Koyker 80 User manual

OWNERS MANUAL
MANUAL NO. 670009 9/9/2013
8
88
80
00
0
LOADER
IMPORTANT-KOYKER DEALER
BE SURE THIS MANUAL IS GIVEN TO THE
PURCHASER FOR FUTURE REFERENCE
KOYKER MANUFACTURING CO., P.O. BOX 409
LENNOX, SD 57039
Phone [phone] E-mail k[email protected]

CONTENTS
CONTENTS PAGE
Introduction.................................................................................................................................................. 1
SAFETY INFORMATION
Safety Alert Symbol..................................................................................................................................... 2
Safety Information .....................................................................................................................................3 - 5
Safety Decals................................................................................................................................................ 6
Tractor & Safety Pointers............................................................................................................................. 7
ASSEMBLY INSTRUCTIONS
Attaching Loader.......................................................................................................................................... 8
Attaching Bucket.......................................................................................................................................... 8
Detaching Loader......................................................................................................................................... 9
OPERATING INSTRUCTIONS
Operation..................................................................................................................................................... 10
SERVICE AND MAINTENANCE
Specifications.............................................................................................................................................. 11
Loader Inspection, Lubrication and Maintenance.......................................................................................12
Hydraulic System Parts Schedule ............................................................................................................... 13
Hydraulic System Parts Diagram................................................................................................................ 14
“80” Loader Parts Diagram......................................................................................................................... 15
Parts Identification Schedule.....................................................................................................................16-17
Hydraulic Cylinders Information................................................................................................................ 18
1 ½” Cylinder Service Kits .........................................................................................................................19
Cylinder Parts Schedule.............................................................................................................................. 20
Cylinder Parts Diagram............................................................................................................................... 21
Piston and Gland Service Diagram ............................................................................................................22
Dinoil Valve Hookup.................................................................................................................................. 23
LIMITED WARRANTY INFORMATION
Limited Warranty........................................................................................................................................ 24

For years, Koyker Manufacturing Company of Lennox, South Dakota, 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 MFWD (Mechanical Front Wheel Drive) tractors, Koyker has again met
the challenge and provided the market with a loader that will allow the efficient use of these tractors in
material handling. The KOYKER 80 Loader provides you with state-of-the-art design and innovation for
your on-farm handling chores.
Features such as quality construction, ease of maintenance, and high performance operating capacities, all
at a low price, make the new 80 Loader 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 basic loader and bucket.
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 (800-456-1107 or E-mail
[e-mail]).
We care about your safety!
Remember ALL safety decals are no charge from the factory. Please replace all safety decals if
missing or damaged. Your safety is important to us.
Page 1
INTRODUCTION

SAFETYALERT SYMBOL
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.
WARNING: Indicates a potentially hazardous situation that, if not avoided, could result in death or serious
injury.
CAUTION: Indicates a potentially hazardous situation that, if not avoided may result 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.
BEFORE 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 12.
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,
light commercial or light grading and digging. Its design is NOT intended for 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

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 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 the 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 the 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.
SAFETY CONTINUED
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 any part of your body to
check for hydraulic leaks. Use cardboard when checking for leaks. See Fig. 1-1. Relieve hydrau-
lic pressure before disconnecting 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.
Replace any damaged or painted-over decals. See Page 6 for replacement decals.
REMEMBER:
1. Move Slowly!
2. Always use care and common sense!
3. Be careful for your own sake and for that of others!
4. Koyker Mfg. Co. includes all reasonable means for accident prevention except a safe and
careful operator.
Page 5
FIG. 1-1

SAFETY DECALS
Page 6
NOTE: See Parts Diagram of this manual for correct safety decal location.

TRACTOR & SAFETY POINTERS
Page 7
The use of good judgment and common sense is necessary by the operator in using this loader. The front and
rear wheels should be set for the widest wheel tread to assure best stability. Use extra caution when rear
wheel weights and tire ballast are added to a loader-equipped tractor. DO NOT ram into frozen dirt piles,
frozen manure piles, ice, etc., with great momentum where sudden shock loads are encountered. Serious and
costly damage may result to both the loader and the tractor.
When scraping or back dragging do not extend the attachment cylinders more than one half of the cylinder’s
stroke. A limited amount of leveling may be done, when the loader valving is arranged with a float control.
This will prevent damage to cylinder rods. Never ride in the bucket.
Before operating the loader, be sure no one is standing near it. Only one person, the operator, should be on
the tractor. Remain at the controls and under no circumstances leave the tractor unattended with the bucket
in a raised position.
Never lift a person in the bucket or walk under a raised bucket.
Never drive your loader-equipped tractor down a hill that is steeper than 15 degrees. Carry all loads low and
use care on side hills.
Always keep unused PTO shaft clutch levers disengaged.
Keep hands, feet, and clothing away from all moving parts.
Hydraulic oil, under pressure, can cause injury. Be sure that all connections are tight and that all pressure is
relieved before disconnecting any lines.
Care must be taken with your loader cylinders. Nicks, scratches, rust, or other shaft damage can result in
worn packing causing cylinder leakage and subnormal performance.
MOVE SLOWLY
USE COMMON SENSE
BE CAREFULFOR YOUR OWN SAKE AND THAT OF OTHER PEOPLE

ATTACHING THE LOADER
IMPORTANT:
Never attempt to attach the loader on steep grades, or surfaces which are not reasonably
level.
NOTE: Refer to loader mount instruction sheets (provided with mount) for correct and safe
mounting of specific loader applications. Refer to hydraulic installation instructions provided
with the loader mount kit for specific applications or contact dealer for correct and safe
hydraulic hookup.
1. Check to be sure that the top surface of both mounting shoes are free of any obstructions and the
loader mount pins are removed.
2. Drive the tractor slowly and carefully in between the loader arms only far enough to permit hook-
up of the hydraulic system hoses.
3. Once all hoses have been properly coupled, drive the tractor forward checking to insure that the
bottom of each upright clears the mount shoes. It may be necessary to operate the lift cylinder
control valve either up or down to provide alignment for attachment of the yoke adapter or brace
arms.
4. To allow the upright base to settle into the mount shoe, tip the bucket down slowly. After the
upright contacts the shoe, be sure that both pilot pins on the bottom of the loader uprights, slide
down into the holes in loader mount.
5. Using the loader hydraulics to line up the top holes in the loader mount with the loader upright
holes. Secure the loader by installing one mount pin (665421) and one #6 hitch pin (640246) on
each side of the loader.
6. After both uprights are secured to the shoes, raise the loader slowly to disengage and store the
loader stand.
7. Prior to operation, be certain to review all safety and operation information contained within this
manual.
Page 8
ATTACHING THE BUCKET
1. For pin on buckets, assemble pins and retaining bolts as shown in the Parts Diagram of this manual.
Make sure all retaining bolts are secure and lubricate necessary points. Inspect pin and bolts periodical-
ly for tightness and wear.

DETACHING THE LOADER
Page 9
IMPORTANT:
Never attempt to detach the loader on steep grades, or surfaces which are not reasonably
level.
1. Remove the loader stands from the cross tube storage location. Raise loader off the ground
slightly to allow for the loader stands to be installed. Remember to use the pins and hitch pins to
secure the loader stands in position.
2. Lower loader and tip bucket slightly forward to relieve the pressure from the mount connection
pins. Remember to shut off tractor and set parking brake before getting off.
3. Remove the #6 hitch pins (640246) and remove the mount pins (665421). If pins do not remove
easily, you may need to put the valve in the float position to relieve the pressure.
4. If a front yoke brace is present, remove the hitch pins and lock pins from the front of the yoke or
remove the front bolts in each brace pipe.
5. Make sure there is slack in the valve hydraulic lines and all other obstructions are removed. Get
on the tractor and start it. Carefully, and very slowly, retract bucket back so pilot pins disengage
out of mount holes. Then carefully back out far enough to permit separation of the uprights from
the mount pockets.
NOTE: Should the loader move when tractor is backed up, try rotating the bucket up or down to
stabilize the loader.
6. Before completely backing out, set the parking brake, shut off the tractor, disconnect and store
the loader system hydraulic hoses. It is important that the hoses be properly stored to keep the
hose couplers as clean as possible. Remember to Re-couple any tractor hydraulic lines, if
necessary.
IMPORTANT:
Never store the detached loader where insufficient soil bearing capacity exists. Good firm clay
or firmly packed dirt are sufficient, providing the area is dry. If stability is in question, use
blocking under the stand foot to disperse the load. Failure to heed, may allow the loader to settle
and prevent attachment at later date.
WARNING: Re-couple any hydraulic hose together for your particular
hydraulic system when necessary to prevent damage to tractor hydraulics.
See your particular mount or hydraulic hook-up instructions.

OPERATION
WARNING:
Never allow anyone to operate the loader until they have carefully reviewed and
understood this owners manual.
Page 10
FILLING THE BUCKET:
Approach and enter the pile with the bucket level.
Roll bucket back gradually as the loader moves through the pile.
RAISING THE BUCKET:
WARNING:
Make sure material in bucket cannot spill out on to tractor when loader boom is
raised. Keep clear of overhead obstructions such as trees, limbs or power lines
when raising the bucket.
Side cutting is the best method of reducing large stockpiles. If the sides of the pile
are too high, use the loader to pull them down and reduce the possibility of slides.
WARNING:
NEVER attempt to operate the loader with someone near the loader frame or
bucket.

SPECIFICATIONS
Page 11
“80” Loader
Maximum lift height to pivot pin (A): 72”
Clearance with bucket dumped (C) 52”
Reach at maximum lift height (D): 24”
Maximum dump angle (E): 45º
**Maximum rollback angle (G): 21º
Digging depth (H): 4”
Overall height in carry position (J): 47”
*Lift capacity to maximum height (V): 500 lbs
*Breakout force (Z): 900 lbs
Hydraulic Control Valve Requirements Two Spool Selective
Control Valve Required for Loader and
Hydraulic Controlled Bucket Cylinders.
Lift and Bucket Cylinders- Double Acting
Bucket Control- Hydraulic Twin Cylinders
Standard Bucket- 3’6” ft. Material
Bucket Cylinder Size (Twin)- 1½” Bore x 14¼” Stroke
Lift Cylinder Size- 1½” Bore x 13 11/16 ”
Stroke
Approximate Weight w/3’6”ft. Bucket (Less Mounts)- 110 lbs
*Raising Time- 6.0 Seconds 1½” Cylinder
*Lower Time- 3.0 Seconds 1½” Cylinder
*Bucket Dump Time- 3.0 Seconds 1½” Cylinder
*Bucket Rollback Time- 4.0 Seconds 1½” Cylinder
*Will vary depending upon each tractors hydraulic operating pressure, flow rate, RPM’s and oil
temperatures. The above data is based on an operating pressure of 2100 PSI, flow of 2.1 gal/min at
1500 RPM’s and room temperature of 60º F.
**Never attempt maximum rollback at maximum height with material in the
bucket. Material may shift causing the tractor to be unstable or may roll out of the
bucket causing injury or death.
Specifications are subject to change without notice and without liability therefore.

LOADER INSPECTION, LUBRICATION, 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 re-torque 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 contamination.
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 any part of your
body to check for hydraulic leaks. Use cardboard when checking for leaks. See Fig. 1-1
Relieve hydraulic pressure before disconnecting any hydraulic line. Failure to heed may
result in serious injury or death.
Page 12
FIG 1-1

Page 13
HYDRAULIC SYSTEM PARTS SCHEDULE
KEY PART NUMBER DESCRIPTION QUANTITY
1......................670003.................1 ½” Lift Cylinder............................................................. 2
2......................670004.................1 ½” Bucket Cylinder........................................................ 2
3......................670011.................1st Oil Line (Yellow) ........................................................ 1
4......................670012.................2nd Oil Line (Green)......................................................... 1
5......................670013.................3rd Oil Line (Red)............................................................. 1
6......................670014.................4th Oil Line (Blue)............................................................ 1
7......................670015.................12” Hydraulic Hose........................................................... 4
8......................670016.................21” Hydraulic Hose........................................................... 2
9......................670017.................27” Hydraulic Hose........................................................... 2

HYDRAULIC SYSTEM PARTS DIAGRAM
Page 14

KOYKER “80” LOADER PARTS DIAGRAM
Page 15

PARTS IDENTIFICATION SCHEDULE
KEY PART NUMBER DESCRIPTION QUANTITY
1 ......................670000 .................Main Frame..................................................................1
2 ......................670001 .................RH Upright ..................................................................1
3 ......................670002 .................LH Upright...................................................................1
4 ......................670003 .................1½” Lift Cylinder.........................................................2
5 ......................670004 .................1½” Bucket Cylinder ...................................................2
6 ......................670005 .................Pivot Pin; 3¾”..............................................................4
7 ......................670006 .................Pivot Pin; 4½”..............................................................4
8 ......................670007 .................Stand ............................................................................2
9 ............................ .......................“80” Decal....................................................................2
10 .....................670010 .................Oil Line Cover.............................................................2
11 .....................670011 .................1st Oil Line ..................................................................1
12 .....................670012 .................2nd Oil Line ................................................................1
13 .....................670013 .................3rd Oil Line..................................................................1
14 .....................670014 .................4th Oil Line..................................................................1
15 .....................670015 .................12” Hydraulic Hose .....................................................4
16 .....................670016 .................21” Hydraulic Hose .....................................................2
17 .....................670017 .................27” Hydraulic Hose .....................................................2
18 .....................654629 .................“American Made” Decal..............................................2
19 ........................... .......................“Koyker” Decal............................................................2
20 .....................666941 .................Serial Number Decal....................................................1
21 .....................666943 .................Warning Decal.............................................................5
22 .....................666944 .................Warning Decal.............................................................1
23 .....................666945 .................Danger Decal ...............................................................1
24 .....................666946 .................Warning Decal.............................................................2
25 .....................665421 .................Mount Pin ....................................................................2
26 .....................641119 .................Pin................................................................................2
27 .....................666031 .................Self Tapping Screw; 1/4”x 1”.....................................4
28 .....................640009 .................HH Cap Screw; 1/4” x 1 ½” ........................................8
29 .....................640126 .................Lockn t; 1/4” ..............................................................13
30 .....................640671 .................#3 Hitch Pin.................................................................4
31 .....................640246 .................#6 Hitch Pin.................................................................2
32 .....................653713 .................Oil Line Clamp ............................................................5
33 .....................670379 .................Stud Grommet..............................................................4
Page 16

PARTS IDENTIFICATION CONTINUED
Optional Buckets & Cylinders
KEY PART NUMBER DESCRIPTION QUANTITY
669988 3½’ Bucket Bundle 1
40.....................640126................. ...........Lockn t; ¼”........................................................... 4
41.....................640009................. ...........HH Cap Screw; 1/4” x 1 1/2”............................... 4
42..................... 670006................. ........... Pivot Pin................................................................ 4
43.....................670018................. ........... 3½’ Bucket Weldment .......................................... 1
669995 4’ Bucket Bundle 1
40.....................640126................. ...........Lockn t; ¼”........................................................... 4
41.....................640009................. ...........HH Cap Screw; 1/4” x 1 1/2”.............................. 4
42..................... 670006................. ........... Pivot Pin................................................................ 4
44.....................670019................. ........... 4’ Bucket Weldment ............................................. 1
Page 17