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Summary of Contents for Kanga PW628
- Page 1 PW628 & DW625 MID RANGE LOADER OPERATORS MANUAL WWW.KANGALOADER.COM 1300 4 KANGA...
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Page 3: Revision Table
CHANGES BY Loader identification Below is a quick reference for identifying your Kanga loader, the First letter represents the Fuel type D for Diesel and P for Petrol. The next letter represents wheeled, the first number represents the series of your kanga loader ans the last 2 numbers indicates the gross horse power. - Page 4 KANGA LOADERS, the Kanga Loaders logo, the Digga Logo. You may not use these trade marks or the names “Digga Loaders Proprietary Limited”, “Kanga Loaders Australia Proprietary Ltd” or “Kanga Loaders”...
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Page 5: Delivery Sheet
DELIVERY SHEET Owner: Date: Address: City: Post Code: State/Territory: Email Address: Owners Phone No: ( Mobile: Dealer/Delivered By : Loader Model and Seriel No: Attachments: Serial No. Salesman / Owner Customer’s name) ………………………….……… to initial Accept delivery of the equipment as detailed above. All equipment has been inspected and is accepted. -
Page 6: Warranty Registration Card
Town/City: Fax: ( Country: Post Code: Delivery Date: KANGA SERIAL NO: Email: Kanga Agent/Sales Person: I (The Purchaser) have read and fully understand the Operator’s Manual, Safety Instructions and warranty conditions. Warranty will only be accepted if this Certificate is completed and returned to:... -
Page 7: Loader Checklist
LOADER CHECKLIST MODEL: INSPECTOR’S NAME: MACHINE BUILT BY: SERIAL No.: DATE: ENGINE No.: VISUAL CHECK OPERATIONAL CHECK 1. Damage. 1. Gauges/switches and connections/dash lights. 2. Loose bolts/nuts. 2. Attachment Plate. 3. Rust. 3. Throttle Lever (not too tight or loose). 4. -
Page 8: Serial Number Registration
SERIAL NUMBER REGISTRATION MAIN COMPONENT SERIAL NUMBERS KANGA Serial No: Engine Type: Serial No: FRONT RIGHT: REAR RIGHT: Wheel Motors: FRONT LEFT: REAR LEFT: Lift Ram: Tilt Ram: Hydraulic Pump: Control Valve: Date Purchased:... -
Page 9: Warranty Details
• Service completed by someone other than an authorized Kanga Loader dealer is not covered by this warranty. • Any attachment not approved by Kanga Loader or any parts that are not genuine Kanga Loader service parts are not covered by this warranty. - Page 10 Kanga Loaders liability under this express warranty, and under any implied warranty that may exist, is limited to repair or replacement of any defective part. In no event shall Kanga Loaders be liable for incidental, special, or consequential damages (including lost profits).
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Page 11: Foreward
FORWARD We thank you for choosing the KANGA LOADER. This machine is the result of extensive design and development, and is acknowledged as being a superior product in its category. We congratulate you on your discerning choice and wish you many years of productive service. -
Page 12: Table Of Contents
PREPARATION FOR USE SAFETY LABEL IDENTIFICATION SAFE OPERATION FIVE STEPS TO EFFECTIVE JSEA NO GO ZONES FOR UNDERGROUND UTILITY SERVICES OPERATOR SAFETY - summary TASK PLANNING FOR THE KANGA LOADER PRE-OPERATIONAL RISK ASSESSMENT RISK ASSESSMENT OPERATING INSTRUCTIONS OPERATING INSTRUCTIONS ATTACHMENTS... - Page 13 TABLE OF CONTENTS MAINTENANCE DAILY OPERATOR MAINTENANCE OPERATOR MAINTENANCE – Safety Checks LOADER ARM MAINTENANCE SERVICE TASKS SERVICE TASKS - Engine SERVICE TASKS - Hydraulics SERVICE TASK - Trenching Valve SERVICE TASKS - Visual SERVICE TASKS - Grease Nipple SERVICE TASK - Radiator (Diesel) SERVICE TASKS - Battery SERVICE TASKS - Pivot Pins SERVICE TASKS - Tyre Pressure...
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Page 14: How To Contact Us
2/49 Yass Road Address: 2/49 Yass Road Address: 1/35 Sterling Road, Minchinbury, NSW 2770 Queanbeyan, NSW 2620 Queanbeyan, NSW 2620 Minchinbury, NSW 2770 SALES Phone: 1300 4 KANGA (1300 4 52642) SPARES Email: parts@kangaloader.com SERVICE BOOKINGS Email: service@kangaloader.com VISIT OUR WEBSITE www.kangaloader.com... -
Page 15: Safety
SAFETY PREPARATION FOR USE INSPECTION AFTER DELIVERY When the machine is delivered, it should be inspected for any evidence of damage caused as a result of shipment before it is declared ready for use. The preparation of the mini loader for use should only be undertaken by a responsible person who has read and understood this manual. -
Page 16: Safety Label Identification
The safety section lists safety precautions required to be taken when operating or maintaining a Kanga Loader. Read and follow all operating and safety instructions contained in this Manual and illustrated on the decals fitted to the Loader, and ensure that you assess the risk of any task by use of the attached Job Safety &... -
Page 17: Safe Operation
SAFE OPERATION The Kanga Loader is a versatile machine, capable of performing a variety of tasks in a safe and effective manner, when used in accordance with established procedures and supported by Risk Assessment. However, to ensure the safety of operators and others, it is important to ensure that... - Page 18 • Position the trailer carrying the Kanga in an area free from traffic, establish a traffic control plan/zone, chock the wheels and ensure that people are not placed in a position where they can be struck by vehicles or equipment being loaded or unloaded.
- Page 19 This, however, reduces its stability when crossing slopes. The Kanga Loader is designed to operate on slopes to a maximum of 20°, under no circumstance is this to be exceeded. The actual safe slope angle may need to be reduced depending on a number of variables, such as site conditions, attachments, condition and configuration of machine and operator experience.
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Page 20: Five Steps To Effective Jsea
FIVE STEPS TO EFFECTIVE JSEA DOCUMENT THE ACTIVITY Assemble those involved in the activity and then, using the JSEA worksheet, write down in step by step form, the tasks that make up the activity. IDENTIFY THE HAZARDS Next to each task, identify what part of the task may cause injury to those engaged in the task or others in the vicinity. -
Page 21: No Go Zones For Underground Utility Services
NO work shall be undertaken without written permission being received from the utility company. • The Kanga Loader and attachments must be kept a minimum distance of 2 meters from all underground services. MAINTAIN A MINIMUM OF 2 METERS DISTANCE FROM ANY UNDERGROUND SERVICE. -
Page 22: Operator Safety - Summary
OPERATOR SAFETY - SUMMARY 15. OPTIMUM OPERATION OF THIS MACHINE IS ACHIEVED AT 2/3 TO 3/4 THROTTLE DANGER FAILURE TO READ THESE SAFETY RULES PRIOR TO ANY MACHINE OPERATIONS MAY LEAD TO SERIOUS INJURY, PROPERTY DAMAGE OR DEATH. -
Page 23: Task Planning For The Kanga Loader
TASK PLANNING & SAFETY CONSIDERATIONS PERFORM A SITE ASSESSMENT Is the terrain stable or suitable to work on? • Unload Loader from a trailer with ramps. • Conduct a thorough site inspection before entering site with Loader. • Consider Wet or boggy conditions. •... -
Page 24: Pre-Operational Risk Assessment
Perform a site assessment ENGAGE YOUR MIND BEFORE USING THE LOADER Assess the risks STEP BACK - Take 5 X 5 Take 5 steps back Take 5 minutes to reflect • Stop and think. • Observe the work area and surroundings. •... -
Page 25: Risk Assessment
OHS&E Risk Assessment/SWMS – Powered Mobile Plant Work Activity Principal Contractor’s Name: Project Reference #: Contractor Name: ABN: Contractor Address: Foreman and contact number: Prepared By: Name 1: Signature: Position: Name 2: Signature: Position: Received and reviewed by: Name: Signature: Position: Date: Date work method prepared: (must be within last 12 months) - Page 26 Supervision: Engineering details/certificates/ authority approval required: Personnel qualification & experience required: Permits e.g. excavation, hot work etc: Training and instruction: Warning signs and control measures: Plant, equipment & materials to be used and the maintenance checks to be Personal protective equipment requirements: completed (details at back of SWMS also): Loader Legislation, codes of practice, standards applicable:...
- Page 27 RISK SIGNIFICANCE (Level of Risk) C = Consequence L = Likelihood 5 = Catastrophic 5 = Almost Certain Death, disablement, significant incident, unacceptable Could occur in most circumstances Risk control legend risk, significant financial cost. 4 = Major 4 = Likely 16-25 Cease activity immediately and implement risk Extensive injuries leading to lost time, major risk- May probably occur in most circumstances...
- Page 28 RAW RISK ITEM WHAT ARE THE BASIC POTENTIAL HAZARDS HAZARD CONTROLS (What controls will RESIDUAL WHO WILL RANKING STEPS (List steps in logical (What may cause an be put in place to prevent an RISK MONITOR & sequence & include injury/illness to occur) injury/illness) N.B.
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Page 29: Operating Instructions
2/3 to ¾ Throttle. CAUTION: The Kanga Loader is not fitted with a “seat belt”. The standing position is a safety feature which allows a quick exit from the machine in case of an emergency. Do not add a restriction system to the machine which will limit your ability to safely exit from the Kanga Loader. - Page 30 CONTROLS On the top face of the KANGA Loader are Six spring centred levers which control the basic functions. The table below indicates the levers with their corresponding functions: LEVER PUSH PULL 4 in 1 Open 4 in 1 Close...
- Page 31 PARKING AND SHUTDOWN When parking the Kanga always select level ground and lower any bucket or attachment fitted fully to the ground. To shut down, reduce the engine speed to idle and turn the key to the off position. Remove the key to prevent unauthorised use.
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Page 32: Attachments
“No other attachment is to be used on this machine unless the design and use of the attachment has been assessed and authorised by Kanga; and has been supported by a compliant Risk Assessment, which has been verified and validated by the Risk... -
Page 33: Hydraulic Attachment Connections
HYDRAULIC ATTACHMENT CONNECTIONS Kanga Loaders are fitted with hydraulic quick release couplings (QRC) to connect the different attachments. The QRCs are paired as male and female to ensure correct hose connections. COLOUR CODING OF QRC’s FOR ATTACHMENTS Left Side : Controlled by the Auxiliary lever on the Control Panel. -
Page 34: In 1 Operating Instructions
4 IN 1 OPERATING INSTRUCTIONS SAFE AND EFFICIENT USE OF BUCKETS When lifting soil from a heap or pile, always have the bucket level. To achieve this, push the Loader arm downwards and use the tilt ram to bring the bucket level with the ground. Towards the end of the run when the bucket is nearly full, gently tilt the bucket (rotate the bucket) towards the Loader. -
Page 35: Power Head Operating Instructions
Start the auger turning in a clockwise direction by activating the “AUX” lever downwards. Lower the auger by pushing the “ARM” lever forward. If the ground is hard the front wheels of the Kanga Loader will lift off the ground. As the auger cuts into the ground the arc of the arm travel will move it out of vertical. -
Page 36: Trencher Operating Instructions
PRE-OPERATION CHECK Ensure that the Trencher is securely attached to the Kanga Loader. Check that the couplings are engaged and check all joints for leaks. Tighten/repair as required. Inspect the cutting teeth, ensuring that they are in good condition and firmly attached. -
Page 37: Back Hoe Operating Instructions
Once the “AUX” lever is engaged, the KANGA Back Hoe attachment is “Alive”. Any movement of the KANGA Back Hoe control levers will cause the Back Hoe to move. Ensure that you are ready to operate the machine and have observed all safety regulations before moving the control levers. -
Page 38: Bucket Broom Operating Instructions
CAUTION: Prior to commencing work, read the Safety Rules of this Kanga Loader Manual. PLEASE NOTE: ALWAYS FIT THE DUST CAPS PROVIDED FOR THE QRC’S TO YOUR ATTACHMENT AND MACHINE WHEN NOT IN USE TO PREVENT DIRT ENTERING THE SYSTEM. -
Page 39: Rotary Hoe Operating Instructions
CAUTION: Prior to commencing work, read the Safety Rules of this Kanga Loader Manual. PLEASE NOTE: ALWAYS FIT THE DUST CAPS PROVIDED FOR THE QRC’S TO YOUR ATTACHMENT AND MACHINE WHEN NOT IN USE TO PREVENT DIRT ENTERING THE SYSTEM PRE - OPERATION CHECK 1. -
Page 40: Safety - Rules For Attachments
The following safety requirements should be read in conjunction with the Safety Rules provided for the base model, i.e., Kanga Loader, Kanga Kid, and the corresponding Operating Instructions accordingly. All tasks and risks associated with the activity are identified using the Job Safety and Environmental Analysis (JSEA) or Risk Assessment (RA) and ALL risk controls are to be identified and implemented before the work commences. - Page 41 TRENCHER SAFETY RULES Always… • Establish and maintain a minimum 4 meter (12 foot) exclusion zone around the local working area a nd ensure no person other than the operator, enters this zone whilst the machine’s engine is running. • Check with Local Authorities and land owners about the presence of underground services within the prospective working area prior to commencement of work.
- Page 42 LOG SPLITTER SAFETY RULES Always… • Establish and maintain a minimum 4 meter (12 foot) exclusion zone around the local working area and ensure no person other than the operator, enters this zone whilst the machine’s engine is running. • Use leather gloves to protect hands from wood splinters. •...
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Page 43: Maintenance
CAUTION: DO NOT operate a Kanga Loader that is known to be damaged or malfunctioning. Remove the key from the ignition and Tag Out the machine using an Out of Service tag and contact your Service Agent. -
Page 44: Operator Maintenance - Safety Checks
DAILY CHECKS Element Comment LOADER Good condition/ adequate tread. Wheels Adequate pressure. Wheel nuts secure. Good condition. Guarding Secure. Good condition of hoses (check for leaks). Hydraulics Good condition of casings (check for leaks). Good condition of rams (check for leaks). Adequate hydraulic oil level. -
Page 45: Loader Arm Maintenance
LOADER ARM MAINTENANCE INSPECTION AND CHECKS Always… • Secure the Arm using the supplied Locking Pins when carrying out maintenance activities, particularly when working with the Arm in the raised position. • Keep a fire extinguisher on hand during maintenance operations. •... -
Page 46: Service Tasks
SERVICE TASKS The following service work should only be carried out by a qualified Service Technician at intervals indicated on the Service Chart. The operating hours are displayed by the Hour Meter on the Instrument Panel. The display will flash for 2 hours when a service is due. -
Page 47: Service Tasks - Engine
SERVICE TASKS - ENGINE ENGINE OIL Change the engine oil after the first 20 hours of operation and thereafter, after every 100 hours. Generally engine oil type SAE 10W-30 is recommended. See Engine Manual for details. Ambient Temperature Oil Type Above 25°C (77°F) SAE 30 or SAE10W-30/SAE10W-40 0°C to 25°C (32°F to 77°F) - Page 48 FUEL FILTER FOR E 10 ETHANOL FUELS – Part Number # DL-001253 The Racor fuel filter if maintained daily and correctly will minimize the ingress of water and hard partials entering into the carburettor and causing corrosion and the engine to run rough. The 10 micron filter must be drained daily or at prior intervals if it becomes saturated with water so the operator must keep an eye on the filter saturation level, when water is visible in the see through bowl or engine performance is noticeably reduced service is required.
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Page 49: Service Tasks - Hydraulics
SERVICE TASKS - HYDRAULICS HYDRAULICS Perform the following work after every 100 operating hours: Check hydraulic fluid level (with arms down and oil cold) top up with Hydraulic Oil ISO 68 NOTE: A significant drop in fluid levels will indicate leakage. The appropriate cold fluid level is indicated on the site gauge. - Page 50 HYDRAULIC PRESSURE SETTINGS The hydraulic system has three pressure settings which have to be set as follows: Lift Pressure Main System Relief Test Point Overcentre Valve Before any testing is carried out run the engine and hydraulic system to warm the hydraulic oil. The oil cooler fan will engage at between 60 and 65°C (145°F).
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Page 51: Service Task - Trenching Valve
TRENCHING VALVE DESCRIPTION The trenching valve is specially designed to convert the Kanga Loader together with the trencher attachment into a high performance trenching machine. The valve provides load sensing to ensure the trencher travel speed stays balanced to the trencher cutting speed regardless of the ground conditions. - Page 52 PRESSURE SETTINGS Before adjusting anything on the trencher valve check all main pressure settings as outlined in chapter “Service Tasks - Hydraulics’ from the Operators Manual. With the same setup as outlined there: hydraulic oil warmed up, pressure gauge (0-300 bar / 0-3400 PSI) plugged into test point, engine running at full speed (3600 rpm) do the following: Over Centre Valve (3) Setting Flow Control Valve (1) fully closed (turned clockwise).
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Page 53: Service Tasks - Visual
SERVICE TASKS - VISUAL VISUAL CHECK Check all over machine for loose bolts, cracks and dents after every 100 operating hours. Tighten loose bolts, and replace if worn or damaged. SERVICE TASKS - RADIATOR (DIESEL) RADIATOR Radiator Hoses and connections should be checked on a regular basis for cracks and wear and the radiator checked for leaks, the radiator fluid should be changed every two years with a coolant to water ratio of 50/50, check the fan belt for wear and replace as required. -
Page 54: Service Tasks - Pivot Pins
SERVICE TASKS - PIVOT PINS BOTTOM PIVOT PINS Before every use, visually inspect all pivot pins for any signs of wear and damage or possible failure. Thoroughly inspect all pivot pins and bushes for wear and damage at an interval of 200 operating hours. -
Page 55: Service Tasks - Tyre Pressure
STUD WHL 7-16 KNOCK-IN Part Number-DL-000458 Visually check tyres on a daily basis and check tyre pressure every 50 operating hours, and check for wear and damage to tyres and tracks. Tyre pressures: KANGA LOADER TYRE PRESSURES GROSS Recommended Tyre Size Pressure... -
Page 56: Decals
DECAL - LOADER - ARM SAFETY PIN L118632 DE-000731 DECAL - KANGA SERVICE AND SPARES NUMBER DE-000735 DECAL - KANGA WITH WITH UNLEADED FUEL LEVEL DL-000993 DECAL - COMMON LOADER PART - SAFETY INSTRUCTIONS DVD L118580 DE-000730 DECAL - DW625 MODEL RH SIDE... - Page 57 DECAL - LOADER - ARM SAFETY PIN L118632 DE-000239 DECAL - LOADER - SWL 250 - 550 L118579 DE-000731 DECAL - KANGA SERVICE AND SPARES NUMBER DE-000732 DECAL - KANGA WITH DIESEL FUEL LEVEL DL-000993 DECAL - COMMON LOADER PART - SAFETY INSTRUCTIONS DVD L118580...
- Page 58 DECAL - LOADER - AUSTRALIAN MADE L118565 DE-000192 DECAL - LOADER - TIE DOWN L118563 DE-000193 DECAL - LOADER - KANGA POWER L118658 DE-000226 DECAL - LOADER - 5-6-7 SERIES LIFTING LUG DE-000234 DECAL - LOADER - NAME PLATE R/H DRIVE TILT...
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Page 63: Specifications - Mid Range Loader
SPECIFICATIONS - MID RANGE LOADER PERFORMANCE PW628 DW625 Max. Lift Capacity 250 kg 551 lbs 250 kg 551 lbs Travel Speed 7 km/h 4.3 mph 7.5 km/h Operating Weight (Machine Only with water filled tyres) 875 kg 1929 lbs 972 kg... -
Page 64: Dimensions - Mid Range Loader
DIMENSIONS - MID RANGE LOADER... -
Page 65: Troubleshooting
TROUBLE SHOOTING This section contains trouble-shooting information to be used for locating and correcting problems which may develop with your KANGA Loader. Troubleshooting and maintenance information relating to the engine are contained in the Engine Manual. ARMS TROUBLE PROBABLE CAUSE REMEDY Reduce load. - Page 66 Control rod or lever broken or Repair or replace control rod or disconnected. lever. Hydraulic lines incorrectly Correctly connect line at connected at Control Valve. Control Valve. Lift Control Valve relief set too low, Adjust relief valve to proper Arm rises and lowers erratically. allowing oil to return to reservoir.
- Page 67 DRIVE SYSTEM TROUBLE PROBABLE CAUSE REMEDY Check oil and replenish as Machine will not drive forwards Hydraulic system oil low. necessary. Oil level should not or backwards. change. Leaks may be present. Check pressure delivery from Worn Control Valve spool. Control Valve.
- Page 68 ENGINE TROUBLE PROBABLE CAUSE REMEDY Engine will not crank over. Low battery output. Recharge or replace battery. Inspect cable(s) and tighten all Loose, disconnected or broken connections. Repair or replace battery cables. cables as necessary. Faulty Starter. Repair or replace starter. Faulty circuit wiring.
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