Koyker FLEXSTOR 1055 User manual

MANUAL NO. 686410 RevA 12/23/2010
OWNERS MANUAL
Model 1055
Grain Bag
Unloader
BE SURE THIS MANUAL IS GIVEN TO THE
PURCHASER FOR FUTURE REFERENCE

CONTENTS PAGE
Introduction ................................................................................................................... 0-3
SECTION 1 - SAFETY INFORMATION
Safety Alert Symbols .................................................................................................... 1-1
Safety Information ....................................................................................................... 1-2
Safety Decals ............................................................................................................ 1-3, 1-4
Decals ............................................................................................................................ 1-4
SECTION 2 - SPECIFICATIONS
Specifications ................................................................................................................ 2-1
SECTION 3 - FEATURES
Features ..................................................................................................................... 3-1, 3-2
SECTION 4 - OPERATION
Before Starting .............................................................................................................. 4-1
Getting Started In The Bag ................................................................................... 4-1 thru 4-13
Switching From Operation To Transportation Position ................................... 4-2 thru 4-7
Connecting The PTO ........................................................................................ 4.3
Unfold the Bag Lift Roller wings ..................................................................... 4-4
Unfold the Gathering Auger extensions ....................................................... 4-4, 4-5
Adjust the Conveyor Position Pin ................................................................. 4-5, 4-6
Preparing The Bag ............................................................................................... 4-7, 4-8
Maneuvering The GBU Into The Bag .................................................................... 4-8,
Using the GBU Drive Wheels ....................................................................... 4-8, 4-9
Using the Tractor ............................................................................................... 4-9
Connecting the bag to the spools ................................................................... 4-10 thru 4-12
Route The Bag ............................................................................................ 4-10, 4-11
Switching Trucks ......................................................................................................... 4-14
End Of Bag .................................................................................................................. 4-14
Removing The Plastic From The Spools ................................................................ 4-15, 4-16
Switching From Transportation To Operation Position ............................................... 4-17
SECTION 5 - PARTS DIAGRAM AND DESCRIPTION
Main Assembly Drawing .............................................................................................. 5-1
Main Assembly Drawing—Decals ............................................................................... 5-2
Main Assembly Drawing—Spools ............................................................................... 5-3
Main Assembly Parts List ......................................................................................... 5-4, 5-5
Frame Assembly Drawing ............................................................................................ 5-6
CONTENTS
0-1

CONTENTS PAGE
SECTION 5 - PARTS DIAGRAM AND DESCRIPTION (Cont’d)
Frame Assembly Parts List ........................................................................................... 5-7
Front Frame Assembly Drawing ................................................................................... 5-8
Front Frame Assembly Parts List ............................................................................ 5-9, 5-10
Back Frame Assembly Drawing ............................................................................. 5-11, 5-12
Back Frame Assembly Parts List ............................................................................ 5-13, 5-14
Top Auger Assembly Drawing .................................................................................... 5-15
Top Auger Assembly Parts List ................................................................................... 5-16
Bag Lift Roller Assembly Drawing ............................................................................. 5-17
Bag Lift Roller Assembly Parts List ............................................................................ 5-18
Conveyor Assembly Drawing ................................................................................. 5-19, 5-20
Conveyor Assembly Parts List ................................................................................ 5-21, 5-22
Clean Out Auger Assembly Drawing .......................................................................... 5-23
Clean Out Auger Assembly Parts List ......................................................................... 5-24
PTO Pump Hydraulics Drawing .................................................................................. 5-25
PTO Pump Hydraulics Parts List ................................................................................. 5-26
Hydraulic Drawing .................................................................................................. 5-27, 5-28
Hydraulic Parts List ........................................................................................... 5-29, 5-30, 5-31
Electrical Drawing ....................................................................................................... 5-32
Electrical Parts List ...................................................................................................... 5-33
SECTION 6 - SERVICE
General Information ...................................................................................................... 6-1
Hourly Service Schedule ............................................................................................... 6-2
Torque Specifications ................................................................................................... 6-3
Grease Zerk Identifier ............................................................................................ 6-4 thru 6-7
SECTION 7 - TROUBLE SHOOTING
Trouble Shooting ...................................................................................................... 7-1, 7-2
SECTION 8 - OPTIONAL KITS
Extension Kit Assembly Drawing ................................................................................ 8-1
Extension Kit Assembly Parts List ............................................................................... 8-2
SECTION 9 - LIMITED WARRANTY INFORMATION
Limited Warranty .......................................................................................................... 9-1
Warranty Limitations and Exclusions ....................................................................... 9-2, 9-3
CONTENTS
0-2

INTRODUCTION
0-3
The purpose of this manual is to explain the operation and maintenance of the Model 1055
Grain Bag Unloader. It also contains a parts list for reference, if replacement parts are needed.
It is recommended that you read this manual in its entirety for the information available in
order to provide the proper care and maintenance of the Model 1055 Grain Bag Unloader. The
Equipment is built to provide many years of dependable service when used properly. Reading this
manual will also provide information on how to use the equipment correctly to prevent any
accidents while using the system.
If you have any further questions, comments, improvements or suggestions regarding the
contents of any of the manual provided, please contact your dealer.
ALL safety decals are no charge from the factory. Please replace all safety decals if damaged
or missing. Your safety is important to us.

The symbol shown below is used to call your attention to instructions concerning your
personal safety. Watch for this symbol it points out important safety precautions. It means
ATTENTION! Become Alert! Your Personal Safety Is Involved!
Read the message that follows and be alert to the possibility of personal injury or death.
DANGER: Indicates an imminently hazardous situation that, if not avoided, will result in death or
serious injury. The color associated with Danger is RED.
WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or
serious injury. The color associated with Warning is ORANGE.
CAUTION: Indicates a potentially hazardous situation that, if not avoided, may result in minor or
moderate injury. The color associated with Caution is YELLOW.
WARNING! Anyone who will be operating or working around the
equipment should first read this manual to familiarize
themselves with the machinery.
SECTION 1 - SAFETY INFORMATION
1-1
SAFETY ALERT SYMBOLS
DANGER
CAUTION
WARNING

SECTION 1 - SAFETY INFORMATION
A careful operator is the best operator. Most accidents can be avoided by observing certain
precautions. To help prevent accidents, read the following precautions before operating this
equipment. Equipment should be operated only by those who are responsible and instructed to do
so. Carefully review the procedures given in this manual with all operators. It is important that all
operators be familiar with and follow safety precautions. Improper use of the equipment can cause
serious injury or death.
1-2
8. Never enter the bag while the machine is
in operation.
9. Be sure the tractor meets the minimum
requirements required to operate the
equipment.
10.Observe all safety recommendations in
operators manual.
Servicing the Grain Bag Unloader.
1. DO NOT work around the equipment in
loose clothing that might catch in any
moving parts.
2. DO NOT clean, lubricate or adjust the
equipment while it is running. Park the
tractor on level ground, turn the engine
off and set the parking brake or block the
wheels.
3. DO NOT use your hand to check for
leaks. Use a piece of cardboard or paper.
Note: Escaping hydraulic fluid under
pressure can penetrate the skin, caus-
ing serious injury.
6. Inspect the hydraulic hoses regularly for
signs of wear, leakage and impending
failure. Take appropriate action to pre-
vent unexpected hydraulic failure.
REMEMBER: All reasonable means for
accident prevention have been provided
except a safe and careful operator.
Transporting the Grain Bag Unloader.
1. Be sure the Conveyor, main auger, roller
wings and gathering augers are in
transport position.
2. NEVER transport the machine with the
main auger in operation position.
3. Be sure the wheel lockouts are in the free
position.
4. Be sure the PTO shaft is stored properly.
5. Never allow riders on the machine while
transporting.
Operating the Grain Bag Unloader.
1. Read the operator’s manual before oper-
ating equipment.
2. Stay clear of auger while raising, lower-
ing, moving left or moving right.
3. Ensure PTO is properly installed prior to
operation.
4. Disengage tractor parking brake prior to
operation.
5. Stand clear of Grain Bag Unloader
wheels, spools and augers while in oper-
ation.
6. Keep hands, feet and clothing away from
moving parts.
SAFETY

SECTION 1 - SAFETY INFORMATION
SAFETY DECALS
1-3
P/N 680292
P/N 666943
P/N 682785 P/N 687218
P/N 686415

P/N 687344
SECTION 1 - SAFETY INFORMATION
SAFETY DECALS
1-4
P/N 687358
P/N 686419
P/N 686418

SECTION 2 - SPECIFICATIONS
2-1
FLEX-STOR GRAIN BAG UNLOADER 1055
Capacity* .................................................................................................... 8000 BU/HR
Hitching ..................................................................................................... Trailer or 3 pt
Overall Transport Size
Length .................................................................................................................... 19’ 5”
Width ....................................................................................................................... 8’ 6”
Height .................................................................................................................... 10’ 2”
Tractor Requirements
HP Minimum ......................................................................................................... 90 HP
PTO .................................................................................................. 540, 1 3/8” 6 Spline
3 pt Hitch** .................................................................................................. Cat II or III
Hydraulic Outlets *** .................................................................................................... 1
Hydraulics Pressure Minimum ........................................................................ 1800 PSI
Hydraulic Flow Minimum ................................................................................. 15 GPM
Main Auger
Size ............................................................................................................................ 17”
Unloading Height ................................................................................................ 12’ 10”
Unloading Reach ..................................................................................................... 9’ 3”
Oil Tank
Capacity ................................................................................................................. 32 gal
Oil Type ................................................................................... Mobil 424 or Equivalent
Main Auger Gear Box
Type ................................................................................................ 1:1 Straight Bevel T
Capacity .................................................................................................................. 72 oz
Oil Type .............................................................................. AGMA 5EP Gear Lubricant
Spool And Wheel Gear Box
Type ........................................................................... 50:1 Right Angle, Hollow Output
Capacity .................................................................................................................. 56 oz
Oil Type ....................................................................................................... EP 85W140
Cylinders
Auger Lift Cylinder ....................................................................... 4” Bore x 14” Stroke
Auger Swing ............................................................................... 2.5” Bore x 36” Stroke
Bag Lift Roller ................................................................................. 3” Bore x 8” Stroke
Hydraulic Motors
Clean out & Charge Auger ................................................................................... 230 cc
Spools & Wheel Drive .......................................................................................... 195 cc
Conveyor ............................................................................................................... 280 cc
NOTES:
*Capacity will vary depending on the type of grain, moisture content and system hydraulic
pressure.
**A Cat II or Cat III Narrow quick hitch will make connecting the machine quicker and
easier.
*** A continuous flow of hydraulic pressure is required. A minimum of 15 GPM at 1800
PSI is needed for the equipment to operate properly
Specifications are subject to change without notice and without liability.

SECTION 3 - FEATURES
3-1
INITIAL SETUP:
The Flex-Stor Grain Bag Unloader
1055 requires no additional setup prior
to operation. The Base Unit is shipped
from the factory completely assembled.
TWO TYPES OF HITCHING:
There are two types of hitches on the
GBU 1055, a drop down trailer hitch
and a 3 pt hitch. The trailer hitch should
be used for transporting and aligning
the Unloader with the bag. The 3 pt
hitch is used during the Grain Bag Un-
loading process.
NOTE: Due to the weight of the GBU 1055,
you will not be able to lift the ma-
chine using the 3 pt hitch. It is rec-
ommended to use the trailer hitch
during transport
FOLDING GATHERING AU-
GERS AND BAG LIFT ROLLER:
The gathering auger extensions and bag
lift roller wings easily fold from opera-
tional to transport position. The GBU
will fold to a width of 8’ 6”, making
transport more convenient.
SELF CONTAINED HYDRAULIC
SYSTEM:
The PTO Pump runs the conveyor,
clean out auger and charge auger. By
having this system separate, the require-
ments for the tractor hydraulics is great-
ly reduced. A smaller, more economi-
cal tractor can be used.
OPERATORS STATION:
The operators station contains the func-
tion control valve manifold, conveyor
cutout ball valve and conveyor pressure
gage. The operator has easy access to
all the functions in one location.
FUNCTION CONTROL VALVE
MANIFOLD:
The function control valve manifold is
were the operator controls the truck au-
ger fold, truck auger swing, bag lift roll-
er, wheel direction, wheel speed, wind-
er direction and winder speed.
CONVEYOR SHUT OFF VALVE:
The conveyor shut off ball valve shuts
off the conveyor, clean out auger and
charge auger allowing the truck auger
to empty before disengaging the tractor
PTO. It reduces the load during PTO
engagement.
BI–DIRECTION UNLOADING:
The truck auger will swing left and
right letting you choose which side of
the bag you want to unload on. This
gives the operator more flexibility and
versatility in choosing a site and layout
for your bags.
CHARGE AUGER:
The charge auger is located in the hop-
per. It moves the grain mechanically
from the conveyor to the main auger.
The auger increases the capacity and
eliminates a bottle neck.
CLEAN OUT AUGER:
The clean out auger prevents grain
build up between the gathering augers
and the horizontal frame guide roller.
FLOATING CONVEYOR:
The conveyor floats up and down. The
conveyor will float over uneven ground
and without digging in allowing the
gathering augers to be positioned closer
to the ground.

SECTION 3 - FEATURES
3-2
DUAL BAG CUTTING KNIVES:
The bag is cut on both the top and bot-
tom by two straight edge sickle sec-
tions. Replacement of the a dull blade
is easy and inexpensive.
BAG CUTTING LOCATION:
The bag is cut 3 ft behind were the
grain is being removed from the bag,
which reduces the possibility of the bag
ripping open down the length of the
bag.
DUAL SPOOLS:
The bag is split in half and then rolled
up on two spools, making the empty
bag easier to handle.
PLASTIC PUSH CYLINDERS:
The Plastic push cylinders remove the
plastic from the spools in a tight roll.
Unlike the competitors who have to un-
wind the plastic off the spool and deal
with the big mess of lose plastic. The
rolls are tight and compact for easier
handling and disposal.
WHEEL DRIVE:
The wheel drive allows you to lock in
the wheels to help assist the machine to
drive into the bag. This allows for a
one man operation. You will not need
an operator in the tractor backing up the
machine.

SECTION 4 - OPERATION
4-1
BEFORE STARTING:
 Make sure all operators have read the
manual and are aware of the operating
procedures and hazards associated
with the Grain Bag Unloader 1055.
 Ensure the appropriate maintenance as
indicated by the schedule on page 6-2
has been completed.
 Select a tractor appropriate in size and
hp (see page 2-1) to operate the Flex-
Stor Grain Bag Unloader 1055.
GETTING STARTED IN THE
BAG:
 Start the Grain Bag Unloading process at
the end of the bag where the storage
process was finished. If any extra length
of bag was left during the storage process,
starting the unloading process will be
easier.
NOTE: It is possible to start from the other
end of the bag (the bull nose end),
but it will require the removal of a
large amount of grain before being
able to use the GBU.
 Back the GBU into position at the end of
bag were the bagging process was
finished, making sure it is centered.
NOTE: It will be easier to maneuver the
GBU into position by using the
trailer hitch.
Leave roughly 10 ft between the
GBU and the bag. This will ensure
there is enough room to switch the
GBU from transport to operation
position.
 SWITCHING FROM
TRANSPORT TO OPERATION
POSITION:
DANGER: Make sure to block the tires to
ensure the Grain Bag Unloader will
not roll during the switching process.
1. Using both implement jacks, raise the
front of the GBU, removing its weight
from the hitch.
2. Remove the hitch pin.
CENTER OF BAG
Implement Jack
(There is one on both
sides)
Bull Nose End Finish End
Start From This End

SECTION 4 - OPERATION
4-2
3. Remove the two pins holding the hitch
top tube in place.
4. Place the top tube into its operation
position and install the pin.
NOTE: Two people are required for
switching the hitch from transport to
operation position safely.
5. Have one person hold the hitch will the
other pulls the tractor ahead a few feet.
Hitch Top Tube
Remove Pins
Install Pin
Securing Bracket
Hitch Top Tube
6. Lift the hitch up to its operation position
and install the pin.
7. Connect the tractor to the GBU using the
3 pt hitch.
NOTE: The front of the GBU may need to be
raised or lowered to align it with the
tractor.
Install Pin
3 pt Hitch Points

NOTE: There are three holes for the top link
pin. Use the appropriate hole for the
type of Cat and method.
For use on Cat III hitches, bushings
are needed the lower link arms along
with a new top link pin. Both these
items are not supplied with the GBU.
See dealer for parts.
When using a Quick Attach 3 pt
Hitch, the front of the GBU may
need to be raised or lowered to align
it with the tractor.
8. Adjust the tractor 3 pt top link so the
GBU is level from front to back.
9. Turn both implement jacks to Transport
position.
10. Connect the PTO drive shaft.
a) Remove the PTO bracket pins.
b) Lift the securing plates up.
SECTION 4 - OPERATION
4-3
c Remove the PTO Shaft from the
transport storage brackets and
connect it to the GBU.
d Connect the other end of the PTO
to the tractor.
NOTE: The tractor PTO needs to be a
540 rpm, 1 3/8” 6 splined.
e) Lower the securing plates.
f) Align the holes and install the
pins.
11. Connect the two hydraulic hoses to the
tractor.
Cat II Quick Attach
Cat III Quick Attach
Cat II
Connect PTO to the GBU
Remove Pins
Lift Securing Plates
Install Pins
Replace Securing Plates
Connect Hydraulic
Hoses To The
Tractor

13. Unfold the Gathering Auger
Extensions.
a) Unfold gathering auger cage and
auger to the operation position.
NOTE: Make sure the auger is
engaged properly with the
drive.
b) Remove latch pin clip and pin.
NOTE: Oil is only permitted to flow in one
direction, so activate the circuit and
check for hydraulic flow.
Continuous flow needs to be
maintained for the GBU to operate.
Select a hydraulic circuit that is
capable of being locked for
continuous flow.
12. Unfold the Bag Lift Roller wings.
a) Remove the pin clip and pin.
b) Lower the Bag Lift Roller wing to
the operation position.
c) Insert pin and pin clip.
d) Repeat procedure for the other
side.
SECTION 4 - OPERATION
4-4
Remove Pins
Install Pins
Operation Position
Remove Latch Pin and Clip

c) Lock the auger cage in place,
make sure that the lock is
engaged.
d) Install the latch pin and clip to
secure the lock handle in the
closed position.
14. Engage the tractor hydraulics and lock the
lever in place for continuous flow.
NOTE: There is a in line check valve to
prevent reverse flow. If there is no
flow, reverse the hoses.
NOTE: The following functions will all be
controlled by the operators station.
15. Adjust the Conveyor Position pin
NOTE: The pin should be adjusted so the
bottom of the gathering auger cage is
about 1” off the ground.
a) Using the Bag Lift Roller, raise
the conveyor so it is not touching
the position pin.
SECTION 4 - OPERATION
4-5
Bag Lift Roller
1” Clearance
between Au-
ger Cage and
Ground
Install Latch Pin and Clip
Lock Engagement Pin
Lift Convey-
or so it is not
touching the
position pin
Operators Station

NOTE: Use the “Rear Roller” valve on the
operators station.
b) Remove the pin clips on both ends
of the pin.
c) Adjust the pin into the appropriate
position hole.
SECTION 4 - OPERATION
4-6
Remove Pins on Both Ends
d Install the pin clips onto both ends
of the pin.
e Lower the Bag Lift Roller until
the conveyor rests on the pin.
16. Decide which side to unload on and rotate
the snout to the correct orientation. The
rubber on the snout will open towards the
same side as the truck auger will be on.
Rest Conveyor on
position pin
Remove Pins
Snout Rubber
Opens to this
side if un-
loading on
passenger
side
Snout Rubber
Opens to this
side if un-
loading on
Drivers side
Rear Roller Valve

SECTION 4 - OPERATION
4-7
DANGER: Make sure there are no overhead
objects that the main auger will hit
will extending and swinging it into
position.
NOTE: The conveyor position pin needs to
be in its operation position (See page
4-5 for instructions). Make sure the
conveyor is resting on the position
pin before swinging the auger.
17. Extend the truck auger by using the
“Auger Fold” valve.
18. Swing the truck auger to the appropriate
side using “Auger Swing” Valve.
 PREPARING THE BAG:
1. Unroll the excess bag. Remove all foreign
material from the plastic (wood, tires,
dirt, etc).
Auger Fold Valve
Auger Swing Valve
Remove All For-
eign Material

2. Cut the top side of the bag along the
center line from the opening to half way
up the slope. Grab the top of the bag and
fold it open.
NOTE: Do not cut up the slope to high or the
bag could split wide open.
3. Cut the bottom side of the bag along the
center line, starting at the opening and
stopping 1’ short of were the grain starts.
 Using the Bag Lift Roller, lift the
conveyor to ensure the auger cages will
not grab the bag when backing up.
 MANEUVERING THE GBU
INTO THE BAG:
NOTE: The GBU can be moved into place
either by using the tractor or the
drive wheels.
Using the GBU Drive Wheels:
a) Lock in both wheel hubs by
moving the lock out indicator
from free to the lock position.
SECTION 4 - OPERATION
4-8
Cut the top
half way up
the slope
Cut the bottom 1’
from the grain
Lift the Conveyor so the Auger Cages
don’t grab the plastic when backing up
to the grain
Lock Out Hubs

SECTION 4 - OPERATION
4-9
b) Move the “Drive Wheel” valve in
either direction to lock the hubs
in.
c) Put the tractor in neutral and
release parking brake.
CAUTION: Do not use the drive wheels to
move GBU unless the tractor is in
neutral and the parking brake is
released
d) Use the “Drive Wheel” valve to
control the wheels to move in the
desired direction.
e) To control the speed, adjust the
“Wheel Speed” handle. Turn the
handle clockwise to decrease and
counterclockwise to increase the
speed.
Drive Wheel Valve
Wheel Speed Handle
Turn handle clockwise to decrease and
counterclockwise to increase speed.
Using the Tractor:
a) Make sure the wheel lock out
hubs are in the free position and
disengaged.
CAUTION: Do not use the tractor to move
the GBU with the wheel lock out
hubs in the lock position and
engaged.
1. Use the preferred method to back the
GBU into the bag. Stop when the cross
augers are just past were the grain starts.
NOTE: Make sure to not run over the bag
when backing up the GBU. The
plastic will need to be connected to
the spools.
Lock Out Hubs
Stop when
the Gather-
ing Augers
are just past
were the
grain starts