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

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 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 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 any part of your body to
check for hydraulic leaks. Use cardboard when checking for leaks. See Fig. 5-1. 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.
FIG. 5-1
Page 5

SAFETY DECALS
Page 6

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 CAREFUL FOR YOUR OWN SAKE AND THAT OF OTHER PEOPLE
TRACTOR & SAFETY POINTERS
Page 7

ATTACHING LOADER
IMPORTANT:
Never attempt loader attachment on grades which are not reasonably level.
1. Check to be sure that the surfaces of the mounts are free of
obstructions. (Fig 8-1)
2. Drive the tractor slowly and carefully in between the loader arms
only far enough to permit hook-up of the hydraulic system hoses.
(Fig. 8-2)
3. Once all hoses have been properly coupled drive the tractor forward
checking to insure that the top pivot shaft on each loader upright
clears the top cradle on each mount tower. (Fig. 8-3)
4. Allow the top pivot shaft to settle into the cradle on the top of each
mount tower. After the uprights slide into the mount raise the loader
slowly to engage firmly into the mount cradles. (Fig. 8-4)
5. To lock the loader onto the mount, install the two 669514 – 1 3/8”
diameter mount pins into the outside of the upright through the mount
tightener, and pin with hitch pin on other side. (Fig. 8-5)
6. To secure the loader to the mount tighten the 1” bolt at the back of
the mount tower. (Fig. 8-6) Re-check bolts after first three hours of
use.
7. After both uprights are secured to the mounts, raise the loader still
further to disengage and store the loader stands in the torque tube of
the loader frame. (Fig 8-7)
8. Prior to operation, be certain to review all safety and operation
information contained within this manual. Check bolts on back of
mount or the first 3 hours of use, then check periodically during
normal maintenance procedure.
Page 8
Fig 8-1
Fig 8-7Fig 8-4 Fig 8-6
Fig 8-5
Fig 8-3
Fig 8-2