Koyker loader installation and unpacking instructions (generic)
Here is a quick (basic) guide on the installation process of a Koyker front end loader. Take time and plan for the delivery of your new loader. If you ordered lift gate service the driver will drop the loader on the ground for you. If you do not get the lift gate service have the equipment on hand to unload the front end loader from the truck. The weight of the loaders range from 500lbs (model 80) to around 3000lbs or more.
complete loader package placed on the ground Lift gate service
Your loader will arrive on a shipping pallet. The parts will be wired and strapped on to the pallet so you will need something to cut them free. Remove the small parts from the pallet, leaving only the loader frame and bucket. Remove the bucket out from under the frame ( I usually just push it over and drag it off with the tractor.) Some of the loader frames will be bolted to the pallet as well, remove the lag bolts from the loader frame, being careful to support the loader frame so it will not fall over and injure someone. With a helper, lay the loader frame over so it rests on the ground as it would sit on the tractor. Remove and discard the shipping pallet.
Bucket removed from pallet. Bracket securing loader frame to pallet.
The first thing I do is lay out all the parts and make sure everything is there before I start assembling the loader. The first part I mount on the tractor is the belly bracket. The bracket is going to very from tractor to tractor. It can be as simple as two plates that mount with four bolts to the sides of the tractor, to a more complex bracket with additional supports running forward and back along the frame rails. Next, I mount the front loader bracket to the front weight bar. I leave everything loose at this time, as you made need the small amount of play to get everything bolted up. Some loader belly brackets also require that the loader mounting shoes be bolted to them, some are welded on from the factory. The next step is to mount the loader frame on to the tractor mounts. This again can very greatly in the process. Small loaders can be picked up and put into place by a couple of fit workers. I have installed numerous Model 80 120, 140, 155, 160 loaders this way. For larger loaders, you are going to need some other equipment like a fork lift, chain hoist, tractor with a front end loader etc. to get the loader frame onto the tractor. Once the loader frame is in the loader shoes, pin it in place. Tighten all of the mounts and the pin locks.
Belly bracket installed
front bracket installed
Loader shoes installed
The hydraulics come next. Install the control valve bracket to the right upright on the main frame. Bolt the control valve to the bracket and connect the 4 control hoses to it. They will be color coded for easy installation. Again this is where the process is going to vary from application to application. On some models you will connect the loader valve to the remote hydraulic valves on the tractor with the supplied hoses. In some cases the hoses are not supplied at all, you will have to have them made. In other applications usually small compact tractors the main hydraulic line coming from the pump will need to be cut with a small tubing cutter ( $5 item ). This line will then be spliced and the pressure side is routed through the control valve and then back to the other end of the cut line. This is done with three lengths of hose so that the loader can be removed from the tractor and the hydraulic line can be restored to its original configuration.
Cutting hydraulic tubing Fittings installed onto tubing
This shows the hose configuration of the tractor when the loader is removed.
using a forklift to raise the loader so that it can be mounted to the tractor for the first time. Once the loader has been installed for the first time it can be removed an installed using the supplied parking stands. The fork lift will not be needed again. On small loaders this can be done with the help of a couple of friends in place of the fork lift.
Loader installation complete
At this point I start the tractor and check for proper operation and leaks. If you start the tractor and it starts to stall or the engine seems to be under a load, shut off the tractor immediately and check the hoses for proper routing . If this occurs when you first move the control valve, shut down the tractor and check the hose routing as well. Operate the loader to its limits both up and down to remove air. Drive the tractor up to the bucket and install it using the quick connects or the supplied pins. Curl and extend the bucket to its limits to purge the cylinders of air. Check the tractor hydraulic fluid as it will be low and fill.
I installed this model 160 loader by myself in about 4 hours. With a helper you should be able to mount your loader in about the same amount of time. If you are doing it for the first time.