ASTEC RT360 User manual

RT360 Trencher
Operator’s Manual
AU103170

Safety Decals on this machine use the words Danger, Warning or Caution, which
are defined as follows:
•DANGER: Indicates an immediate hazardous situation which,
if not avoided, will result in death or serious injury.
The color associated with Danger is RED.
•WARNING: Indicates a potentially hazardous situation which,
if not avoided will result in serious injury.
The color associated with Warning is ORANGE.
• CAUTION: Indicates a potentially hazardous situation which,
if not avoided, may result in minor or moderate injury.
It may also be used to alert against unsafe practices.
The color associated with Caution is YELLOW.
© 2005 Astec Underground
THIS SAFETY ALERT SYMBOL INDICATES IMPORTANT SAFETY
MESSAGES IN THIS MANUAL. WHEN YOU SEE THIS SYMBOL,
CAREFULLY READ THE MESSAGE THAT FOLLOWS AND BE ALERT TO
THE POSSIBILITY OF PERSONAL INJURY OR DEATH.
IMPROPER OPERATION OF THIS MACHINE CAN CAUSE INJURY OR DEATH.
BEFORE USING THIS MACHINE, MAKE CERTAIN THAT EVERY OPERATOR:
• Is instructed in safe and proper use of the machine.
• Reads and understands the Manual(s) pertaining to the machine.
• Reads and understands ALL Safety Decals on the machine.
• Clears the area of other persons.
• Learns and practices safe use of machine controls in a safe, clear area
before operating this machine on a job site.
It is your responsibility to observe pertinent laws and regulations and
follow Astec instructions on machine operation and maintenance.

i AU103170 H5B
TABLE OF CONTENTS
TO THE OWNER . . . . . . . . . . . . . . . . . . . . . . . . 1
360 Trencher . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
AFTER DELIVERY CHECK . . . . . . . . . . . . . . . . . . . 2
RIGHT, LEFT, FRONT AND REAR OF MACHINE . . . . 2
IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . . . 3
SAFETY/DECALS/HAND SIGNALS . . . . . . . . . . 5
SAFETY MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . 5
PERSONAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . 5
UTILITY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . 5
BEFORE OPERATION . . . . . . . . . . . . . . . . . . . . . . 6
FAILURE IN OPERATION . . . . . . . . . . . . . . . . . . . . 7
MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . 7
PARKING THE MACHINE . . . . . . . . . . . . . . . . . . . . 7
CAST DUCTILE IRON . . . . . . . . . . . . . . . . . . . . . . . 7
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 8
BURN PREVENTION . . . . . . . . . . . . . . . . . . . . . . . 8
PRESSURIZED HYDRAULIC FLUID AND GASES . . . . 8
HAZARDOUS CHEMICALS. . . . . . . . . . . . . . . . . . . . 8
FIRE AND EXPLOSION PREVENTION . . . . . . . . . . . 9
FIRE EXTINGUISHER . . . . . . . . . . . . . . . . . . . . . . . 9
READ OPERATORS MANUAL. . . . . . . . . . . . . . . . . . 9
SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . 10
HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTRUMENTS AND CONTROLS . . . . . . . . . . . . 17
INSTRUMENT PANEL AND CONTROLS . . . . . . . . . . 17
GROUND DRIVE CONTROL LEVERS . . . . . . . . . . . . 19
BACKFILL BLADE CONTROLS . . . . . . . . . . . . . . . . . 19
PLOW CONTROL AND LIFT LEVERS . . . . . . . . . . . . 19
HYDRA-BORER CONTROL LEVER . . . . . . . . . . . . . . 20
SELECTOR VALVE CONTROL LEVER . . . . . . . . . . . . 20
BACKHOE CONTROL LEVERS . . . . . . . . . . . . . . . . . 20
BACKHOE TRANSPORT LINKS . . . . . . . . . . . . . . . . 21
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATOR’S SEAT . . . . . . . . . . . . . . . . . . . . . . . . 22
ETHER STARTING AID (If Equipped) . . . . . . . . . . . 22
SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
OPERATING INSTRUCTIONS . . . . . . . . . . . . . . 25
ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . 25
RUN-IN MAINTENANCE SCHEDULE . . . . . . . . . . . . 25
OPERATING IN HOT WEATHER . . . . . . . . . . . . . . . 25
OPERATING IN COLD WEATHER . . . . . . . . . . . . . . 25
STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . 26
ENGINE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . 27
ENGINE STARTING AIDS . . . . . . . . . . . . . . . . . . . . 27
COLD WEATHER START. . . . . . . . . . . . . . . . . . . . . 27
BOOSTER BATTER CONNECTIONS . . . . . . . . . . . . . 28
PARKING AND STOPPING THE ENGINE . . . . . . . . . . 29
MACHINE OPERATION. . . . . . . . . . . . . . . . . . . . . . 29
TRENCHER OPERATION . . . . . . . . . . . . . . . . . . . . 30
TRENCHER BOOM TYPES . . . . . . . . . . . . . . . . . . . . 30
TRENCHER CHAIN AND TEETH. . . . . . . . . . . . . . . . 30
BEFORE YOU OPERATE . . . . . . . . . . . . . . . . . . . . . 33
CUTTING A TRENCH . . . . . . . . . . . . . . . . . . . . . . . 33
BACKHOE OPERATION . . . . . . . . . . . . . . . . . . . . . 35
CABLE PLOW OPERATION . . . . . . . . . . . . . . . . . . . 36
HYDRA-BORER OPERATION . . . . . . . . . . . . . . . . . 37
DRY BORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
WET BORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
TRANSPORTING THE MACHINE ON A TRAILER . . . . 41
MOVING A DISABLED MACHINE . . . . . . . . . . . . . . 41
WHEELS/TIRES . . . . . . . . . . . . . . . . . . . . . . . . 43
WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . 43
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . 45
GENERAL SAFETY BEFORE YOU SERVICE MACHINE 45
PLASTIC AND RESIN PARTS . . . . . . . . . . . . . . . . . 45
ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 45
ENGINE HOURMETER . . . . . . . . . . . . . . . . . . . . . . 45
CAPACITIES AND LUBRICANTS . . . . . . . . . . . . . . . 46
LUBRICATION/MAINTENANCE CHART . . . . . . . . . . 47
LUBRICATION POINTS - 10 HOURS . . . . . . . . . . . . 49
LUBRICATION POINTS - 100 HOURS . . . . . . . . . . . 51
ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . 52
AIR CLEANER. . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
HYDRAULIC OIL SYSTEM . . . . . . . . . . . . . . . . . . . 57
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . 60
AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
HYDRA-BORER. . . . . . . . . . . . . . . . . . . . . . . . . . . 61
MAINTENANCE/ADJUSTMENTS . . . . . . . . . . . . 63
ENGINE DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . 63
PUMP DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . 63
JACKSHAFT DRIVE BELTS . . . . . . . . . . . . . . . . . . 64
TRENCHER DRIVE CHAIN . . . . . . . . . . . . . . . . . . . 65
DIGGING CHAIN TENSION . . . . . . . . . . . . . . . . . . 66
PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . 67
ROLL-OVER PROTECTIVE STRUCTURE . . . . . . . . . 67
CLUTCH ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . 69
FIRE EXTINGUISHER . . . . . . . . . . . . . . . . . . . . . . 69
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . 71
BATTERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
INSTRUMENT PANEL FUSE . . . . . . . . . . . . . . . . . . 72
SEAT INTERLOCK SYSTEM . . . . . . . . . . . . . . . . . . . 72
STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
STORING THE MACHINE . . . . . . . . . . . . . . . . . . . 73
REMOVAL FROM STORAGE . . . . . . . . . . . . . . . . . . 73
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 75
DIGGING CHAIN. . . . . . . . . . . . . . . . . . . . . . . . . . 75
CHAIN IDENTIFICATION . . . . . . . . . . . . . . . . . . . . 75
CHAIN COMPONENT IDENTIFICATION . . . . . . . . . . 76
ENGINE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
TRAVEL SPEEDS . . . . . . . . . . . . . . . . . . . . . . . . . 84
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . 84
TIRE AIR PRESSURES . . . . . . . . . . . . . . . . . . . . . 84
BACKHOE BUCKETS . . . . . . . . . . . . . . . . . . . . . . . 84
WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
BASIC MACHINE DIMENSIONS . . . . . . . . . . . . . . . 85
HARDWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
DETAIL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . A1
AFTER DELIVERY CHECK . . . . . . . . . . . . . . . . . B1

TABLE OF CONTENTS
AU103170 H5B ii

1 AU103170 H5B
TO THE OWNER
RT360 TRENCHER
PIC00113
This manual contains important information about the
safe operation, adjustment and maintenance of your
Astec Trencher. Refer to the Index at the end of this
manual for locating specific items about your machine.
This Trencher conforms to current safety regulations.
Use this manual as a guide. Your Trencher will remain a
reliable working tool as long as it is kept in good working
condition and serviced properly.
Do NOT operate or permit anyone to operate or
service this machine until you or the other persons
have read and understand the safety, operation
and maintenance instructions in this manual. Use
only trained operators who have demonstrated the
ability to operate and service this machine
correctly and safely.
This Trencher, with standard equipment and authorized
attachments, is intended to be used for general earth
moving purposes, handling, ditch digging, etc. Make sure
that the machine is properly equipped and follow the
instructions and safety precautions in this manual.
Do Not use this machine for any application or
purpose other than those described in this manual.
Consult an authorized Astec dealer on changes, additions
or modifications that can be required for this machine to
comply with various country regulations and safety
requirements. Unauthorized modifications will cause
serious injury or death. Anyone making such unauthorized
modifications is responsible for the consequences.
This machine (P.I.N. JAF0163709 and after) is equipped
with a SEAT INTERLOCK SYSTEM which requires the
operator to be seated in the operator’s seat when starting
or operating this unit. If the operator does not remain
seated when the ground drive and the digging chain
clutch levers are NOT in the NEUTRAL or DISENGAGE
position, the system will stop the engine in 5 seconds. It
is the operator’s responsibility to operate this machine in
a safe manner. DO NOT lay weighted objects on the seat,
bypass, tamper with, or try to defeat the SEAT
INTERLOCK SYSTEM.
This Operator’s Manual is to be stored in the manual
compartment equipped on this machine. Make sure this
manual is complete and in good condition. Contact your
dealer to obtain additional manuals. Contact your dealer
for any further information or assistance about your
machine. Your dealer has Astec-approved service parts.
Your dealer has technicians with special training that
know the best methods of repair and maintenance for
your Trencher.
A18933
Operator’s Manual Storage

TO THE OWNER
AU103170 H5B 2
AFTER DELIVERY CHECK
Two copies of the After Delivery Check are in the back of this manual. One copy is for you and one copy is for the
dealer. Make sure that your dealer does the After Delivery Check after the first 100 hours of machine operation.
Your cost for this inspection will be for filters, oil and/or other accessories. If the dealer comes to your machine, there
can also be a cost for the time and distance traveled.
RIGHT, LEFT, FRONT AND REAR OF MACHINE
Right-hand and left-hand, when used in this manual, indicate the right and left sides of the machine as seen from the
operators seat facing the machine engine and operating the controls.
PIC00113
REAR
VIEWED FROM RIGHT SIDE
FRONT

3 AU103170 H5B
IDENTIFICATION NUMBERS
Write your machine Product Identification Number (P.I.N.) and Serial Numbers on the lines provided below. If needed,
give these numbers to your dealer when you need parts or information for you machine.
Make a record of the numbers. Keep the record and your Manufacturer’s Statement of Origin in a safe place. If the
machine is stolen, report the numbers to your local law enforcement agency.
MACHINE MODEL NUMBER: RT360 Trencher
1. PRODUCT IDENTIFICATION NUMBER (P.I.N.) ________________________________________________________
2. ENGINE SERIAL NUMBER ________________________________________________________
3. ROPS SERIAL NUMBER ________________________________________________________
4. TRANSMISSION SERIAL NUMBER ________________________________________________________
5. CABLE PLOW MODEL AND SERIAL NUMBER ________________________________________________________
6. BACKHOE MODEL AND SERIAL NUMBER ________________________________________________________
7. HYDRA-BORER SERIAL NUMBER ________________________________________________________
A18933
1. PRODUCT IDENTIFICATION NUMBER
A18942
2. ENGINE SERIAL NUMBER
A18960
3. ROPS
866363
4. TRANSMISSION
1
2
3
4

IDENTIFICATION NUMBER
AU103170 H5B 4
866201
5. PLOW
866192
6. BACKHOE
A19239A
7. HYDRA-BORER
5
6
7

5 AU103170 H5B
SAFETY/DECALS/HAND SIGNALS
SAFETY MESSAGE
This machine has been designed and built to meet or
exceed current safety regulations and standards.
However, this does not completely exclude the risk of
accidents. It is therefore essential to follow basic safety
rules and procedures.
The strict execution of the instructions provided in this
manual will help prevent accidents during machine use,
maintenance and repair operations.
These instructions will only be effective if the machine
receives proper maintenance. Any defects or
abnormalities must be repaired immediately.
Do not use the machine for applications other than those
which are described in this manual.
In the event of a particular problem, requiring some
intervention or application not described in this manual,
contact your Astec dealer immediately.
Most accidents involving machine operation and
maintenance can be avoided by following basic rules and
precautions. Read and understand all the safety
messages in this manual, and the safety signs on the
machine before you operate or service the machine. See
your Astec dealer if you have any questions.
READ THIS MANUAL COMPLETELY and make sure you
understand the characteristics of speed, stability, and
steering of this machine. The machine must be used only
by trained operators. KEEP THE OPERATOR’S MANUAL IN
THE STORAGE BOX under the hood and make sure it is
always fastened to the machine, in complete and good
condition. See your dealer for additional manuals. Also
see the inside of the rear cover of this manual.
A18933
OPERATOR’S MANUAL STORAGE
The safety information given in this manual does not
replace safety codes, insurance regulations, or local laws.
Make sure your machine has the correct equipment
according to these rules or laws.
IMPORTANT:
Safety messages in this section point out
situations which can be encountered during the normal
operation and maintenance of your machine. These safety
messages also give possible ways of dealing with these
conditions. Additional safety messages are used in the
text of the manual to show specific safety hazards.
PERSONAL SAFETY
Safety Decals on this machine use the words Danger,
Warning or Caution, which are defined as follows:
•DANGER:Indicates an immediate
hazardous situation which, if not avoided,
will result in death or serious injury. The color associated
with Danger is RED.
• WARNING: Indicates a potentially
hazardous situation which, if not avoided
will result in serious injury. The color associated with
Warning is ORANGE.
• CAUTION: Indicates a potentially
hazardous situation which, if not avoided,
may result in minor or moderate injury. It may also be
used to alert against unsafe practices. The color
associated with Caution is YELLOW.
ISO two panel pictorial symbol decals are shown in both
vertical and horizontal configurations and are defined as
follows:
•The Signal panel indicates the nature of the hazard.
•The Message panel indicates the appropriate avoidance
of the hazard.
•Background color is YELLOW.
•Prohibition symbols such as and if
used are RED.
UTILITY SAFETY
Safety precaution MUST be followed when working near
buried utility lines
During operation it is likely that you will be working
around or near buried utility lines which may include, but
are not limited to:
•Electrical Power Line
•Gas Line
•Water Line
•Communication Line - Telephone or Cable Television
•Sewer Line
STOP

SAFETY
AU103170 H5B 6
Before beginning any trenching, drilling or other
construction work it is your responsibility to be
aware of all such utility lines buried in the area of
your project and to avoid them.
ALWAYS have all local utility companies mark the location
of their lines.
In U.S.A. and Canada call one of many “One Call System
Directory” services. If you do not know the local number,
call the national number (U.S.A. and Canada only): 1-888-
258-0808.
Check with local authorities for laws, regulations
and/or strict penalties requiring you to locate and
avoid existing utilities.
RH99G001
CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU TRENCH
Know the utility color code (U.S.A. and Canada):
Electric .......................................................... Red
Gas, Oil or Petroleum.................................. Yellow
Communication, Telephone, Television ........ Orange
Water ................................................. ..........Blue
Sewer.............................................. Green/Brown
Proposed Excavation.................................... White
Surveying ..................................................... Pink
Reclaimed Water and Slurry ........................ Purple
After locating the utility lines, carefully dig a hole by hand
and/or automatic vacuum equipment to the utility line to
verify the location and depth of the line.
BEFORE OPERATIONS
•Avoid loose fitting clothing, loose or uncovered long
hair, jewelry and loose personal articles.
•Different jobs may require different protective
equipment. Items such as hard hats, protective shoes,
heavy gloves, reflector type vests, respirators and ear
protection may be required. Know and use the
equipment that is required before you start the job.
•Be prepared for emergencies. Always have a first aid
kit and a good fire extinguisher with you and know how
to use each.
•Know the hand signals used on your job. Follow the
instructions of the flagman, signs, etc. See Hand
Signals in this manual.
•Check that all doors, guards, covers and safety decals
are installed correctly or closed. NEVER operate the
machine without guards in place.
•Foreign material such as ice or grease on the controls,
steps or hand rails can cause an accident. Keep these
areas clean.
•Remove all loose objects from operators area and from
the machine. Loose objects can jam controls and cause
accidents.
•If your machine is equipped with the optional ROPS,
always fasten the seat belt before you start the engine.
•Make sure all persons are away from the machine
before you start the engine.
•Always face the machine and use the hand rails and
steps when getting on the machine. Do not rush.
•Before you start each day, walk around the machine
and check for oil or fluid leaks. Replace all broken,
loose, worn or missing parts and do the required
lubrication and maintenance as shown in this manual.
•Engine exhaust fumes can cause death. If you operate
this machine in an enclosed area, use good ventilation
to replace the exhaust fumes with fresh air.
•Know the rules, laws and safety equipment necessary
for transporting this machine on a road or highway.
Rotating beacon, backup alarm, SMV and other safety
equipment items are available from you dealer.
•Make sure the parking brake/emergency brake is
applied and all controls are in Neutral before starting
the engine.
WARNING:
Always contact your local One-
Call system and any utility companies which
do not subscribe to One-Call before the start
of your digging project.

SAFETY
7 AU103170 H5B
FAILURE IN OPERATION
•In the event of poor performance or machine failure,
stop the machine immediately and report the matter.
Take measures to prevent further use until the
malfunction is corrected (Place a DO NOT OPERATE
tag on the control panel, remove the key, turn off all
power sources, etc.) Before working on any hydraulic
or electrical circuits, refer to the maintenance sections
in this manual.
•Support or lower all attachments to the ground before
leaving or servicing the vehicle.
MACHINE OPERATION
•Check all controls in a clear area and make sure the
machine is operating correctly.
•DONOTlet other persons ride on the machine. Other
persons can fall or will cause an accident.
•Dust, fog, smoke, snow, etc., may decrease your vision
and cause an accident. Stop the machine or decrease
the speed until you can see everything around you in
the work area.
•Contact with high voltage power lines, underground
cables, etc., can cause serious injury or death from
electrocution.
•Before you drive or operate in an area with high
voltage lines or cables, contact your utility companies
or one of the Digging Hot Line numbers. You MUST
HAVE THE POWER DISCONNECTED OR KEEP A
SAFE WORKING DISTANCE from the lines or
cables. You must know the safe working distance from
the high voltage power equipment and must know any
federal, state/provincial or local safety codes or
regulations that apply to the job site.
•Electrical cables, gas pipes, water pipes or other
underground objects can cause injury or death. Learn
the location of underground hazards before you
operate your machine in a new area.
•If this machine turns over, you can be injured or killed.
You must make a judgment if weather, road or earth
conditions will permit safe operation on a hill, ramp or
rough ground.
•Operate the machine controls from the operators seat
only.
•Stay away from hazardous areas such as ditches,
overhangs, etc. Walk around the work area before you
start and look for hazards.
•Be alert and always know the locations of all workers in
your area. Keep all other persons completely away
from your machine. Injury or death can result if you do
not follow these instructions.
•If your view of the work area is not clear, always have
a signal person direct your movement. Know and
understand each signal from the signal person before
you start. If your visibility is reduced, install a guard rail
and warning signs to keep other persons away.
•DO NOT operate this machine while under the
influence of alcohol or drugs.
• NEVER allow anyone in the trench while digging.
• NEVER allow anyone to stand in the vicinity of the
trench while operating the trencher or backfill blade.
Stop the trencher and ground drive if anyone comes
close to the trencher or machine.
PARKING THE MACHINE
•When you park the machine, select level ground
whenever possible. If you must park on a slope or
incline, position the machine at right angles to the
slope.
•When you park the machine and before you leave the
operators area, always support or lower all
attachments to the ground, apply the parking brake,
stop the engine and remove the key.
•Follow the instructions in this manual for parking the
machine.
•Always face the machine and use the hand rails and
steps when getting off. Do not rush and do not jump
from the machine.
CAST DUCTILE IRON
•Before you weld, cut or drill holes in a part on this
machine, make sure the part is not cast ductile iron.
See your dealer if you do not know if a part is cast
ductile iron.
•Unauthorized modifications to cast ductile iron parts
can cause injury or death. Welding, cutting or drilling
can cause cast ductile iron to break. Do not weld, cut
or drill to repair or to attach items to cast ductile iron
parts on this machine.
WARNING:
Shut off engine and remove key
before performing any maintenance or repair
work.

SAFETY
AU103170 H5B 8
MAINTENANCE
•Before you service the machine, park on a level
surface.
•Before you service the machine, put a Do Not Operate
tag on the control panel. A Do Not Operate tag (Part
Number AU103157) is included with each new
machine. Extra tags are available from your dealer.
PIC00056
•Improper service or repair can cause injury or death. If
you do not understand a service or adjustment
procedure, see the Service Manual for this machine or
see your dealer.
•Unauthorized modifications to this machine can cause
injury or death. Do not make unauthorized
modifications to this machine. Always see your dealer
before you weld, cut or drill holes in your machine.
•When you service this machine, always wear face or
eye protection, safety shoes and other protective items
as required.
•If you must service this machine with the engine
running, have another person help you. Follow the
instructions in this manual or the Service Manual. Do
not leave the operator’s seat with the engine
running.
•Metal chips or debris can cause eye injury. Always wear
eye or face protection especially when you use a
hammer on this machine. Use a hammer with a soft
face, such as brass, to drive hardened pins.
•When you replace parts on your machine, always use
Astec parts. See your dealer.
•If you must service the machine with an attachment
raised, always block up the attachment.
•To prevent accidental movement of the machine,
always block the tires before you service the machine.
BURN PREVENTION
•Battery acid causes severe burns. Batteries contain
sulfuric acid. Avoid contact with skin, eyes, or clothing.
Antidote - EXTERNAL: Flush with water. INTERNAL:
Drink large quantities of water or milk. Follow with milk
of magnesia, beaten egg or vegetable oil. Call a doctor
immediately. EYES: Flush with water for 15 minutes
and get prompt medical attention.
•When the battery electrolyte is frozen, the battery can
explode if, (1) you try to charge the battery, or (2) you
try to jump start and run the engine. To prevent the
battery electrolyte from freezing, try to keep the
battery at full charge. If you do not follow these
instructions, you or others in the area can be injured.
PRESSURIZED HYDRAULIC
FLUID AND GREASE
•Hydraulic fluid or grease injected into your skin can
cause severe injury or death. Keep your hands and
body away from any pressurized leak. If fluid is
injected into your skin, get medical attention
immediately and have the fluid removed.
HAZARDOUS CHEMICALS
•If you are exposed to or come in contact with
hazardous chemicals you can be seriously injured. The
fluids, lubricants, paints, adhesives, coolants, etc.,
used with your machine can be hazardous.
•Material Safety Data Sheets (MSDS) provide
information about the chemical substances within a
product, safe handling procedures, first aid measures
and procedures to be taken when the product is
accidentally spilled or released. MSDS are available
from your dealer.
WARNING: Battery acid may cause burns.
Avoid contact.
WARNING: Fluid under pressure can pierce
skin and cause injury or death. Stay away.
WARNING: Improper handling or use of
chemicals may result in illness, injury, or
equipment damage. Follow instructions on
labels and in material safety data sheets
(MSDS).

SAFETY
9 AU103170 H5B
•Before you service your machine, check the MSDS for
each fluid, lubricant, etc., used in this machine. This
information indicates what the risks are and how to
service the machine safely. Follow this information
when servicing the machine.
•Before you service this machine and before you
dispose of the old fluids and lubricants, always
remember the environment. DO NOT put oil or fluids
into the ground or into containers that can leak.
•Check with your local environmental or recycling center
or your dealer for correct disposal information.
FIRE OR EXPLOSION
PREVENTION
•Engine fuel can cause an explosion or fire. Do not fill
the fuel tank with the engine running, if you are near
an open fire, or if you are welding, smoking, etc.
•Use nonflammable cleaning solvent to clean parts.
•Sparks or flame can cause the hydrogen gas in a
battery to explode. To prevent an explosion, do the
following:
1. When disconnecting the battery cables, disconnect
the negative (-) cable first; when connecting the
battery cables, connect the negative (-) cable last.
2. When connecting jumper cables to start the engine,
use the procedure shown in this manual. See Booster
Battery Connections in this manual.
3. Do not short circuit the battery posts with metal
items.
4. Do not weld, grind, or smoke near a battery.
•Sparks from the electrical system or engine exhaust
can cause an explosion and fire. Before you operate
this machine in an area with flammable dust or vapors,
use good ventilation to remove the flammable dust or
vapors before you start.
•Remove all trash or debris from the machine. Make
sure that oily rags or other flammable materials are not
stored on the machine.
•A fire can cause injury or death. Always have a fire
extinguisher near by or on the machine. Make sure the
fire extinguisher is serviced according to the
manufacturers instructions.
•Check for fuel, oil, and hydraulic fluid leaks. Replace
worn or damaged hoses or lines. After repairs are
made, clean the machine before you operate.
•If you weld, grind or use a cutting torch on the
machine, always remove the starting fluid container
from the machine. Use compressed air to remove the
ether fumes from the area.
•Starting fluid (ether) can cause injury or death. Do not
breath starting fluid vapors. Wear face protection when
you remove or install a starting fluid container or when
you use an aerosol spray starting fluid. Use starting
fluid according to the instructions in this manual.
FIRE EXTINGUISHER
Type of Fire Extinguisher
It is recommended that you have a fire extinguisher close
by. The fire extinguisher of the type shown is available
from your dealer.
153L95
READ OPERATOR’S MANUAL
Decals which display the “Read Operators Manual” symbol
are intended to direct the operator to the Operators
Manual for further information regarding safety,
maintenance, adjustments and/or procedures for specific
areas of the machine. When a decal displays the following
symbol refer to the Operators Manual.
237187A1
“READ OPERATORS MANUAL”
When a decal displays the symbol shown below, refer to
the appropriate page of the Service Manual.
BC00G075
“READ SERVICE MANUAL”
WARNING: Fire or explosion possible.
Fumes could ignite and cause burns. No
smoking, no flame, no spark.

SAFETY
AU103170 H5B 10
SAFETY DECALS
•Make sure that you read all safety and instruction
decals. Check these decals every day before you start.
Clean these decals if you cannot read the words.
•When you clean the decals, use only a cloth, water and
mild soap. Do not use solvent, gasoline, etc.
•You must replace a decal if the decal is damaged,
missing or cannot be read.
•If a decal is on a part that is replaced, make sure you
install a new decal on the new part. See your dealer for
new decals.
A18933
A18932
(ONE EACH SIDE OF MACHINE)
321-3218
BD01F321
321-3705
321-3217
321-3905
ATTENTION: Injury or death can result if you
cannot read a safety decal or if a safety decal is
missing. Replace any missing or damaged safety
decal and keep all safety decals clean. See your
Astec dealer for new safety decals.
1
1
1
3
2
645
2
3
4

SAFETY
11 AU103170 H5B
321-3214
321-7030
A18945
321-5701
PIC00114
321-6714
321-7040
5
6
2
7
7
8
9
8
9

SAFETY
AU103170 H5B 12
A18915
H438908
A18913
H348999
(1 EACH SIDE)
BD01H260
H438910
H438909
(1 EACH SIDE)
10
10
11
11
12
13
12
13

SAFETY
13 AU103170 H5B
Hydra-Borer (if equipped)
A19239A
124016A1
Backhoe (if equipped)
866192
866213
321-4481
(1 EACH SIDE)
11
14
15
15
15

SAFETY
AU103170 H5B 14
HAND SIGNALS
It is recommended that you and the flagman on the job use hand signals for communications. Before you start, make
sure that you both understand the signals that will be used.
PDE0003A
COME TO ME
PDE0005A
STOP
PDE0002A
START ENGINE
PDE0002
STOP ENGINE
PDE0003
MOVE AWAY FROM ME
PDE0004
ALL STOP AND HOLD
PDE0006A
RAISE LOAD OR BUCKET
PDE0006
LOWER LOAD OR BUCKET
PDE0004A
GO THIS FAR
PDE0005
EMERGENCY STOP
PDE0007
RAISE LOAD OR BUCKET SLOWLY
PDE0007A
LOWER LOAD OR BUCKET SLOWLY

SAFETY
15 AU103170 H5B
HAND SIGNALS (continued)
PDE0008A
TURN MACHINE/SWING LOAD LEFT
PDE0010
LOWER BACKHOE BOOM
PDE00011
BACKHOE DIPPER OUT
PDE0012
BACKHOE BUCKET DUMP
PDE0008
TURN MACHINE/SWING LOAD RIGHT
PDE00010A
RAISE BACKHOE BOOM
PDE00011A
BACKHOE DIPPER IN
PDE00012A
BACKHOE BUCKET DIG

SAFETY
AU103170 H5B 16
NOTES