Kanga 5 Series User manual

Jaden Kanga Group
Jaden Kanga – OPERATORS MANUAL Page
1
OPERATORS MANUAL
Patents Pending US 6397967, 438218 & 10/096997 AU 65424/99 UK 2345046
AU Registered Design 138603
JADEN-KANGA GROUP Ph 61 7 5593 4567 Fax [phone]
Email [e-mail]
PO Box 54, Burleigh Heads QLD 4220 Australia

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Owner: Date:
Address:
City: Post Code:
State/Territory: Email Address:
Owners Phone No: Mobile:
Dealer / Delivered By:
Loader Type ( KL, KK, TK ) and Serial No:
Attachments: Serial No.
(1)
(2)
(3)
(4)
(5)
I ( Customers name ) ………………………….………
1. Accept delivery of the equipment as detailed above. All equipment has
been inspected and is accepted.
2. Have had the operational and safety procedures explained to me for the
loader and attachments and have been provided a copy of these
procedures for reference and use.
3. Have received a copy and understand the Operators Manual and safety
information contained therein for all equipment and attachments
supplied.
4. Understand that I am required to perform a risk assessment/JSEA
covering all tasks before I operate this machine and/or any attachment.
5. Understand the warranty conditions and maintenance requirements for
the Loader and attachments.
Comments:
( COMPLETE SERIAL NUMBER REGISTRATION ON PAGE 30 )
Purchaser’s Signature:
……………………………………………………………………..
Salesman / Owner
to initial
Date:
…… / …… / ……….
DELIVERY
SHEET

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KANGA LOADERS: WARRANTY REGISTRATION FORM
Read the Warranty section towards the rear of this manual before completing the Warranty Registration
Form below. Once read, complete and return within 30 days of the delivery date to –
KANGA LOADERS, PO BOX 54, BURLEIGH HEADS, QUEENSLAND 4220, AUSTRALIA
or if purchased in the USA –
KANGA LOADERS USA, 3326 HIGHWAY 51, FORT MILL, SC 29715, USA.
Owner Phone ( )
Address: Mobile
Town/City Fax
( )
Country: Post Code
Delivery Date: KANGA Serial No
Email:
Dealer:
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
KANGA LOADERS Pty. Ltd, PO Box 54, Burleigh Heads, Queensland, 4220
Within 30 days of the delivery date.
Purchaser’s Signature:
....................................................................................
Date:
…... / .…. /.…...
WARRANTY
SHEET

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Model: ______________________________ Inspectors Name: _____________________
Serial No.: ___________________________ Machine built by: _____________________
Engine No.: __________________________ Date: _______________________________
Hour Meter: __________________________
Visual Check
√
√√
√ x
Operation
√
√√
√ x
1. Damage 1. Gauges/Switches and connections/dash lights
2. Loose Bolts/Nuts 2. Attachment (s) plate
3. Rust 3. Throttle Lever (not too tight or loose)
4. Leakage Oil or Water 4. Levers and Linkages (aux stop cable adjustment)
5. Wiring / oil cooler connection 5. Unusual Noises or vibrations ( drive chains to slack)
6. Paint Work 6. Petrol Engine Idle RPM 1350-1450 rpm = rpm
7. Any untidy weld spots or runs 7. Petrol Engine max RPM 3550-3650 rpm = rpm
8. Check of fittings alignment 8. Is Machine Easy to start
9. Is loader clean and tidy 9. Is hour meter / tacho working test time = hrs
10.Are pipes and hoses clear of parts on loaders 10. Check that lift cylinder stops in correct positions
11.Are Hershel plugs clear of tank and hydraulic lift tubes
Service
√
√√
√ x
Guidance
√
√√
√ x
1. Tie Down Lugs Fitted On Body 1. Correct Stickers Applied UK C/E sticker
2. Correct Attachment Plate/ operation ok with test jig 2. Correct Tyre Pressure sticker attached
3. Lubricate Loader grease all linkages 3. Identification Plate (correct number stamped)
4. All Pins and Bushes Fitted and Tight 4. Safety/Operating Manual
5. Belt Tension Fan/Alternator 5. Safety/Operating Video
6. Wheel Condition/Wheel Nuts been tensioned 100 ftlb 6. Engine Manual (Honda Warranty Form)
7. is the track slot forward and Tyre Direction correct
8. is the Tyre Pressure to specification
Fluid Compartment Check
√
√√
√ x
9. Radiator Core, Hoses and Fittings 1. Battery Electrolyte Level
10. Air Element and hose clearance and Connections tight 2. Engine Oil Level
11. Sediment in Fuel filter/tank (drain fuel tank) 3. Hydraulic Oil Level
12. Drive chain tension (second hand loaders only) 4. Fuel Level
13. Is Engine EPA Compliant 5. Inspect Fuel tanks for leaks
14. Is PTO Direction Correct 6. Radiator water Level
15. Has valve tag been removed 7. Hydraulic filter housing directions and elements tight
16. Are QRC's correctly aligned and covers fitted
17. Spare key fitted correctly to machine
Other
√
√√
√ x
18. Ensure battery is secure and boot is on alternator 1. Is Pass Sticker Attached and Signed
19. 8 Series U Beaut bracket stop bolt fitted 2. Check machine to be shipped against order
20. Is the Splash Plate Fitted 3. Is the loader ready for despatch
21. Check oil cooler connection to fan 4. Is the track tool attached to the machine
22. Ensure control knobs are not split and are secured 5. Ensure Diesel has oil Funnel
23. Is the control knob on trencher valve clear of guard 6. have back protection bars been ordered and fitted
CUSTOMERS COMMENTS
INSPECTORS COMMENTS
"Received the above loader , attachments and documentation as stated above in good condition. The correct operation of the loader has
been explained to our satisfaction. We understand that this loader should be operated by a properly trained operator. We are aware that
the use of this loader in any manner or place which it is not designed will render it unsafe."
DISTRIBUTOR'S NAME: INSPECTOR'S SIGNATURE:

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FOREWORD
We thank you for choosing the KANGA Loader. This machine is the result of design and development
over many years, it is acknowledged as being a superior product in the mini loader category. We
congratulate you on your discerning choice and wish you many years of productive service.
Read this manual carefully before operating or repairing your machine as it contains important
technical information, safety precautions and operating instructions. Compliance with Safety
Precautions and Risk Management standards together with the correct operation and attention to
maintenance procedures are necessary to ensure a long, safe and trouble free working life for your
KANGA Loader
Some illustrations in this publication show details or attachments that may be different from your
machine. Guards and covers may have been removed for illustrative purposes, however, the
machine in its operational state must always be operated with all guards and safety controls in place.
Continuing improvement and advancement of product design may have caused changes to your
machine which are not included in this publication. We advise you to read, study and understand this
manual before under taking any maintenance.

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CONTENTS
FOREWORD........................................................................................................................4
CONTENTS .........................................................................................................................6
SAFETY...............................................................................................................................8
HOW TO CONTACT US......................................................................................................9
safety.........................................................................................................................10
PREPARATION FOR USE ................................................................................................10
SAFE OPERATION ...........................................................................................................11
SAFETY—Summary.........................................................................................................14
NO GO ZONES FOR UNDERGROUND UTILITY SERVICES...........................................15
SAFE - JOB SAFETY CHECK SHEET..............................................................................16
TASK PLANNING FOR THE KANGA LOADER ...............................................................17
RISK RANKING CHART ...................................................................................................18
SAFETY - Rules for Attachments....................................................................................20
operating instructions .............................................................................................24
OPERATING INSTRUCTIONS ..........................................................................................24
SERIAL NUMBER REGISTRATION..................................................................................28
maintenance .............................................................................................................29
DAILY OPERATOR MAINTENANCE................................................................................29
OPERATOR MAINTENANCE - SAFETY CHECKS...........................................................30
SERVICE CHART..............................................................................................................31
SERVICE TASKS ..............................................................................................................32
SERVICE TASKS - Hydraulics.........................................................................................33
SERVICE TASKS - Grease Nipple ...................................................................................35
SERVICE TASKS - Tyre Pressure....................................................................................36
SERVICE TASKS - Battery...............................................................................................36
SERVICE TASKS - Drive Chain .......................................................................................37
SERVICE TASKS - Pivot Pins..........................................................................................37
TROUBLESHOOTING.......................................................................................................38
tracks.........................................................................................................................42
TRACKS (Series 7 only) - Safety/Parts ...........................................................................42
TRACKS INSTALLATION.................................................................................................43

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spare parts...........................................................................................................................................44
DRIVE TRAIN - ASSEMBLY DRAWING ...........................................................................44
MAIN FRAME & ARM 5, 6 & 7 SERIES - ASSEMBLY DRAWINGS.................................45
MAIN FRAME - PARTS LIST ............................................................................................46
ENGINE & HYDRAULICS 5 SERIES - ASSEMBLY DRAWINGS .....................................47
ENGINE & HYDRAULICS - PARTS LIST..........................................................................48
HYDRAULIC CONNECTIONS - Series 5 ..........................................................................49
HYDRAULIC CONNECTIONS - Series 6 ..........................................................................50
HYDRAULIC CONNECTIONS - Series 7 ..........................................................................51
DECALS ............................................................................................................................52
HOW TO ORDER SPARE PARTS ....................................................................................54
attachments.............................................................................................................. 55
HYDRAULIC ATTACHMENT CONNECTIONS .................................................................55
4 IN A BUCKET.................................................................................................................56
ROTARY HOE (TILLER)....................................................................................................57
STANDARD AUGER POWER HEAD................................................................................58
HIGH TORQUE AUGER POWER HEAD...........................................................................59
POWER HEAD OPERATING INSTRUCTIONS.................................................................61
STANDARD TRENCHER ..................................................................................................62
HEAVY DUTY KC TRENCHER .........................................................................................63
KC TRENCHER CRUMBER BAR .....................................................................................65
TRENCHER OPERATING INSTRUCTIONS......................................................................66
BUCKET BROOM..............................................................................................................67
warranty.................................................................................................................... 68
WARRANTY: 1 YEAR OR 1000 HOURS ..........................................................................68
SPARE PARTS WARRANTY: 6 MONTHS.......................................................................69
specifications........................................................................................................... 70
SPECIFICATIONS - 5 Series ............................................................................................70
DIMENSIONS - 6 Series....................................................................................................71
SPECIFICATIONS - 6 Series ............................................................................................72
DIMENSIONS - 6 Series....................................................................................................73
SPECIFICATIONS - 7 Series ............................................................................................74
DIMENSIONS - 7 Series....................................................................................................75
appendices............................................................................................................... 76
JOB SAFETY AND ENVIRONMENTAL ANALYSIS (JSEA) WORKSHEET.....................76

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SAFETY
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 or 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 & Environmental analysis
(JSEA) sheet.
If you are unable to identify hazards or do not understand the process for use of the
JSEA chart, stop the job and consult a qualified Occupational Health and Safety
consultant.
This symbol has been used throughout this manual to
highlight important safety information. Ensure you
read and understand the information before embarking
on any related task.
This Symbol has been used throughout this manual
to highlight critical
safety information to prevent
death and injury
DANGER
These symbols are pic
tograms and refer to compulsory Personal
Protective Equipment (PPE) that must be worn and / or actions
that must be taken by the operator to allow safe operation of the
machine to occur

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HOW TO CONTACT US
Head Office
Phone: Aus: [phone]
Int: [phone]
Fax: Aus: [phone]
Int: [phone]
Email: [email protected]
Postal: Jaden-Kanga Group Pty Ltd
PO Box 54
Burleigh Heads, Queensland 4220, Australia
Address: Jaden-Kanga Group Pty Ltd
43 Alex Fisher Drive
Burleigh Gardens Industrial Park
Gold Coast, Queensland 4220, Australia
Spares & Mechanical Support
Phone: Aus: 1300 4 KANGA (1300 4 52642)
Int: [phone]
Fax: Aus: [phone]
Int: [phone]
Email: [email protected]
Operating Tips & Support:
Phone Aus: 1300 4 KANGA (1300 4 52642)
Int: [phone]
Visit our website
www.kanga-loader.com
Safety & Risk Management Support:
Safety & Forensic Engineering Pty Limited
Phone: [phone]
Email: [e-mail]

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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. The requirements are
simple and coupled with the use of good common sense, together with general occupational health and
safety knowledge and a visual inspection should not pose any problems. The following checklist
provides suggestions for detecting defective, damaged or improperly installed parts.
CHECK BEFORE USE
1
Inspect the machine chassis for any visible damage.
2
Visually inspect all components to assure their security of attachment.
3
Inspect all areas for evidence of hydraulic oil, engine oil or fuel leakage.
4
Inspect boom arm assembly area for security of components and sufficient
lubrication. Check hydraulic cylinders for oil leakage and visible damage.
5
Check hydraulic oil lines for correct connection and for signs of leakage.
6
Check wheel and tyre assemblies for loose or missing wheel nuts, any visible
damage and proper tyre inflation
7
Check wheel drive motor assemblies for any visible damage and oil leakage.
8
Inspect all cylinders for rust, nicks, scratches or foreign material on shafts. Check
for hydraulic oil leaks at the seal and fitting areas.
9
Inspect the engine compartment for loose or missing components and any
evidence of damage or leakage.
10
Check the hydraulic fluid level is within operating limits as marked on the dip stick
12
Check the engine oil level is within operating limits as marked on the dip stick.

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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 the capacity of the machine is not exceeded and that the Loader is operated
appropriately and only after all tasks associated with the work at hand have been
documented and the relevant risk control measures implemented.
To ensure the safe operation and transport of your Kanga Loader, the following basic Safety
Rules must be understood and complied with at all times.
Safe Loading/Unloading and Transp ortation:
•When loading/unloading the Kanga from the trailer, it is important that the trailer remains attached
to the towing vehicle.
•Due to the incline and sharp change of angle experienced when using a ramp for loading and
unloading onto a trailer, it is recommended that when traversing the ramp, the operator operate
the loader from behind, rather than from the driving platform. This removes the counterbalance
effect of the operators’ bodyweight, and improves stability for this operation only.
•Loading/unloading should be conducted at very slow speed (essentially creeping).
•Use appropriately rated slings, shackles and attach to the lifting point on the top of the machine
when lifting the machine
•Always use the tie down points on each side of the machine to secure the Loader when
transporting.
•Always use witches hats, signage and traffic signals to control the unloading/loading zone,
particularly when in close proximity to operational roads.
Before Commencing Work:
•Ensure all safety instructions are clearly understood, that operating manuals have been read and
that operators are familiar with the controls of the Kanga Loader.
•Ensure that the daily inspection routine has been successfully conducted. It is particularly
important to ensure that all attachment-locking pins are fully engaged and secure.
•Ensure the driving platform is free from dirt, grease or mud before use.
•Check all controls for proper response. Shut down the machine if a fault is detected, tag the
machine out with an ’Out of Service’ tag and contact the local Service Agent.
•Review the working site for hazards through the use of a Job Safety Analysis and/or Risk
Assessment and implement the risk control measures to eliminate or minimise their effects, such
as:
oOverhead power lines
oUnderground services
oExcavations
oSlopes or adverse cambers
oConfined spaces
oOther obstructions
oOther people or animals accessing the working area or machine

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ALWAYS…
• Completely read and understand the Operator’s Manual supplied with the machine.
• Undertake a Job Safety Analysis (JSEA) and/or Risk Assessment before any use of both the
Kanga Loader and the trailer upon which the loader and / or attachments are carried. A blank
JSEA is provided in Appendix A for use. Photocopy as required.
• Use the Job Safety Checklist to check that the relevant safety procedures are in place before
work commences.
• 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.
• Demarcate the work area with barricades and/or witches hats before using the Kanga Loader.
• Identify, mark and delineate all underground services before any work commences.
• Have both feet planted firmly on the driving platform at all times when operating the Kanga
Loader. This is especially important when carrying loads, as body weight provides additional
counter-balance to the bucket load.
• Come to a complete stop before changing direction from forward to reverse and vice versa.
Failure to do so can affect the stability of the Loader and may also damage the drive of your
machine.
• Come to a complete stop before operating other hydraulic controls.
• Reverse down slopes at slow speed when carrying loads.
• Ensure the machine is fully stopped and turned off before alighting or exiting the machine.
Never use control levers as hand holds, instead utilize the handholds using the thumbs to
operate the control levers.
• Travel at speeds suitable for the conditions and as determined by the task JSEA or Risk
Assessment.
• When travelling over undulating surfaces and / or rough terrain, it is essential that the
operator ensures that the speed is appropriate to the conditions and to creep over the rough
terrain at minimum speed. The recommended normal operating speed of the machine is 2/3 to
¾ throttle.
• Wear approved, appropriate Personal Protective Equipment
(PPE), such as:
ohearing protection,
oThe machine is designed to operate at 2/3 throttle, at a lower
speed the noise levels are reduced to both the operator and
bystanders.
osafety footwear,
oeye protection,
ohard hat,
olong, close fitting protective clothing, and
ohigh visibility vest or clothing, etc.
•Keep hands, feet and clothing away from all moving parts, including
hydraulic rams,
•Keep arms within the confines of the machine.
•Keep alert, and avoid being distracted whilst operating Loader.
•Remove the key and chock the wheels whenever the Loader is to be left unattended
and/or unsupervised.

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NEVER…
•Operate this machine or the trailer without undertaking a Risk Assessment or
JSEA.
•Operate this machine without Personal Protective Equipment (PPE)
•Exceed the Safe Working Load (SWL) of 250 KG (550 lbs).
•Carry passengers on any part of the Loader or attachments.
•Place feet under the driving platform.
•Smoke (or approach the Loader with a naked flame) whilst
operating or refuelling.
•Leave the engine running whilst refuelling.
•Tie or secure yourself to any part of the machine or attachment.
•Fool around while operating the loader or attachments.
•Carry a load with the bucket raised. Carry all loads as close to the ground as
practicable.
•Never traverse across slopes, especially on uneven ground.
•Jerk the control levers. Always use a steady, even action to achieve proper
control.
•Touch exhaust, hydraulic pipes and fittings, drive chains or guards.
•Park or leave Loader unattended on a slope.
•Remove safety decals.
•Remove safety guarding.
•Use mobile telephones or portable radios.
•Operate machine for extended periods at full throttle
CAUTION
Always exercise care when operating on slopes. The Kanga Loader has been
designed to be able to access restricted areas, due to its minimal width. This,
however, reduces its stability when crossing slopes.
The Kanga Loader is designed to operate on slopes to a maximum of 20
o
.
The actual safe slope angle will depend on a number of variables, such as
site conditions, attachments, condition and configuration of machine and
operator experience.
Crossing slopes should be avoided wher
ever possible. If it is not possible,
slopes should be traversed with loads lowered as far as possible, reduced
speed and extreme caution.

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SAFETY—Summary

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NO GO ZONES FOR UNDERGROUND UTILITY
SERVICES
No work is to commence on any worksite until you have checked if it contains underground
services. Here is how you can find out.
oThe Dial Before You Dig service (in Australia), call 1100 provides free and easy
access to the records of a large number of organizations, including
telecommunications, water, electricity and gas.
oTo see a list of organizations registered with the service or to log an enquiry
electronically, visit the Dial Before You Dig website at www.dialbeforeyoudig.com.au,
or telephone 1100 (otherwise consult with your local environment department)
If underground services are present, you must comply with the No Go Zones.
If the worksite contains or is suspected to contain ANY underground services, before any
work commences, you must follow the relevant No Go Zone safety procedures:
•No Go Zone safety procedures are available from all gas, water, telecommunications and
electricity companies.
•You must follow these safe systems of work at
all times. If you cannot comply with these safety
procedures, then 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 metres from all
underground services.
Minimum of 2 metre distance from ANY
Underground Service

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SAFE - JOB SAFETY CHECK SHEET
To ensure you work safely with Kanga Machines - carry out these
checks and questions BEFORE you start. Use a blank copy of the
JSEA in Appendix A to assist you keep T.R.A.C.K. of the process.
T hink through the Task
oThink about each step in the task/s
oPermits and authorizations needed to work
oEquipment and tools that are to be used
oThe area in which you are to operate the machine and attachments
R ecognise the Hazards
oCheck your environment is safe
oUndertake your Daily Operator Maintenance Safety Checks
oCheck equipment and tools are safe and fit for purpose
oIdentify any hazards using the Job Safety and Environmental Analysis
Worksheet (JSEA)
oIdentify and isolate damaging energies
oCheck above and below for potential hazards
oDetermine exclusion zone and delineate with witches hats
A ssess the Risks
oCould a serious injury of accident be avoided
oWhat equipment/systems could be damaged
oWhat is the likelihood and consequence
oWhat needs to happen to reduce the risk
C ontrol the Hazards
oEliminate (remove the hazard)
oSubstitute (use tracked machine with low center of gravity)
oEngineering (guards, covers, handrails)
oAdministrative (SOP’s, permits, signage)
oCorrect PPE (hearing protection, glasses, gloves)
K eep Safety First in all Tasks
oCheck for changes in work conditions (slope)
oMonitor safety controls for effectiveness
oIf the Task changes, reassess Safety/Risks
oLook after yourself and your mates

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TASK PLANNING FOR THE KANGA LOADER

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RISK RANKING CHART
How Do I Risk Assess A Hazard?
Using the Kanga Risk Assessment tools:
1. Determine the likelihood of the hazard occurring e.g. in this example we have
determined - Remote
2. Determine the severity of the consequence e.g. in this example we have
determined - Significant
3. The resultant score (X) is (5)which is a “Low” risk - we now need to refer to the
Risk Ranking Matrix for what action is required
Note: The higher the score the higher the risk
RISK RANKING CHART
LIKELIHOOD TO
OCCUR
P
R
O
B
A
B
L
E
O
C
C
A
S
I
O
N
A
L
P
O
S
S
I
B
L
E
R
E
M
O
T
E
V
E
R
Y
U
N
L
I
K
E
L
Y
CONSEQUENCES
Severity
Personal injury
Extreme
Fatality
25
24
22
19
15
Severe
Permanent injury or health issue
(e.g. loss of limb)
23
21
18
14
10
Serious
Lose time from work or major
treatment by doctor/hospital
20
17
13
9
6
Significant
Minor treatment injury by doctor.
16
12
8
5
3
Minor
Near miss of minor potential
consequence or first aid injury
11
7
4
2
1
Risk Ranking Matrix
Acti
on Required
High Risk
(20—25)
Implement immediate risk control action
measures e.g. cease activity, make job/area
safe, seek advice and guidance from qualified
persons
Medium Risk
(7-19)
Plan and implement risk control action
measures - seek advice fr
om Kanga if in doubt
about any aspect of the hazard / risk
Low Risk
(1-6)
No immediate action, assess overall risk in line
with available resources -
contact Kanga if in
doubt about any aspect of the hazard / risk

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SAFETY - Rules for Attachments
Only Jaden-Kanga designed and approved
attachments are to be used on this
machine.
No other attachment is to be used on this
machine unless the design and use of the
attachments has been assessed and
authorised by Jaden-Kanga and has been
supported by a compliant Risk
Assessment, which has been verified and
validated by Safety and Forensic
Engineering Pty Limited.