I

Multi-purpose Tractor

Honda H5518A4

FL5540KO

I

Thank you for purchasing an HTA Front Loader attachment for your tractor. This manual covers the assembly, operation and maintenance of the HTA

for the troubleshooting section and warranty service information.

Read this manual and the owner’s manual

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 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

H5518 A4 Multi-purpose Tractor. For your convenience,

forthe Honda H5518 A4 Multi-purpose Tractor before

if

resold.

Motor

Co.,

Inc. reserves the right to make changes at

it

also provides a parts guide,

FL5540 front loader

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. Please read these messages carefully.

A

safety message alerts you to potential hazards that could hurt you or others. Each safety

message is proceded by WARNING, CAUTION.

These words mean:

a

safety alert symbol and one of three words: DANGER,

You

WILL be

If you

You

tf

0

Each message tells you what the hazard is, what can happen, and what or reduce injury.

Damage Prevention

You will also see other important messages that are proceded by the word NOTICE. This word means:

I

NOTICE

Messages.

.I

You

lnstnrctlons

Your equipment

CAN

you

CAN

don’t

damaged

Using this product

Read

to

and understand this Operator’s Manual

do

so

could result in personal injury

for

a

purpose not intended can cause injury

or

equipment damage.

KILLED

follow

be

KILLED

follow

be HURT

if

you

don’t follow instructions.

before

or

SERIOUSLY

Instructlons.

or

SERIOUSLY

Instructlons.

If you

don’t

follow

you

or

other property can

or

operating

the

front

HURT

can

do

be

property damage.

loader;

to avoid

failure

If a problem should arise, or

-

authorized Honda Multi

purpose Tractor dealer.

if

you have any questions about your front loader, consult an

1

1 .GENERAL

2 . INTRODUCTION

Front loader safety Maintenance safety Safety label locations

3

.

PACKAGING INVENTORY

4 . TRACTOR PREPARATION 5 . LOADER SPECIFICATIONS

6

.

ASSEMBLY INFORMATION

Sub-frame installation/removal Front loader assembly

Operational checks

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1

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5..

PAGE

1

3

4

7

8

9

10 11

12

13 19

25

7 . OPERATING INSTRUCTIONS

8

.

LOADER REMOVAL

Storage

9

.

LOADER INSTALLATION 10 .TROUBLESHOOTING 11 . LUBRICATION and MAINTENANCE

Lubrication and maintenance chart.

12 . PARTS 13 . WARRANTY SERVICE

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27

-31

35 37 41 43 44 45

.

51

.

2

~

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

of

achieve years 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

machine will travel when in use.

The illustrations and data used in this manual are current at time of printing, but due to possible

-

line production changes, your machine may vary slightly in detail. Extra equipment that may

in be shown redesign and change the machine as may be necessary without notification.

on

dependable performance. Some information may be general in nature due

"

as

used throughout this manual are determined by facing the direction the

the machine

is

optional at extra cost. The manufacturer reserves the right to

NOTE: Illustrations used in this manual may not show

to

ensure safe operation of tractorAoader. Referto Safety Section of this 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 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 service, always remember to give the dealer the following information:

-

Correct part description or part number.

-

Model number

-Serial number of your machine.

of

your machine.

-

purpose Tractor Dealer. To obtain prompt, efficient

all

safety equipment that is recommended

it

may be necessary to know

3

FRONT

LOADER

SAFETY

FRONT LOADER SAFETY

Operating the tractor

and

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

and

front loader requires

special

efforts

on

your

part

to ensure your safety

loader.

SAFE

OPERATING RULES

Severe personal injury

(

pages

Always make pre accident

To avoid severe personal injury

25

thru

30

or

equipment damage.

All parts, especially guards and shields, should be

place.

Be sure all nuts, bolts and screws are tight.

Do

not remove any guards, warning labels, shields or safety devices; they are installed for your

saf.ety.

The tractor

-

you are also wearing the seat belt.

-

the

roll

ROPS

is securely attached and has not been modified

or

equipment damage may result

)

are not followed.

-

operation checks ( page

or

equipment damage, observe the following precautions.

over protective structure

if

the operating instructions on

25

)

before you start the engine. You may prevent an

in

good condition, and securely fastened in

(ROPS)

will only protect you from injury

or

structurally damaged.

if;

or

front

Know how to stop the engine quickly. Thoroughly understand operation of all controls.

or

Never permit anyone to operate the tractor

The tractor

loader. Keep children and pets at a safe distance during operation.

Never allow anyone to get under the front loader bucket

bucket is raised or tractor engine Always wear sturdy shoes

tractor

Be alert.

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,

is

an operator

or

the front loader.

Do

not operate the front.loader when you are tired,

worn

only

vehicle,

or

boots

or broken parts immediately.

do

is

running.

and avoid wearing bulky

front loader without proper instructions.

not allow passengers to ride on the tractor.or front

or

reach through the

or

loose clothing while operating the

ill

or

under the influence

lift

arms when the

of

alcohol

The exhaust contains poisonous carbon monoxide gas that can cause

if

and may lead to death,

the front loader

is

operated in an enclosed place.

loss

of consciousness

The use of heavy equipment andor pulling or lifting excessive loads may adversely affect

To

avoid

loss

vehicle stability or control.

-

Use only recommended tractor hitch attachment points.

-

Limit loads to those within tractor and front loader limitations as stated in this manual and in the

tractor owner’s manual.

-

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

a

increase the chance of injury in

rollover.

of control that can result in severe personal injury:

Adjust the seat belt

Be sure that the main transmission lever is in

(PTO) levers are Operate the tractor and

operating characteristics and controls.

Do

not operate the tractor or front loader until you are sure the area in front and behind

of people and pets.

Sudden stops Be especially careful during sharp turns and when front loader bucket has material in it.

Carry the front loader and front vision.

Using the front loader for handling large objects such recommended.

equipment damage or severe personal injury,

This tractor utilizes Four Wheel Steering tractors and will affect front loader operation. Practice use of the front loader

so

it is snug.

“Neutral” and the front and rear Power Take

in

the

“Off‘

position before starting the engine.

the front loader at slow speeds until you become familiar with all

of

the tractor or front loader during operation could cause the tractor to overturn.

arms at a

These items can easily shift or roll down the front loader arms causing

low

position during transport. This will enhance vehicle stability

as

round hay bales, logs or oil drums is not

(4WS). The feel of 4WS

is

slightly different from other

in

a

wide safe area.

of

is

Off

the

clear

FRONT

LOADER

SAFETY

Never operate the tractor or front loader when visibility

weather; your ability to see obstacles will become impaired. Avoid loose

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 the slope may cause the tractor to overturn. Operate the front loader arms gradually by

movements that could cause damage to the front loader Use added caution when working with shifting or loose loads

cause vehicle instability

To avoid when operating the front loader on sloping or uneven surfaces.

fill,

loss

rocks and holes. They may cause vehicle instability or cause the vehicle to

"

feathering" the loader controls to prevent abrupt

or

fall out of the bucket and cause personal injury.

of control

or

overturning, always reduce speed and exercise extreme caution

is

diminished by darkness

useage.

and

tractor.

in

the.loader bucket. It could

or

by bad

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,

To

avoid

loss

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

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

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,

-park on level ground and lock the parking brake.

of

control

or

rapidly accelerate up a sloping surface.

or

overturning, do not stop or turn on sloping surfaces.

loss

lock

only while driving

ALWAYS;

of

6

-lower the front bucket flat to the ground.

-

disengage the front loader drive system.

-

stop the engine and remove the key.

If

you find

the wheels.

it

necessary to park on a grade, be sure to lock the parking brake and securely block

MAINTENANCE SAFETY

Maintenance of the

safety

the

and

the safety of others. Know these requirements before perfoming maintenance on

tractor or front loader.

Before performing Before cleaning, inspecting or servicing the loader be sure to;

-lower the front loader bucket flat to the ground.

-move the front

-

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 objects.

Operating the front loader or the tractor with damaged,

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

this form

tractor

of

injury, or gangrene may result.

and

front loader requires

maintenance/inspections,read

PTO

to the off position

special

the instructions thoroughly.

so

could result in eye injuries from possible flying metal

efforts on your part to ensure your

worn,

or

broken parts may result in

a

few hours by a doctor familiar with

All nuts, bolts, and fasteners must be properly secured.

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.

-

AS REQUIRED

.\\

\

7

SAFETY LABEL LOCATIONS

Read these

SAFETY

LABELS

IMPROPER

SERIOUS INJURY

0

Before

lower loader to fho ground and shut off engine.

Rolleve hydraulic dlreonnecHng oil lines.

before

SERVICING

conlclng

you

CAN

OR

or

adjustment

pressure

operate the front loader.

CAUSE

DEATH

before

MCTOR

CAUSE SERIOUS INJURY

OR

a

Add

wheel

oounterwelghts rtablllly.

Ddve

tractor Place

transpomng especially on an lncllne

or

e

Put

when

TIP-OVER

DEATH

recommended

ballast and/or

and

at

loader

rough tenaln.

Mer

parked.

Read

and understand

lnstructlons

all operator‘s manual

before

operation.

for

turn

slow

speed.

low

kads,

on ground

In

CAN

when

FALL

FROM

LOADS CAN

CAUSING SERIOUS INJURY OR DEATH

BUCKET

INFORMATION

Special loader attachments handling large objects are available from agricultural suppliers.

i

for

PACKAGING INVENTORY

.............................................................................................................................................

.................

................~....,..~.....................~...~..~~..............~...~....................................................,........,,..

....................................................................

SECURED

T

PACKAGING

I

O

C

RATE

BO~OM

I

INVENTORY

................................

.

..................,....CIC.......,,

........

\

.............,...,.....

12

Required

37.5

Ibs.

I

3

j

1

..

c,,..,,..,,

...

WEIGHTS

.........,.....\,.....I..........

each

...l.l\>llll.i

.

..................................................................................................

...............................................

LARGE CARTON

1

SMALL CARTON

..........................

..

TRACTOR PREPARATION

HARDWARE BAG CONTENTS QNT'Y DESCRIPTION

5

h"

lynchpin

2 1Omm x 30mm

2

12mm x 25mm

2

%!-13Xl

16

12 3/4xl'/4

2 2 2

#11

V2-13xl3AW

98"

7/16-14Xl

lh"

clipxpin

0

flat washer

V4"

hex

hd

hex

hd

hex

hd

capscrew

ga. machine bushing

hex

hd capscrew

hex

hd capscrew

capscrew capscrew

-

2

4

6

4

4 4

2 2 2 2

1

%6"-14 7/ls"

V2"-13 l!"

1s

5/1sW-l

5/16

VIS"

5/16"-l8 13A"

54s"

#

2

nylon

hex

lockwasher

hex

flat washer

lock

washer

8

x

1

"

lockwasher flatwasher

flatwasher

hose clamp

tie

nut

hex

hd capscrew

hd

capscrews

TRACTOR PREPARATION

This loader is not intended to be used with any other attachments mounted on tractor.

REAR COUNTER WEIGHT

m-

The use of adequate rear countenveight is required for proper loader stability. Refer to Tractor Owner's Manual for specific recommendations on counterweighting tractor.

1-

DO NOT EXCEED THE RATING

REFER TO OWNER'S MANUAL PROVIDED WITH TRACTOR.

FOR

MAXIMUM

GROSS

VEHICLE WEIGHT.

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.

--Certain specific conditions may not permit safe use

or may require more carefully restricted Operation at

ROLL-OVER PROTECTION STRUCTURE (ROPS) SYSTEM

The tractor

ROPS

system must be in place and used properly to ensure adequate operator

of

loader at loader rating

the

rated load.

protection.

LOADER HYDRAULIC SYSTEM

Follow

TRACTOR

recommendations in this operator's manual for hydraulic fluid specifications.

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.

24

Ag Tire pressure

psi.

10

LOADER SPECIFICATIONS

A

-

LOADER SPECIFICATIONS

ITEM

Rated Bucket Size (width) Hydraulic cylinder Counterweights

........................

Lift

Capacity

................

..................

...........................

Sub-frame Hydraulic Pump Drive

Tractor Type

Weight w/ subframe Maximum Lift Height

Reach @ Maximum Height. Reach whucket Bucket roll Maximum Dump angle Digging Depth Below Grade

.....................

...............

.................

................

............

on

back

ground

angle

............

...............

.....

......

........

.........

........

.........

H55

18 A4 only

........

FL5540

400lb

42in (1050mm

Double acting

Suit case type 37.5lb x 12

(17.0kgx 12)

Frame mount type Front PTO coupled

-

Ag tires recommended

5501b

'A'

'B'

'C'

'D' 17'36'

'E'

'F'

(180kg)

(250kg)

72.1 in (1 837mm)

16.4in (409.3mm)

47.9in (1195.2mm)

47'31

.

3.02in (80.5mm)

)

11

ASSEMBLY INFORMATION

GENERAL

ASSEMBLY INFORMATION

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

used

on Honda equipment

Pounds (Newton Meters).

AMERICAN

Bolt Head Markings

Proper torque for American fasteners

in

Recommended Torque

Foot

SA€

Grade

(No

Dashes1

SAE

Grade 5

(3

Dashes1

METRIC

4;$d

6

Numbers appearing on bolt heads indicate ASTM class.

2

Use

75%

'

fasteners. Use for lubricated fasteners;

Proper torque for metric fasteners used on Honda equipment. Recommended Torque

of the specified torque'value for plated

85%

of the specified torque values

in

Foot Pounds (Newton Meters).

eoLT

(mm)

DIA.

5

6

8

10

12

"8"

CLASS

1.8

7.3

14.5

25

ASTY

4.0

(2.41

3

(41

(10)

(20)

(34)

74

*STY

8.8

(100)

CLASS CLASS

5.1

8.7

21.1 42

73

ASTY

9.8

(6.91

(12)

(29)

(57)

(99)

ASTY

CLASS

10.0

6.5

(8.8)

11.1 (15)

27

(37)

53

(72)

93

(126)

I

12

FL5540

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.

SUB-FRAME

and

COUNTERWEIGHT INSTALLATION/REMOVAL

--

1-d-

Never operate the tractor without

the lower cover.

INSTALLATION INSTRUCTIONS

1

C(M#ECO)IUCISWFACESBEIWEENBUWMrPrJllL

i

MOW

ME

BRAcILl

DY

3.

WHEN

1.

m

UNDBnDE

IIcHlEN

SIDE

LHWW

ME

IpAm

ISMOVEDWHLEMHL1COMRISOCFORWIJSAB3

NOT

lWITWE0

INSWING

MOUmNC

IOU&

FRAME

Io

ME

CAN

KHTr

29

BE

mofm

WE

Q)

WLR

29

ft-&

8-09

Hn

DAMACED

TopOK

RMCBl

09

TopouD.

F ME

h

TOpouO.

lpAcrop

lWIT.

Note: A second label is included with this

operator's manual. Install this label onto the

original

2.

frame

lower

cover.

Remove the drawbar and replace it with

the bottom bracket using the two

x

25mm hex

12 washers and two capscrews with

hd

capscrews

10

3%"

washers.

with

x

30mm hex hd

7/16"

NEW LOWER FRONT COVER

Torque

follows:

front

cover

and rear bracket bolts

10mm

12mm

Bolts Bolts

29

43

ft-lbs.

(29

(60

as

Nm).

DRAWBAR

BOirOM

..

. . -.

/

BRACKET

BOLTS

.

. .

13

FLS540 SUB-FRAME

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 60mm inner wall

a

clearance of approximately

(2.4in) between sub-frame and the

of

the left front tire.

and

COUNTERWEIGHT INSTALLATlONlREMOVAL

5.

Drive the tractor fomvarc

,,om the rear

the sub-frame, over the drive on plate keeping it parallel with the sub

-

frame.

o

SUB-FRAME

If

GUIDE

Page

14

SUB

-

FRAME

FL5540 SUB-FRAME

6.

Stop the tractor when the mast fixing pad

comes even with the floor board of the

tractor.

and

COUNTERWEIGHT INSTALLATION/REMOVAL

7.

Using two people, lift the sub-frame and

-

engage the pipe of sub

-

shaped channel of the bottom bracket.

U

NOTE:

Use two people to lift sub-frame.

frame into the