Koyker 545 User manual

OWNERS MANUAL
MANUAL NO. 669519
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 [email protected]
2/1/06

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 ................................................................................................................................... 9
Detaching Loader.................................................................................................................................. 10
OPERATING INSTRUCTIONS
Operation............................................................................................................................................... 11
SERVICE AND MAINTENANCE
Specifications........................................................................................................................................ 12
Loader Inspection, Service, and Maintenance ...................................................................................... 13
Hydraulic System Parts List.................................................................................................................. 14
Hydraulic System Parts Diagram.......................................................................................................... 15
“545” Loader Parts Diagram................................................................................................................. 16
Parts Identification Schedule ..............................................................................................................17-18
Bucket Parts Diagram ........................................................................................................................... 19
Bucket Parts Identification Schedule .................................................................................................... 20
Hydraulic Cylinder Information ........................................................................................................... 21
Hydraulics Information......................................................................................................................... 22
3” Cylinder Service Kit......................................................................................................................... 23
Hydraulic Cylinder Parts List ............................................................................................................... 24
Hydraulic Cylinder Parts Diagram........................................................................................................ 25
Piston and Gland Diagram ................................................................................................................... 26
LIMITED WARRANTY INFORMATION
Limited Warranty................................................................................................................................27-29
TORQUE SPECIFICATIONS
Torque Specifications ........................................................................................................................... 30

INTRODUCTION
During a considerable period of time, Koyker Manufacturing Company of Lennox, South Dakota, made a
study of the farm loader industry and concluded that the farmer needs a loader that provides fast
attachment, quality, dependability, few parts, ruggedness, good delivery, and ease of maintenance, all at a
fair price. The fast attaching “545” Farm Loader has achieved these goals. With proper care and handling,
it will give many years of good service in normal farm operations.
Please be sure to follow the manual and give it proper care.
TO THE PURCHASER
You have purchased an excellent product. With proper care and use, it will give you years of good safe
service. Use only KOYKER or KOYKER approved parts in the general maintenance and repair of your
equipment. Please fill out ownership registration card as soon as possible.
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
[email protected])
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 in important to us.
Page 1

SAFETY ALERT 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 13.
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. It’s 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