Koyker GRAPPLE FORK 400 User manual

OWNERS MANUAL
MANUAL NO. 657456
400-500-600 LOADER
GRAPPLE FORK
IMPORTANT – KOYKER
DEALER
BE SURE THIS MANUAL IS GIVEN TO THE
PURCHASER FOR FUTURE REFERENCE
KOYKER MANUFACTURING CO., P.O. BOX 409
LENNOX, SD 570 9
12/15/00

CONTENTS
CONTENTS PAGE
Introduction...................................................................................................................................... 1
Safety Information ........................................................................................................................ 2 - 5
Operation.......................................................................................................................................... 6
Inspection, Lubrication, and Maintenance...................................................................................... 7
Grapple Parts iagram – 400-500-600 ............................................................................................ 8
Grapple Parts List – 400-500-600.................................................................................................... 9
Installation Instructions – 400-500-600 .......................................................................................... 10
Hydraulic Parts List – 400-600 ....................................................................................................... 11
Hydraulic Parts iagram – 400-600 ............................................................................................... 12
Installation Instructions; Hydraulics – 400-600.............................................................................. 13
Hydraulic Parts List – 500 .............................................................................................................. 14
Hydraulic Parts iagram – 500....................................................................................................... 15
Installation Instructions; Hydraulics – 500 ..................................................................................... .16
Warranty ......................................................................................................................................... 17
Cylinder Warranty .......................................................................................................................... 18
Hydraulic Cylinder Information ..................................................................................................... 19
3” Cylinder Service Kit................................................................................................................... 20
Cylinder Parts List and iagram..................................................................................................... 21
Piston and Gland iagram .............................................................................................................. 22

INTRODUCTION
For years, Koyker Manufacturing Company of Lennox, South akota, has provided the farm loader
industry with innovative ideas for a more efficient and dependable means of material handling. Now, with
the increasing popularity of the MFW (Mechanical Front Wheel rive) tractors, Koyker has again met
the challenge and provided the market with loaders and attachments that will allow the efficient use of
these tractors in material handling. The KOYKER Grapple Fork provides you with state-of-the-art design
and innovation for your material handling chores.
Features such as quality construction, ease of maintenance, and high performance operating capacities, all
at a low price, make the Grapple Fork one of the most efficient loaders ever. With proper care and
handling, it will provide many years of dependable service.
This manual is designed to provide you with important information regarding the Grapple Fork. Our
sincere intent, in providing this manual, is to help you or those involved better understand the machine and
to prevent accidents.
Should you have any questions, comments, improvements, or suggestions regarding the contents of any of
the manuals provided, please contact Koyker Manufacturing Company at your earliest convenience.
We care about your safety!
Page 1

SAFETY ALERT SYM OL
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! ecome 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 hazar dous situation that, if not avoided, will result in death or
serious injury.
WARNING: Indicates a potentially hazar dous situation that, if not avoided, could r esult in death or
serious injury.
CAUTION: Indicates a potentially hazar dous situation that, if not avoided may r esult in minor or
moderate injury.
WARNING!
Anyone who will operate or work around a front-end loader should first read this
manual.
Page 2

SAFETY
Improper use of a loader can cause serious injury or death. The following safety precautions, and those
given on the tractor mount installation instructions, should be thoroughly understood before attempting to
operate this machine.
EFORE OPERATING:
Carefully study and understand this manual, the specific tractor mount instructions, and the
attachment (s) manual (s).
Prior to operation, inspect the loader for system leaks and damaged, missing, or malfunctioning
components in an effort to avoid the possibility of a dangerous failure involving structural
members or hydraulic system components.
Be certain any repairs necessary are completed prior to loader operation.
Follow recommended maintenance procedures and precautions on Page 7.
Completely familiarize yourself and others involved with the operation of the hydraulic control
valve before operating the loader.
Be certain all bystanders are clear of the machine and operation area prior to operation.
It may be necessary to add wheel ballast or rear weights as recommended by the tractor
manufacturer to maintain stability of the machine to prevent tipping or upset which could result in
serious injury or death. See mounting instructions for specific information.
It is recommended that both front and rear wheel treads be set to the widest recommended width to
prevent tipping or upset which could result in serious injury or death.
This loader is designed for farm type operations such as snow removal, barn and feedlot cleaning
or light grading and digging. It’s design is NOT intended for commercial and /or industrial use.
DURING OPERATION:
Never operate the machine other than from the tractor operator’s seat.
Be sure operating area is clear of others during machine operations.
Never lift, hoist, or carry humans in the bucket or on any portion of the loader or loader
attachments. Failure to heed, may result in serious injury or death.
Page 3

SAFETY CONTINUED
Transport the machine load at the slowest speed possible and with the loader boom at the lowest
transport position to avoid tipping or upsetting, which may result in serious injury or death.
Be extremely careful when working on inclines or near loose fill, rocks, and holes as they can cause
tipping or upsetting which may result in serious injury or death.
Be certain to avoid overhead electrical wires when operating loader. Contact with power lines may
cause serious injury or death.
Avoid sudden stops when lowering or lifting the loader boom to prevent loss of control over the
machine and/or load, which may result in serious injury or death.
Use maximum ballast and the widest recommended wheel setting on your tractor when handling
large, round bales or large shiftable loads.
Never attempt to ram with the bucket at high speed or full tractor power. Sudden impact may result
in structural failure and possible serious injury or death.
Never adjust or perform maintenance on the loader or tractor with the unit in motion, or without
power source locked out.
Never get under bucket or lift arms or reach through the lift arms or bucket linkage when the loader
is in operation. Inadvertent movement may cause serious injury or death.
FOLLOWING OPERATION:
Whenever machine is not in operation, lower the loader boom and set the tractor brakes, disengage
drive, shut the engine off, and remove the ignition key before dismounting the tractor.
If loader is to be disengaged from tractor, be sure that loader is securely supported on a hard, level
surface and that the stand is securely engaged. Be certain all connections between tractor and
loader are free before disengaging.
TRANSPORTING:
Use safety lights and SMV emblem in addition to whatever local codes require when equipment is
being transported on the road or highway. Check with proper authorities for legal limitations.
Transport all loads at a slow and safe speed.
Carry the load as low as possible and maintain adequate visibility and good round clearance at all
times.
Page 4

SAFETY CONTINUED
PERFORMING MAINTENANCE:
Carefully review, understand, and follow the “maintenance” section in this owners manual before
attempting to service loader.
Lower the bucket or attachment to the ground, shut off tractor engine, and relieve pressure in the
hydraulic system before adjusting, lubricating, or servicing the loader.
Escaping hydraulic oil under pressure can penetrate the skin. Never use body to check for hydrau-
lic leaks. Use cardboard when checking for leaks. See Fig. 1-1. Relieve hydraulic pressure before dis
conecting any hydraulic line. Failure to heed may result in serious injury or death.
Before disconnecting hydraulic lines, lower the loader and attachments. Lock out the hydraulic
supply and relieve all hydraulic pressure.
REMEM ER:
1. Move Slowly!
2. Always use care and common sense!
3. Be careful for your own sake and for that of others!
FIG. 1-1
Page 5

WARNING:
Never allow anyone to operate the Grapple Fork until they have carefully reviewed
and understood this owner’s manual.
OPERATING THE GRAPPLE FORK:
With the forks fully opened, approach and enter the pile slowly.
Adjust attachment tilt as necessary.
After entering the pile, slowly close the grapple and roll attachment back.
Raise loader only enough to permit maneuvering
Before moving, carefully check for hazards and/or obstructions.
Never lift off center.
Be certain material cannot fall or spill out on tractor when raised. Keep clear of overhead
obstructions such as trees, limbs, or power lines when raising the loader and grapple fork.
Never lift higher than required. Travel with load at lowest position.
NEVER attempt to operate the loader or grapple for k with unauthor ized or untrained
persons near.
OPERATION
Page 6

LOADER INSPECTION, LU RICATION, AND
MAINTENANCE
Lower the bucket to the ground, shut off tractor engine, and relieve the pressure in the hydraulic system
before adjusting, lubricating, or servicing the loader.
Inspect all pins and grease fittings before each use and lubricate with heavy duty grease as indicated in this
manual.
Periodically check all bolts for looseness and retorque if necessary
Before storage, be certain all hydraulic cylinders are fully collapsed so that the rod will not be exposed to
the elements or damaged.
Be certain hydraulic system remains sealed at all times to prevent inclusion contaminants.
Check and maintain an adequate fluid level in the tractor reservoir prior to use.
Inspect all hydraulic system hoses and fittings. Replace prior to further operation if damaged.
WARNING:
Escaping hydraulic oil under pressure can penetrate the skin. Never use body to
check for hydraulic leaks. Use cardboard when checking for leaks. See Fig. 1.
Relieve hydraulic pressure before disconnecting any hydraulic line. Failure
to heed may result in serious injury or death.
FIG. 1-1
Page 7

GRAPPLE FORK PARTS DIAGRAM 400-500-600
Page 8

KEY PART NUM ER DESCRIPTION QUANTITY
1...................... 665800................. RH Mast ................................................................... 1
2...................... 665801................. LH Mast ................................................................... 1
3...................... 657330................. Frame ...................................................................... 1
4...................... 657338................. Tooth . ...................................................................... 4
5...................... 661569................. Strap - Grapple Fork Frame ..................................... 2
Bag of Hardware #662
6...................... 658139................. Reinforcement Plate................................................. 2
7...................... 640080................. Carriage Bolt; 5/8” x 2” ........................................... 4
8...................... 640159................. Lockwasher; 5/8” .................................................... 4
9...................... 640142................. Hexnut; 5/8”............................................................ 4
10..................... 640071................. HH Cap Screw; 1/2” x 5 1/2” ................................. 4
11..................... 640157................. Lockwasher; 1/2” ................................................... 16
12..................... 640139................. Hexnut; 1/2”........................................................... 16
13..................... 640980................. HH Cap Screw; 3/4” x 2 1/2” ................................. 8
14..................... 640162................. Lockwasher; 3/4” .................................................... 8
15..................... 640146................. Hexnut; 3/4”............................................................ 8
16..................... 640096................. HH Cap Screw; 1/2” x 3 1/2” ................................. 6
GRAPPLE PARTS IDENTIFICATION SCHEDULE 400-500-600
Page 9

INSTALLATION INSTRUCTIONS 400-500-600
Page 10
INSTALLATION NOTES:
Install all parts with appropriate fasteners “finger tight” before tightening any bolt.
1. Install the RH & LH masts (Item 1 & 2) to the bucket by drilling three (3) 9/16” holes in top of bucket
and install with 1/2” x 3 1/2” HH Cap screws, lockwashers and hexnuts (Item 16,11 & 12). Attach rein-
forcement plate (Item 6) to bottom of top lip of bucket. Attach bottom of mast with 5/8” x 2” HH Cap-
screws, lockwashers and hexnuts (Item 7, 8 & 9). If your grapple fork was purchased with a bucket the
holes are pre-drilled in the top of the bucket.
2. Attach the main frame (Item 3) to the mast by sliding the strap (Item 5) between the cylinder mounts
and attach to the main frame with 1/2” x 5 1/2” HH Capscrews, lockwashers and hexnuts (Item 10, 11 &
12).
3. Fasten the teeth (Item 4) to the main frame (Item 3) with 3/4” x 2 1/2” HH cap screws, lockwashers &
hexnuts (13, 14 & 15).

KEY PART NUM ER DESCRIPTION QUANTITY
1...................... 657339................. Cylinder ................................................................... 2
2...................... 655159................. Grapple Fork Oil Line ............................................. 2
3...................... 658589................. 18” Hydraulic Hose.................................................. 2
4...................... 658590................. 26” Hydraulic Hose.................................................. 2
5...................... 650366................. 70” Hydraulic Hose.................................................. 2
6...................... 657343................. Tee..... ...................................................................... 2
7...................... 663201................. 90 Elbow .................................................................. 2
8...................... 657199................. Pivot Pin................................................................... 2
9...................... 640021................. HH Capscrew; 5/16” x 2 1/4” ................................. 4
10..................... 640128................. Locknut; 5/16” ........................................................ 4
11..................... 655165................. Clamp ...................................................................... 2
12..................... 640149................. Lockwasher; 1/4” .................................................... 5
13..................... 640127................. Hexnut; 1/4”............................................................ 5
14..................... 660369................. Pivot Pin................................................................... 2
15..................... 663207................. Adapter..................................................................... 4
16..................... 641758................. Quick Coupler Set.................................................... 2
17..................... 651080................. Grapple Fork Oil Line – 400-600 ............................ 2
18..................... 661665................. HH Cap Screw; 1/4” x 1 1/4” ................................. 2
19..................... 660194................. Clamp ...................................................................... 4
20..................... 663503................. Insulator ................................................................... 6
21..................... 661030................. Clamp ...................................................................... 2
22..................... 652393................. Plastic Tie................................................................. 4
HYDRAULIC PARTS IDENTIFICATION SCHEDULE 400-600
Page 11

HYDRAULIC PARTS DIAGRAM 400-600
Page 12

INSTALLATION NOTES:
Install all parts with appropriate fasteners "finger tight" before tightening any bolt.
1. Install the cylinders (Item 1) to the mast by attaching the tube terminal to the bottom bracket with
7/8" x 4" hex head capscrews and jamnuts (Items 8 and 9). Pull the rod terminal out of the cylinder
and attach to the top bracket with 7/8" x 5" hex head cap screws and jamnuts (Items 9 and 10).
2. Attach the grapple fork oil line (Item 2) in the main frame tube with 1/4"hexnuts, lockwashers,
clamps and insulators (Items 11, 12, 13, 14 and 15). Attach the main frame grapple oil lines (Item 18)
to the right side of the loader main frame just above the existing lines with 1/4" x 1 1/4" socket head
screw, clamps, insulators, long clamps, lockwashers and hexnuts (Items 19, 13, 14, 20, 11 and 10).
See Insert for detail. Adjust the oil lines so that they are properly staked on the main frame.
3. After the oil lines have been secured, install the 1/2" JIC male end of a 1/2" JIC male x 1/2" NPT male
adapter (Item 16) into the end of grapple fork oil lines. Attach the male halve of a quick coupler
(Item 17) on to the remaining end of connector.
4. Remove the port plugs from the cylinder ports. Install two 90 degree elbows (Item 7) into the ports
in the left cylinder. Install two tees (Item 6) into the ports on the right cylinder..
5. Install a 18" hose (Item 3) into the rod end port in both cylinders. Install a 26" hose (Item 4) to
the tube end port in both cylinders. Connect lines to the grapple fork oil lines.
6. Install a 70" hose (Item 5) to the remaining port in the tee and install the 1/2"JIC end of a
1/2" JIC x 1/2" NPT male adapter (Item 16). Note: Make sure the same hoses are attached to the
same grapple line.
7. Install the female halve of a quick coupler (Item 17) to the end of a 70" hose (Item 5) and attach
to male halve end of quick coupler. Installation is now complete.
INSTALLATION INSTRUCTIONS - HYDRAULICS 400-600
Page 13

KEY PART NUM ER DESCRIPTION QUANTITY
1...................... 657339................. Cylinder ................................................................... 2
2...................... 655159................. Grapple Fork Oil Line ............................................. 2
3...................... 658589................. 18” Hydraulic Hose.................................................. 2
4...................... 658590................. 26” Hydraulic Hose.................................................. 2
5...................... 650366................. 70” Hydraulic Hose.................................................. 2
6...................... 657343................. Tee..... ...................................................................... 2
7...................... 663201................. Elbow ...................................................................... 2
8...................... 657199................. Pivot Pin................................................................... 2
9...................... 640021................. HH Capscrew; 5/16” x 2 1/4” ................................. 4
10..................... 640128................. Locknut; 5/16” ........................................................ 4
11..................... 655165................. Clamp ...................................................................... 2
12..................... 640149................. Lockwasher; 1/4” .................................................... 5
13..................... 640127................. Hexnut; 1/4”............................................................ 5
14..................... 660369................. Pivot Pin................................................................... 2
15..................... 663207................. Adapter..................................................................... 4
16..................... 641758................. Quick Coupler Set.................................................... 2
17..................... 651084................. Grapple Fork Oil Line – 500.................................... 2
18..................... 661665................. HH Capscrew; 1/4” x 1 1/4” ................................... 2
19..................... 660194................. Clamp ...................................................................... 4
20..................... 663503................. Insulator ................................................................... 6
21..................... 661030................. Clamp ...................................................................... 2
22..................... 652393................. Plastic Tie................................................................. 4
HYDRAULIC PARTS IDENTIFICATION SCHEDULE 500
Page 14

HYDRAULIC PARTS DIAGRAM 500
Page 15

INSTALLATION NOTES:
Install all parts with appropriate fasteners "finger tight" before tightening any bolt.
1. Install the cylinders (Item 1) to the mast by attaching the tube terminal to the bottom bracket with
7/8" x 4" hex head capscrews and jamnuts (Items 8 and 9). Pull the rod terminal out of the cylinder
and attach to the top bracket with 7/8" x 5" hex head cap screws and jamnuts (Items 9 and 10).
2. Attach the grapple fork oil line (Item 2) in the main frame tube with 1/4"hexnuts, lockwashers,
clamps and insulators (Items 11, 12, 13, 14 and 15). Attach the main frame grapple oil lines (Item 18)
to the right side of the loader main frame just above the existing lines with 1/4" x 1 1/4" socket head
screw, clamps, insulators, long clamps, lockwashers and hexnuts (Items 19, 13, 14, 20, 12 and 11).
See Insert for detail. Adjust the oil lines so that they are properly staked on the main frame.
3. After the oil lines have been secured, install the 1/2" JIC male end of a 1/2" JIC male x 1/2" NPT male
adapter (Item 16) into the end of grapple fork oil lines. Attach the male halve of a quick coupler
(Item 17) on to the remaining end of connector.
4. Remove the port plugs from the cylinder ports. Install two 90 degree elbows (Item 7) into the ports
in the left cylinder. Install two tees (Item 6) into the ports on the right cylinder..
5. Install a 18" hose (Item 3) into the rod end port in both cylinders. Install a 26" hose (Item 4) to
the tube end port in both cylinders. Connect lines to the grapple fork oil lines.
6. Install a 70" hose (Item 5) to the remaining port in the tee and install the 1/2"JIC end of a
1/2" JIC x 1/2" NPT male adapter (Item 17). Note: Make sure the same hoses are attached to the
same grapple line.
7. Install the female halve of a quick coupler (Item 17) to the end of a 70" hose (Item 5) and attach
to male halve end of quick coupler. Installation is now complete.
INSTALLATION INSTRUCTIONS - HYDRAULICS 500
Page 16

WARRANTY
Koyker Manufacturing Company (Koyker) warrants to the original purchaser only that the goods
manufactured by Koyker are free from defects in material and workmanship under normal use and service
and when properly installed for a period of one (1) year from the date of purchase. Any defective part or
component must be returned to the factory at the purchaser’s expense for inspection by Koyker. The
obligation on Koyker is limited to repairing or replacing at its factory any part or component determined to
its satisfaction to be defective. KOYKER SHALL NOT E LIA LE FOR INCIDENTAL OR
CONSEQUENTIAL DAMAGES. All tr anspor tation charges shall be paid by pur chaser . Pur chaser
must notify Koyker of a claim by registered or certified mail, return receipt requested, within thirty (30)
days after discovery or the claim shall be deemed waived.
THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED
OR IMPLIED INCLUDING ANY IMPLIED WARRANTY OF MERCHANTA ILITY OR
FITNESS FOR A PARTICULAR PURPOSE. No warr anty is given by Koyker for parts,
components, or trade accessories furnished by Koyker but not manufactured by it. They are covered by
the warranty of their manufacturer, if any. No person, firm, or corporation including the selling dealer is
authorized to assume for Koyker any other liability in connection with the sale of these goods.
User shall notify KOYKER in writing within 30 days, of any accident or occurrence involving KOYKER
products resulting in personal injury of property damage and shall cooperate fully with KOYKER in
investigating and determining the cause of such accident of occurrence. In the event that user fails to give
such notice to KOYKER and so cooperate, user agrees to indemnify and waive KOYKER harmless from
all loss or damage arising from such accident or occurrence.
Page 17

CYLINDER WARRANTY
All cylinder claims shall be handled by Koyker ealers. All hydraulic cylinders are thoroughly inspected
before shipment from the factory. Therefore, no claims can be granted where a cylinder has been damaged
or
abused (including, but not limited to, bent tubes, dents, nicks, abused threads, attempted alterations, or
welding), nor unless made to Koyker within one (1) year from sale to original purchaser.
Any defective cylinder reported to Koyker within one (1) year from sale by dealer to original purchaser
will
be replaced after properly inspected by Koyker. In such case, notify your Koyker ealer and he will give
you proper instructions.
If inspection proves cylinder is not defective and has been abused or otherwise damaged, any changes will
be paid by original purchaser immediately after he has been notified of result of Koyker's inspection of
the cylinder sent in for inspection.
Leaks around the shaft seal and internal bypass leaks can be field repaired. Service kits are available for
this repair.
Page 18