ASTEC TF300B Operator's Manual

ASTEC TF300B is a trencher that is designed to help you get the job done quickly and efficiently. With its powerful engine and durable construction, the TF300B is ideal for a variety of trenching applications.

The TF300B features a variety of advanced features that make it easy to use and maintain. The intuitive controls and comfortable operator's seat make it easy to operate the trencher for hours on end. The TF300B is also equipped with a number of safety features that help to protect the operator and the machine.

Whether you're a professional contractor or a homeowner, the ASTEC TF300B is the perfect trencher for your needs.

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TF300B Trencher

Operator’s Manual

AU103168

C7B

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.

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.

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.

TO THE OWNER . . . . . . . . . . . . . . . . . . . . . . . . . 1

TF300B TRENCHER . . . . . . . . . . . . . . . . . . . . . . . . 1

AFTER DELIVERY CHECK . . . . . . . . . . . . . . . . . . . . 1

RIGHT, LEFT, FRONT AND REAR OF MACHINE . . . . . 2

IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . 3

MACHINE COMPONENTS . . . . . . . . . . . . . . . . . . . . 4

SAFETY/DECALS/HAND SIGNALS . . . . . . . . . . . 5

SAFETY MESSAGE . . . . . . . . . . . . . . . . . . . . . . . . . 5

PERSONAL SAFETY . . . . . . . . . . . . . . . . . . . . . . . . 5

UTILITY SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . 5

BEFORE OPERATIONS . . . . . . . . . . . . . . . . . . . . . . 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 GREASE . . . . 8

HAZARDOUS CHEMICALS . . . . . . . . . . . . . . . . . . . . 8

FIRE OR EXPLOSION PREVENTION . . . . . . . . . . . . . 9

FIRE EXTINGUISHER . . . . . . . . . . . . . . . . . . . . . . . 9

READ OPERATOR’S MANUAL . . . . . . . . . . . . . . . . . . 9

SAFETY DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . 10

HAND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . 12

INSTRUMENTS AND CONTROLS . . . . . . . . . . . . 13

INSTRUMENT PANEL AND CONTROLS . . . . . . . . . . 13

KEY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

THROTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

FORWARD/REVERSE LEVER . . . . . . . . . . . . . . . . . 13

RIGHT STEERING BRAKE LEVER . . . . . . . . . . . . . . 13

AMMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SPEED CREEP CONTROL . . . . . . . . . . . . . . . . . . . . 13

TRENCHER BOOM LEVER . . . . . . . . . . . . . . . . . . . 13

LEFT STEERING BRAKE LEVER . . . . . . . . . . . . . . . 13

TRENCHER CLUTCH LEVR . . . . . . . . . . . . . . . . . . . 14

NEUTRAL INDICATOR LAMP . . . . . . . . . . . . . . . . . 14

RANGE CONTROL LEVER . . . . . . . . . . . . . . . . . . . 14

BACKFILL BLADE CONTROLS . . . . . . . . . . . . . . . . . 14

LEFT STEERING BRAKE LEVER . . . . . . . . . . . . . . . 14

RIGHT STEERING BRAKE LEVER . . . . . . . . . . . . . . 14

FORWARD/REVERSE LEVER . . . . . . . . . . . . . . . . . 14

BLADE ANGLE CONTROL . . . . . . . . . . . . . . . . . . . . 14

BLADE LIFT CONTROL . . . . . . . . . . . . . . . . . . . . . 14

SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

OPERATING INSTRUCTIONS . . . . . . . . . . . . . . 17

ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . 17

RUN-IN MAINTENANCE SCHEDULE . . . . . . . . . . . . 17

OPERATING IN HOT WEATHER . . . . . . . . . . . . . . . 17

OPERATING IN COLD WEATHER . . . . . . . . . . . . . . 18

STARTING THE ENGINE . . . . . . . . . . . . . . . . . . . . 18

ENGINE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . 19

BOOSTER BATTERY CONNECTIONS . . . . . . . . . . . . 19

PARKING AND STOPPING THE ENGINE . . . . . . . . . 20

MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . 20

STEP AND HAND RAIL . . . . . . . . . . . . . . . . . . . . . 21

OPERATOR POSITION . . . . . . . . . . . . . . . . . . . . . 21

TRENCHER OPERATION . . . . . . . . . . . . . . . . . . . . 21

TRENCHER BOOM TYPES . . . . . . . . . . . . . . . . . . . 22

TRENCHER CHAIN AND TEETH . . . . . . . . . . . . . . . 23

BACKFILL BLADE OPERATION . . . . . . . . . . . . . . . . 25

TRANSPORTING THE MACHINE ON A TRAILER . . . . 26

LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . 27

GENERAL SAFETY BEFORE SERVICING MACHINE . . 27

PLASTIC AND RESIN PARTS . . . . . . . . . . . . . . . . . 27

ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 27

ENGINE HOURMETER/TACHOMETER . . . . . . . . . . . 27

CAPACITIES AND LUBRICANT SPECIFICATIONS . . . 28

LUBRICATION/MAINTENANCE CHART . . . . . . . . . . 29

ACCESS DOORS AND COVERS . . . . . . . . . . . . . . . 30

LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . 32

FLUID LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

ENGINE LUBRICATION . . . . . . . . . . . . . . . . . . . . . 34

OIL VISCOSITY/TEMPERATURE USAGE CHART . . . 34

AIR FILTERING SYSTEM . . . . . . . . . . . . . . . . . . . . 36

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

HYDRAULIC OIL SYSTEM . . . . . . . . . . . . . . . . . . . 38

TRANSMISSION AND GEAR REDUCTION HOUSING 40

TRENCHER DRIVE CHAIN LUBRICATION . . . . . . . . 41

ADJUSTMENT/MAINTENANCE . . . . . . . . . . . . . 43

TRENCHER DRIVE BELT TENSION . . . . . . . . . . . . . 43

TRENCHER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . 43

TRENCHER DRIVE CHAIN TENSION . . . . . . . . . . . 44

TRENCHER DIGGING CHAIN TENSION . . . . . . . . . 45

TRACK ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . 46

ROLL-OVER PROTECTION STRUCTURE . . . . . . . . . 48

SEAT BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

FIRE EXTINGUISHER . . . . . . . . . . . . . . . . . . . . . . 49

ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

OVERLOAD PROTECTION . . . . . . . . . . . . . . . . . . . 52

SEAT INTERLOCK SYSTEM . . . . . . . . . . . . . . . . . . 52

MACHINE STORAGE . . . . . . . . . . . . . . . . . . . . . 53

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 55

BOOM IDENTIFICATION . . . . . . . . . . . . . . . . . . . . 55

ENGINE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

OPERATING DATA AND DIMENSIONS . . . . . . . . . . 56

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1

I AU103168 C7B

OPERATING INSTRUCTIONS

AU103168 C7B II

TO THE OWNER

TF300B TRENCHER

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.

PIC00118

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.

BD01C043

Operator’s Manual Storage Under The Hood

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.

1 AU103168 C7B

TO THE OWNER

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.

TRENCHER OPERATION

RIGHT SIDE

FRONT REAR

LEFT SIDE

BACKFILL BLADE OPERATION

RIGHT SIDE

FRONT REAR

LEFT SIDE

B901043 / B901044

AU103168 C7B 2

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 in a safe place. If the machine is stolen, report the numbers to your local law enforcement agency.

MACHINE MODEL NUMBER:

TF300B Trencher

1. PRODUCT IDENTIFICATION NUMBER (P.I.N.) ________________________________________________________

2. ENGINE SERIAL NUMBER ________________________________________________________

3. ROPS SERIAL NUMBER (IF EQUIPPED) ________________________________________________________

B4021588

1. PRODUCT IDENTIFICATION NUMBER

BD01C044

3. ROPS

2. ENGINE SERIAL NUMBER

BD01C041

3 AU103168 C7B

IDENTIFICATION NUMBER

MACHINE COMPONENTS

1. SEAT

2. HAND RAIL

3. ENGINE HOOD

4. TRENCHER RESTRAINT BAR

5. TRENCHER CHAIN

6. TRACK

7. BACKFILL BLADE

PIC00119

AU103168 C7B 4

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 r e c e i v e s p r o p e r m a i n t e n a n c e . A n y d e fe c t s o r 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.

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 used are RED.

and

STOP

UTILITY SAFETY

Safety precaution MUST be followed when working near buried utility lines

BD01C043

OPERATOR’S MANUAL STORAGE UNDER THE HOOD

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.

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

AU103168 C7B

SAFETY

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.

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.

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.

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 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 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.

RH99G001

CALL ALL LOCAL UTILITY COMPANIES BEFORE YOU TRENCH

• 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.

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.

AU103168 C7B 6

• 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 both steering brake levers are completely pulled back in the locked position and all controls are in

Neutral before starting the engine.

SAFETY

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.

• 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.

WARNING: Shut off engine and remove key before performing any maintenance or repair work.

• Support or lower all attachments to the ground before leaving or servicing the vehicle.

• 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.

• Operate the machine controls from the operators seat only.

• DO NOT operate this machine while under the influence of alcohol or drugs.

MACHINE OPERATION

• Check all controls in a clear area and make sure the machine is operating correctly.

• DO NOT let 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.

• 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.

• 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.

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.

AU103168 C7B

SAFETY

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.

BURN PREVENTION

WARNING:

Avoid contact.

Battery acid may cause burns.

• 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.

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.

•

PRESSURIZED HYDRAULIC

FLUID AND GREASE

WARNING:

HAZARDOUS CHEMICALS

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).

Fluid under pressure can pierce skin and cause injury or death. Stay away.

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.

• 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.

AU103168 C7B 8

SAFETY

• 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.

• 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.

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.

FIRE OR EXPLOSION

PREVENTION

WARNING: Fire or explosion possible.

Fumes could ignite and cause burns. No smoking, no flame, no spark.

• 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.

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.

“READ SERVICE MANUAL”

BC00G075

9 AU103168 C7B

SAFETY

SAFETY DECALS

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.

• 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.

AU103168 C7B

BD01F321

321-3905

393538A1

321-7040

BD01H254

321-3213

BD01H259

SAFETY

BD01H260

H438908

H438910

H438909

AU103168 C7B

SAFETY

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.

COME TO ME

PDE0003A

MOVE AWAY FROM ME

PDE0003

GO THIS FAR

PDE0004A

STOP

PDE0005A

ALL STOP AND HOLD

PDE0004

EMERGENCY STOP

PDE0005

START ENGINE

PDE0002A

RAISE LOAD

PDE0006A

PDE0008

TURN MACHINE/SWING LOAD RIGHT

STOP ENGINE

AU103168 C7B

PDE0002

LOWER LOAD

PDE0006

PDE0008A

TURN MACHINE/SWING LOAD LEFT

INSTRUMENTS AND CONTROLS

INSTRUMENT PANEL AND CONTROLS

1. KEY SWITCH

2. THROTTLE

3. FORWARD/REVERSE LEVER

7. TRENCHER BOOM LEVER

8. LEFT STEERING BRAKE LEVER

9. TRENCHER CLUTCH LEVER

4. RIGHT STEERING BRAKE LEVER 10. NEUTRAL INDICATOR LAMP

5. AMMETER 11. RANGE CONTROL LEVER

6. SPEED CREEP CONTROL

KEY SWITCH

The key switch (1) has the following three positions:

1. OFF - Use this position to stop the engine, deenergize the electrical system and to remove the key.

2. ON - Turn the key clockwise to the first position to energize the electrical system. The key will return to this position after you release the key from START.

3. START - Turn the key clockwise to the second position to actuate the starter motor to start the engine.

Release the key switch as soon as the engine starts.

NOTE: See STARTING THE ENGINE in this manual for the correct procedure to start the engine.

THROTTLE

Pull back the throttle handle (2) to increase the engine speed. Push the handle forward to decrease the engine speed.

FORWARD/REVERSE LEVER

Push the lever (3) FORWARD for forward ground travel.

Pull the lever REARWARD for reverse ground travel.

NEUTRAL is in the center position.

NOTE: You MUST be seated in the operator’s seat to

ENGAGE the Forward/Reverse Lever or the engine will shut down in 2 seconds .

RT160024

RIGHT STEERING BRAKE LEVER

Pull the lever (4) REARWARD to disengage power to the right track. Pull the lever farther rearward to apply the right brake. Pull the lever all the way rearward to lock the right brake.

AMMETER

The ammeter (5) shows the rate of charge or discharge of the battery. When the needle is to the right of 0, the alternator is charging the battery. If the needle is to the left of 0 during normal engine operation, the battery is discharging. Stop the engine and check for a problem in the charging system.

SPEED CREEP CONTROL

This control (6) works with the Forward/Reverse Lever (3) to let you vary the ground speed of the machine during trenching operation. Actuate the Forward/Reverse Lever

(3). Turn the Speed Creep Control clockwise to increase the ground speed or counterclockwise to decrease the ground speed.

TRENCHER BOOM LEVER

Pull the lever (7) REARWARD to raise the trencher boom.

Push the lever FORWARD to lower the trencher boom.

LEFT STEERING BRAKE LEVER

Pull the lever (8) REARWARD to disengage power to the left track. Pull the lever farther rearward to apply the left brake. Pull the lever all the way rearward to lock the left brake.

13 AU103168 C7B

INSTRUMENTS/CONTROLS

TRENCHER CLUTCH LEVR

This lever (9) actuates the digging chain and spoil auger.

Push the lever to the left to actuate the digging chain and spoil auger. Pull the lever to the right to stop the digging chain and spoil auger.

NOTE: You MUST be seated in the operator’s seat to

ENGAGE the Trencher Clutch Lever or the engine will shut down in 2 seconds.

NEUTRAL INDICATOR LAMP

This lamp (10) will illuminate when the key switch is ON and the ground drive control and the digging chain clutch lever are in the NEUTRAL position.

RANGE CONTROL LEVER

Move this lever (11) to the left for LOW range and to the right for HIGH range. Use LOW for trenching and HIGH for transport or back filling. If you cannot shift the range control into a position, momentarily actuate the Forward/

Reverse Lever (3) to let the gears in the transmission mesh.

BACKFILL BLADE CONTROLS

3 4 5

1. LEFT STEERING BRAKE LEVER 4. BLADE ANGLE CONTROL

2. RIGHT STEERING BRAKE LEVER 5. BLADE LIFT CONTROL

3. FORWARD/REVERSE LEVER

LEFT STEERING BRAKE LEVER

Pull this lever (1) REARWARD to disengage power to the left track. Pull the lever farther rearward to apply the left brake. Pull the lever all the way rearward to lock the left brake.

RIGHT STEERING BRAKE LEVER

Pull this lever (2) REARWARD to disengage power to the right track. Pull the lever farther rearward to apply the right brake. Pull the lever all the way rearward to lock the right brake.

AU103168 C7B 14

BD01F243

FORWARD/REVERSE LEVER

Push this lever (3) FORWARD for forward ground travel.

Pull the lever REARWARD for reverse ground travel.

NEUTRAL is in the center position.

NOTE: You MUST be seated in the operator’s seat to

ENGAGE the Forward/Reverse Lever or the engine will shut down in 2 seconds.

BLADE ANGLE CONTROL

Push this lever (4) FORWARD for angle right. Pull the lever REARWARD for angle left.

BLADE LIFT CONTROL

Push this lever (5) FORWARD to lower the blade. Pull the lever REARWARD to raise the blade. The blade control valve is equipped with a float position. The float is engaged when the lever is pushed FORWARD. To disengage float, pull the lever rearward.

SEAT BELT

INSTRUMENTS/CONTROLS

NOTE: The illustrations that follow show the correct procedure to fasten and release the belt.

B901048

When the machine is equipped with a ROPS, wear the

Seat Belt during machine operation.

WARNING: You are protected by the ROPS system (Roll Over Protective Structure). The seat belt is an important part of the ROPS system.

Before you operate this machine, always fasten the seat belt. If the machine rolls over and you

DO NOT have the seat belt fastened, you can be crushed by the ROPS or the machine.

WARNING: Securely fasten your seat belt. Your machine is equipped with a ROPS cab, ROPS canopy or ROPS frame for your protection. The seat belt can help insure your safety if it is used and maintained. Never wear a seat belt loosely or with slack in the belt system. Never wear the belt in a twisted condition or pinched between the seat structural members.

1. Fasten the belt end into the left-hand buckle.

BP98J021

BP98J022

2. To release the seat belt, push the button on the buckle.

IMPORTANT: Make sure the belt end and buckle are securely fastened.

15 AU103168 C7B

INSTRUMENTS/CONTROLS

NOTES

AU103168 C7B 16

OPERATING INSTRUCTIONS

ENGINE OPERATION

Before Starting The Engine

WARNING : Before starting engine, study operator’s manual safety messages. Read all safety signs on machine. Clear the area of other persons. Learn and practice safe use of controls before operating. It is your responsibility to understand and follow manufacturer’s instructions on machine operation, service, and to observe pertinent laws and regulations.

Operators and service manuals can be obtained from your equipment dealer.

5. Do not run the engine at low idle speeds for long periods of time.

6. Before shutting engine off, allow engine to run at idle without load for a few minutes. This will permit the engine parts to cool evenly.

7. After the first five (5) hours of operation, inspect all areas of the machine for leaks or unusual component wear.

8. Operate the machine with normal loads for the first eight (8) hours.

9. See After Delivery Check in the back of this manual.

Have your dealer do the after delivery check.

Walk-Around Inspection

Do the following items each day before you start the engine.

1. Check for leaks under the machine. Repair leaks as necessary.

2. Check the tracks for wear and debris. Clean the tracks as necessary.

3. Check the machine for debris, especially around the engine area. Make sure this area is clean so engine cools properly.

4. Clean or replace any safety or instructional decal that cannot be read.

5. Clean the operators area and remove any loose items.

6. Check the machine for broken, damaged, loose or missing parts. Replace, tighten or adjust as required before you operate the machine.

7. See the Maintenance Chart in this manual and do all the 10 hour items.

NOTE: If this is a new machine or a machine with a rebuilt engine, see Run-In procedure.

Run-In Procedure For a New Machine

During the first 20 hours of operation for a new machine or a machine with a rebuilt engine, the following procedure should be followed:

1. Before putting the machine to work, run the engine at half throttle for one-half hour without a load.

2. Gradually increase engine RPMs and add light load to the engine.

3. Check the oil level every hour for the first five (5) hours.

4. Keep the engine at normal operating temperatures.

RUN-IN MAINTENANCE SCHEDULE

The following items are to be done during the Run-In

Period and are in addition to the items listed above as well as those listed in the Lubrication/Maintenance Chart.

AFTER FIRST 5 HOURS OF OPERATION

Change the engine oil and filter after the first five hours of operation. See Changing Engine Oil in this manual.

AFTER FIRST 50 HOURS OF OPERATION

Have your dealer do the After Delivery Check. See After

Delivery Check in this manual.

OPERATING IN HOT WEATHER

Extreme conditions, hot or cold, place unusual demands on equipment. The owner or operator can minimize temperature related problems on equipment by following these general recommendations.

Your TF300B has an air-cooled gasoline powered engine.

Air-cooled engines run hotter than standard automotive engines. The following precautions must be followed when operating in hot ambient temperature.

1. Clean all dirt and debris from the oil cooler and engine area to make sure there is proper air flow to cool the engine. Wipe debris from air inlets in the hood side panels.

2. Use lubricants of the correct viscosity. See the

Recommendation Chart in this manual.

3. Check the air cleaner more frequently during extreme dust conditions.

4. Use the correct engine speed and transmission range for your operating conditions. Run the engine at high idle. Do not overload or lug down the engine. Allow the engine to take a cooling breath every once in a while.

AU103168 C7B

OPERATING INSTRUCTIONS

OPERATING IN COLD WEATHER

Cold weather conditions cause special problems. During these conditions your machine will require special attention to prevent serious damage. Cold weather maintenance will extend the service life of your machine.

1. BATTERY AND ELECTRICAL SYSTEM: Clean the battery and make sure the battery is at full charge.

NOTE: A fully charged battery at -17°C (0°F) has only 40 percent of the normal starting power. When the temperature decreases to -29°C (-20°F), the battery has only 18 percent of the power remaining.

2. If you add water to the battery and the temperature is below 0°C (32°F), make sure you charge the battery or run the engine for approximately 2 hours.

This procedure will prevent battery freezing.

Inspect the battery cables and terminals. Clean the terminals and put a coat of grease on each terminal to prevent corrosion.

3. LUBRICANTS: You must follow the recommended oil and filter service for the engine and the hydraulic system as shown in this manual. Use the correct viscosity oil in each component for the ambient temperatures the machine is operated in (see

Lubrication in this manual).

4. FUEL SYSTEM: Fuel must be clean and free of water.

Use only a good grade of lead-free gasoline.

Check for water in the fuel system. Cold temperatures can cause condensation to form in the fuel tank. Always fill the fuel tank at the end of the day.

5. GENERAL: Before you operate, move the machine slowly at low speed and actuate each hydraulic control several times to warm the oil.

The engine and hydraulic system MUST be at operating temperature before the machine is put to work

Keep the digging chain and track assemblies free of mud and snow which might freeze up after operation.

STARTING THE ENGINE

The Seat Interlock System REQUIRES the operator to be seated in the operator’s seat when starting and operating this machine.

NOTE: If the operator DOES NOT remain seated when the control levers are not in NEUTRAL , the system will stop the engine in 2 seconds. It is the operators responsibility to operate this machine in a safe manner.

DO NOT lay a weighted object on the seat, bypass or tamper with the Seat Interlock System in any way.

AU103168 C7B 18

WARNING: Before starting engine, study operator’s manual safety messages. Read all safety signs on machine. Clear the area of other persons. Learn and practice safe use of controls before operating. It is your responsibility to understand and follow manufacturer’s instructions on machine operation and service, and to observe pertinent laws and regulations.

Operators and service manuals can be obtained from your equipment dealer.

The following procedure should be followed when starting the engine on your TF300B:

1. Check oil level (See Checking Engine Oil in this manual).

2. Seat Interlock and Neutral Start: The Seat Interlock

System REQUIRES the operator to be seated on the operator’s seat when starting and operating this machine. The forward-neutral-reverse lever on the control console must be in the neutral position in order to start the unit. The trencher drive must be disengaged (off) in order to start the unit.

NOTE: If the operator does not remain seated when the control levers are not in neutral, the system will stop in 2 seconds.

3. Make sure all controls are in the neutral position. If the machine is equipped with a ROPS, the operator should fasten and tighten the seat belt low around the waist.

4. Engage the brakes by pulling both Steering Brake levers completely rearward.

5. Pull the throttle lever to the high idle position.

6. Pull out the choke control.

7. Turn the key switch to the first position (ON). When the transmission and trencher drive are in the neutral position, and the operator is on the seat, the green neutral indicator light on the dash will be illuminated.

The light will not illuminate and the unit will not start if these three conditions are not satisfied.

8. Turn the key switch to the start position to crank the engine.

9. Release the key as soon as the engine starts to run. If the engine starts and stops, DO NOT actuate the starter motor again until the starter motor stops turning.

NOTE: DO NOT operate the starter motor more than 5 seconds at one time. Let the starter motor cool for 10 seconds before you actuate the starter motor again.

OPERATING INSTRUCTIONS

10. After the engine starts, run the engine at half throttle for approximately 5 minutes, adjusting the choke control as the engine temperature increases.

11. After the engine has warmed, check that the choke control is completely pushed in.

12. Run the engine at low idle speed for one or two minutes before increasing the engine speed and moving the machine.

13. Cycle all unit components before putting the machine to work. Check that all controls and components work properly.

ENGINE SPEED

Do not run the engine at low idle speed for long periods of time. This can cause a low operating temperature.

Long periods at idle speed can cause acids and deposits to form in the engine oil.

For maximum engine life and machine performance, it is recommended that you operate the engine with the choke pushed fully in and the throttle in the HIGH IDLE (speed) position when operating conditions permit and when safe.

BOOSTER BATTERY CONNECTIONS

WARNING: Batteries contain acid and explosive gas. Explosion can result from sparks, flames or wrong cable connections. To connect the jumper cables correctly to the battery of this machine, see the correct method shown on this page. Failure to follow these instructions can cause serious injury or death.

2. Remove the seat and seat plate from the machine.

BD01C049

3. Make sure all controls are in NEUTRAL and the

Steering Brake levers are completely rearward in the

LOCKED position.

RT160033

1. Make sure the jumper battery is 12 volts.

2. If using another machine for power, make sure the two machines DO NOT touch.

3. Connect the positive (+) jumper cable to the positive

(+) battery terminal (1).

WARNING: Always wear face protection when making battery connections.

Make sure the person making the connections is wearing face protection.

1. Disengage the clips that fasten the seat plate to the machine.

BD01F322

4. Connect the negative (-) jumper cable to a good frame ground away from the batteries.

5. Start the engine.

6. When the engine starts, first disconnect the negative

(-) jumper cable from the frame, and then disconnect the positive (+) jumper cable last.

AU103168 C7B

OPERATING INSTRUCTIONS

PARKING AND STOPPING THE

ENGINE

WARNING: Jumping on or off the machine can cause an injury. Always face the machine, use the hand rails and steps, and get on or off the machine slowly.

PIC00120

1. STEPS 2. HAND RAIL

1. When the work day is finished, make sure the machine is parked on level ground. The machine must be on level ground before you do scheduled maintenance.

IMPORTANT: If you must temporarily park the machine on a slope or incline, position the machine at right angle to the slope.

NOTE: If the machine is to be driven onto a trailer or flat bed truck that is not a level surface, it is recommended that the engine oil level be checked prior to driving unit onto truck of trailer. This will satisfy the oil level check recommendation prior to starting the unit the next morning.

2. Put all controls in the NEUTRAL or OFF position. Pull both Steering Brake levers completely back to lock the brakes.

3. If the unit has been operating under a heavy load, decrease the engine speed to 1/4 throttle for a few minutes to evenly cool the engine.

4. Push the throttle lever towards the SLOW position and turn the key switch to the OFF position. Remove the key from the ignition switch.

5. Always use the hand rail and step to get on or off the machine.

6. Fill fuel tank at the end of each day of operation to prevent condensation and moisture in the tank.

MACHINE OPERATION

The Seat Interlock System REQUIRES the operator to be seated in the operator’s seat when starting and operating this machine.

NOTE: If the operator DOES NOT remain seated when the control levers are not in NEUTRAL, the system will stop the engine in 2 seconds. It is the operator’s responsibility to operate this machine in a safe manner.

DO NOT lay a weighted object on the seat, bypass or tamper with the Seat Interlock System in any way.

WARNING: The operator presence/seat interlock system provides protection from injury.

Do not disable the system.

WARNING: Before each period of operation, check the machine for correct operation of the steering, brakes, hydraulic controls, instruments, and safety equipment. Check the NEUTRAL position of the transmission control Lever. A machine that runs correctly can prevent accidents.

Make all necessary repairs or adjustments before you operate the machine.

WARNING: Avoid exposure to dust containing crystalline silica particles. This dust can cause serious injury to the lungs

(silicosis).

WARNING: DO NOT operate the machine while under the influence of alcohol or drugs.

WARNING: Operate controls only when in the operator’s seat.

WARNING: CLEAR THE WORK AREA OF ALL

BY-STANDERS. During digging maintain a minimum safety zone of 50 ft. (15 M) around the machine.

WARNING: Hillside operation can be dangerous. Rain snow, ice, loose gravel, soft ground, etc., change the ground conditions. You must make a judgement if your machine can be safely operated on any hillside or slope greater than 20°.

AU103168 C7B 20

STEP AND HAND RAIL

OPERATING INSTRUCTIONS

Backfill Operating Position

Sit on the operator’s seat facing the Backfill Blade of the machine. Operate the controls for the machine and backfill blade in this position. See Backfill Blade Controls in this manual.

PIC00120

1. STEPS 2. HAND RAIL

Face the machine and use the hand rail and step to get

ON or OFF the machine. DO NOT use the control levers as grab handles.

OPERATOR POSITION

WARNING: Operate controls only when in the operator’s seat.

Trencher Driving, Transport Position

Sit on the operator’s seat facing the Trencher end of the machine. Operate the controls for the machine and trencher in this position. See Instrument Panel Controls in this manual.

PIC00121

BD01F317

TRENCHER OPERATION

WARNING: CLEAR THE WORK AREA OF ALL

BY-STANDERS. During digging maintain a minimum safety zone of 50 ft. (15 M) around the machine.

WARNING: Make sure all people are clear of the digging chain while the digging chain is rotating.

Serious injury or death can result from contact with the digging chain.

WARNING: Sharp moving parts - do not remove restraint bar. Keep clear of hazardous area. KEEP

CLEAR. Serious injury or death can result from bodily contact.

AU103168 C7B

OPERATING INSTRUCTIONS

WARNING: Know the location of underground cables, water pipes, gas lines, etc. Injury or death can result from cutting a cable or gas line.

TRENCHER BOOM TYPES

WARNING: CLEAR THE WORK AREA OF ALL

BYSTANDERS. DURING DIGGING KEEP

SPECTATORS AWAY. The digging chain of your trencher can throw rock and soil debris a considerable distance.

WARNING: while digging.

Never allow anyone in the trench

WARNING: Be careful when working near the side of a trench. Serious injury or death can result if the walls of the trench fall.

Sprocket Boom (if equipped)

The sprocket boom is the most efficient boom for digging in light to medium soil. Friction is reduced because the chain is riding on sprockets and not rubbing on a boom channel. More power is available for digging when friction is reduced.

WARNING: Operate controls only when seated in the operators seat.

Selecting Correct Tools for the Job

You can increase the digging speed and still get long life from you trencher if you use the correct trencher components. Read the following section on how to select the correct combination of parts for your machine.

Then, see your Astec dealer and ask for complete information on trencher parts.

As a general rule, always select the shortest boom, lightest chain and lightest teeth to get the job done.

Then, in hard digging conditions, select a high tensile strength chain, a channel boom, and anti-backflex chain with rock and frost teeth.

When you make the selection, know the trench width, trench depth, soil and weather conditions of the job.

1. Select the boom length.

2. Select the boom type (sprocket or channel).

3. Select the chain type (tensile strength and standard or anti-backflex).

4. Choose the teeth (cupped, rock and frost carbide cutters, or both).

5. Choose the tooth width and arrangement.

6. Determine if you need dirt drags.

BD01F334

Channel Boom (if equipped)

The channel boom is designed to give support to the chain when digging in hard or rocky ground or when the ground is frozen. The design also prevents rocks from getting between the chain and the boom and gives full support to the digging chain.

BD01F320

AU103168 C7B 22

OPERATING INSTRUCTIONS

Boom Position When Digging

For the best digging performance and smoothest machine operation, the boom must be in the full down digging position. In this position, the machine is pulled down for better traction. The ground drive simply pulls the digging teeth into the face of the trench.

When the boom is raised from the full down position, the digging load pulls the machine more rearward. This pulling reduces traction and may cause the machine to bounce and pull when the chain contacts roots or rocks.

The rearward pull of the digging operation also works against the ground drive causing the machine engine to work harder.

WARNING: Make sure all people are clear of the machine and working area while the digging chain is rotating. Serious injury or death can result from contact with the digging chain or flying debris.

MOST EFFICIENT

BOOM IN FULL

DOWN POSITION

DIGGING

LOAD

SHORTER

LEAST EFFICIENT

BOOM NOT IN FULL

DOWN POSITION

DIGGING

LOAD

LONGER

TRENCHER CHAIN AND TEETH

Chain Types

The correct chain for the job is very important. Soil conditions determine the type of chain needed. A chain that is too light will wear fast or break. A chain that is too heavy increases the load and slows the trencher speed.

Standard Digging Chain

The standard digging chain works fine in most digging conditions. However, because of the design, the standard chain teeth can rotate back (backflex) when digging in heavy or rocky ground. When this backflexing action starts, the teeth do not remain at the correct digging angle and the trenching speed is reduced.

Anti-Backflex Digging Chain

This chain is designed for hard digging conditions. The side plates of each link are close together. As the chain leaves the sprocket, each link comes together with the next and forms a solid digging channel. This action keeps each digging tooth at the correct digging angle.

IMPORTANT: Correct chain tension is very important for this type of digging chain. See Digging Chain Tension for

Sprocket/Channel Boom in this manual.

Teeth

The most important parts of the trencher are the teeth.

The type of teeth that you select and the arrangement you use makes a big difference in the digging efficiency and tooth life.

B2228A88

RB97F067

NOTE: Additional digging teeth combinations may be available to meet particular soil conditions. See your Astec dealer for additional information.

23 AU103168 C7B

OPERATING INSTRUCTIONS

BEFORE YOU OPERATE

TRANSPORT

POSITION

WARNING: Be careful when working near the side of a trench. Serious injury or death can result if the walls of the trench fall.

WARNING: Sharp moving parts - do not remove restraint bar. Keep clear of hazardous area. KEEP

CLEAR. Serious injury or death can result from bodily contact.

WARNING: while digging.

Never allow anyone in the trench

OPERATING

POSITION

WARNING: Make sure all people are clear of the digging chain while the digging chain is rotating.

Serious injury or death can result from contact with the digging chain.

Cutting a Trench

NOTE: Know the location of all underground utilities before starting.

1. Make sure all persons are away from the machine before you start the engine and while you are trenching.

2. See Starting the Engine in this manual. Start the engine. Run the engine at 1/4 throttle until the engine is at operating temperature.

3. After the engine has reached operating temperature, move the machine to the work area and put the machine in the correct position to cut the trench.

Make sure that the end of the trencher boom is several feet beyond the starting point of the trench.

4. Align the machine to the center line of the new trench.

5. Put the crumber (if equipped) in the TRANSPORT position.

6. Move the Range Control into the LOW position.

RH97H014

7. Turn the Creep Speed Control counterclockwise until the control is completely OPEN.

8. Lower the Trencher Boom to within several inches of the ground.

9. Move the Trencher Clutch Lever to the left to actuate the digging chain and spoil auger.

10. Increase engine speed to 3/4 throttle. Slowly lower the boom and cut the trench until the boom is at the correct depth

11. Increase the engine speed to full throttle.

12. Put the Forward/Reverse Lever in REVERSE. Rotate the Speed Creep Control to adjust the ground speed.

Slowly CLOSE the Creep Speed Control until machine begins to move rearward.

NOTE: This will counteract the digging chain contact with the ground which is pulling the unit FORWARD

NOTE: The trencher operates best at full throttle. Adjust ground speed to keep from lugging the engine .

13. After the trench is approximately 610 mm (2 feet) long, stop the machine. Raise the boom and pull the

Trencher Clutch Lever to the right to stop the digging chain.

14. Move the crumber bar into the operating position.

15. Move the Trencher Clutch Lever to the left to actuate the digging chain and spoil auger.

16. Increase engine speed to 3/4 throttle. Slowly lower the boom into the open trench until the boom is at the correct depth.

17. Increase the engine speed to full throttle.

18. Put the Forward/Reverse Lever in REVERSE. Rotate the Speed Creep Control to adjust the ground speed.

NOTE: The trencher operates best at full throttle. Adjust ground speed to keep from lugging the engine.

AU103168 C7B 24

OPERATING INSTRUCTIONS

19. Any steering must be gradual. Actuate the Steering

Brake Levers as necessary to steer the machine.

NOTE: Do not make sharp turns with the boom in the ground. Sharp turns with the trencher operating will cause damage to the machine.

20. Check the digging chain tension when starting a new trench in each location. See Trencher Digging Chain

Tension in this manual.

21. When the trench is completed, stop the machine.

Raise the boom slowly from the trench. Move the

Trencher Clutch Lever to the right to stop the digging chain.

22. Turn the Speed Creep Control clockwise several turns until the control is completely CLOSED.

NOTE: When transporting the machine or backfilling, make sure the Speed Creep Control is completely CLOSED

(turned clockwise).

Cutting A Straight Trench

To cut a straight trench, place a string line far enough to one side of the machine to clear the machine.

Cutting A Curved Trench

You can cut a gradual curve by pulling the Steering Brake

Lever about half way in the REARWARD position to disengage power to the track. The machine will gradually turn in the direction of the disengaged track.

NOTE: Do not make sharp turns with the boom in the ground. Sharp turns with the trencher operating will cause damage to the machine.

To cut a sharp curve with the trencher, see the illustration below.

BACKHOE

EXCAVATION

HOLE

EXAMPLE “A” EXAMPLE “B”

B1493A88

Example “A” If the cable or pipe is flexible enough for a sharp 90 degree corner, cut a new trench 90 degrees to the previous trench.

Example “B” If the cable or pipe is not flexible enough for a sharp corner, use a backhoe to open up the corner to allow for a more gradual bend.

PIC00122

BACKFILL BLADE OPERATION

WARNING: Along a trench, high bank or overhang, the machine can fall and cause injury or death. You must make a judgement if your machine can be safely operated near any of these areas.

STRING LINE

B901050

STRING LINE AND ADJUSTABLE POINTER

Align the adjustable pointer at the rear of the machine with the string. Cut the trench as instructed herein, while keeping the pointer aligned with the string.

WARNING: Be careful when working near the side of a trench. Serious injury or death can result if the walls of the trench fall.

1. See Backfill Blade Controls in this manual. Move the

Steering Brake Levers to the rear of the machine for backfill operation.

25 AU103168 C7B

OPERATING INSTRUCTIONS

2. See Instrument Panel Controls in this manual. Make sure the Speed Creep Control is fully CLOSED (turned clockwise).

3. Move the Range Control Lever to HIGH range.

NOTE: If the engine lugs down while you are backfilling, move the Range Control Lever to the LOW range.

4. Move the machine into position at the end of the trench.

5. When backfilling parallel with the trench, the machine will do a better job if you make 2 or 3 passes at the spoil pile.

6. If the spoil pile is too large, operate the machine at right angles to the trench.

You must know the rules or laws for safety that are used in each area that you will be in. Make sure that your truck and machine are equipped with the correct safety equipment.

1. Make sure the trailer and ramp can support both your weight plus the weight of the machine.

2. Always have the attachments in the TRANSPORT position when loading or unloading.

3. Put a block at the front and rear of the trailer wheels.

4. Be careful, move the machine slowly onto the trailer.

5. Pull both Steering Brake Levers all the way

REARWARD to lock the brakes.

B901051

TRANSPORTING THE MACHINE ON

A TRAILER

WARNING: Know the rules, regulations, laws and safety equipment necessary for transporting or operating this machine on a road or highway.

Rotating beacon, backup alarm, slow moving vehicle emblem and other safety equipment items are available from your dealer.

WARNING: The machine can slip and fall from a trailer or ramp and cause injury or death. Make sure the trailer and ramp are not slippery. Remove all oil, grease, ice, etc. Carefully move the machine off or onto the trailer with the machine centered on the trailer and ramp.

B901052

BD01F318

BRAKES APPLIED

6. Lower the Backfill Blade and Trencher to the trailer.

7. Stop the engine and remove the key.

8. Put blocks at the front and rear of each track.

9. Use chains to fasten the machine to the trailer using chain tensioners. Use the front and rear tie downs to secure chains to machine.

10. Measure the distance from the ground to the highest point of the machine. You must know the clearance height of the machine.

11. Remove the blocks from the front and rear of the trailer wheels.

12. After you have driven a few miles, stop the truck and check your load. Make sure the chains are still tight and that the machine has not moved on the trailer.

UNLOADING - Put a block at the front and rear of the trailer wheels. After the blocks and chains are removed fro m t h e ma ch i n e , p u t th e a tt a c h m en t s i n t he

TRANSPORT position. Start the engine, and slowly move the machine off the trailer.

AU103168 C7B 26

LUBRICATION

GENERAL SAFETY BEFORE

SERVICING MACHINE

WARNING: Improper service or repair can cause injury or death. If you do not understand the service procedures for this machine, see your dealer or the service manual for this machine.

Use the correct safety clothing and safety equipment.

Understand how to use a fire extinguisher and first aid kit.

BE ALERT! Know where to get assistance. Know how to use a first aid kit.

BE AWARE! Take advantage of training programs offered.

Do not service this equipment without proper training.

WARNING: Raised equipment on the machine without an operator can cause injury or death.

Before you leave the machine, always support or lower the equipment (trencher boom, etc.) to the ground and stop the engine.

WARNING: Replace all covers or guards after servicing or cleaning the machine. NEVER operate the machine with covers or guards removed.

Read the safety decals and information decals on the machine. Read the operator’s manual. Understand the operation of the machine before you start servicing.

PLASTIC AND RESIN PARTS

Avoid using gasoline, kerosene, paint thinner, etc., when cleaning plastic windows, console, instrument cluster, monitor, gauges, etc. Use ONLY water, mild soap and a soft cloth when you clean these parts.

Using gasoline, kerosene, thinner, etc., will cause discoloration, cracking or deformation of the part being cleaned.

ENVIRONMENT

Before you service this machine and before you dispose of the old fluids or lubricants always remember the environment. DO NOT put oil or fluids into the ground or into containers that can leak.

Check with your local environment or recycling center or your dealer for correct disposal information.

B801147T

ENGINE HOURMETER/TACHOMETER

When the engine is running, this gauge will show the engine speed (RPM). When the engine is stopped, this gauge will indicate the number of actual whole hours the engine has run. Use the engine hourmeter along with the

Lubrication/Maintenance Chart in this manual to service your machine at the correct time periods.

NOTE: This gauge contains a non-replaceable battery.

Dispose of the gauge in a responsible manner upon replacement .

PIC00056

Before you service the machine, put a Do Not Operate tag on the control panel. This tag, Astec part number

AU103157 is available from your dealer. The Do Not

Operate tag is included with your machine.

BD01F327

AU103168 C7B

LUBRICATION

CAPACITIES AND LUBRICANT SPECIFICATIONS

FUEL TANK

Capacity ........................................................................................................................... 20.8 L (5.5 U.S. Gal.)

Type of Fuel.........................REGULAR LEAD FREE Gasoline (with minimum average octane rating of 85 or higher)

ENGINE CRANKCASE

Capacity .............................................................................................................................1.9 L (2.0 U.S. Qts.)

Type of Oil ..........................................................................Astec SAE 30 (see Engine Lubrication in this manual)

HYDRAULIC SYSTEM

Reservoir Capacity............................................................................................................. 26.5 L (7.0 U.S. Gal.)

Type of Fluid over 5°C (40°F).........................................................................................Astec Engine Oil SAE 30

Type of Fluid under 5°C (40°F)....................................................................................... Astec Engine Oil 10W30

TRANSMISSION

Capacity ...........................................................................................................................0.95 L (1.0 U.S. Qts.)

Type of Fluid ............................................................................................................Single Grade Engine Oil API

GEAR REDUCTION HOUSING

Capacity ...........................................................................................................................0.47 L (0.5 U.S. Qts.)

Type of Fluid ............................................................................................................Single Grade Engine Oil API

GREASE FITTINGS

Type of Lubricant ............................................................................................................. Astec Moly HT Grease

BATTERY

Capacity ........................................................................................................................................ As Required

Type of Fluid ...................................................................................................... Drinking or Distilled Water Only

AU103168 C7B 28

LUBRICATION

LUBRICATION/MAINTENANCE CHART

FREQUENCY IN HOURS

R SERVICE POINTS

Trencher Digging Chain Tension

Trencher Clutch (See Note 1)

Engine Oil Level (See Note 4)

Air Cleaner (See Note 1)

Hydraulic Reservoir Oil

Trencher Shaft (See Note 2)

Trencher Boom Mount (See Note 2)

Trencher Clutch Yoke (See Note 2)

Trencher Sheave (See Note 2)

Steering Brake Lever (See Note 2)

Backfill Blade (See Note 2))

Battery Electrolyte Level (See Note 2)

Fuel Filter

Engine Oil Filter

Trencher Drive Belt Tension (See Note 3)

Trencher Drive Chain Tension (See Notes 1 and 3)

Track Tension

Engine Oil Cooler (See Note 2)

Trencher Drive Chain

Hydraulic Filter

Transmission Oil

ROPS Structure

Seat Belts

Hydraulic Reservoir Suction Screen

Gear Reduction Housing Oil

Engine Valve Clearance

2 10

1 10

100

250

500

50 250

1000

250

1000

500

Spark Plug 500

*

- As Required

NOTE 1 :See adjustment procedure in this manual.

NOTE 2 :Intervals shown are for normal conditions. If the machine is to be used in severe conditions, high temperature, mud, heavy dust, etc., intervals should be more frequent.

NOTE 3 :If drive chain is new, check and adjust after every 2 hours of operation until tension remains constant.

NOTE 4 :If the engine is new, change the engine oil after the first 5 hours of operation. Then change the oil after every

50 hours of operation.

29 AU103168 C7B

LUBRICATION

HOOD

ACCESS DOORS AND COVERS

BD01C051

Unlatch hood and raise until support rod locks into place.

One latch on each side of hood.

BD01F326

For increased service access the hood may be positioned over center onto the front dirt guard. Push forward slightly on the hood and push the latch toward the left side of the slot (2), then continue to push the hood over center.

BD01G013

Check that rod (1) is positioned correctly in slot before releasing grip on hood.

PIC00124

HOOD OVER CENTER, FULL ACCESS

To close the hood from the wide open position, pivot hood to the vertical position; position the rod toward the left of the slot and enter the rod into the slotted hole.

AU103168 C7B

HOOD SHOWN OPEN

PIC00123

LUBRICATION

BATTERY AND FUEL TANK

BD01C049

To gain access to the battery, raise the seat housing a few inches, then pull rearward.

1. FUEL FILL

TRENCHER DRIVE CHAIN

BD01C056

B4032990

TRENCHER DRIVE CHAIN COVER

IMPORTANT: Ensure that all doors and covers are closed and latched before operation.

31 AU103168 C7B

LUBRICATION

LUBRICATION

BASIC MACHINE

6 5 5

3. TRENCHER SHEAVE

B4033790

4

3

1

2

1. TRENCHER BOOM MOUNT

2. TRENCHER SHAFT

3. TRENCHER SHEAVE

BC01C152

4. TRENCHER CLUTCH YOKE

5. STEERING BRAKE LEVER

6. TRENCHER DRIVE CHAIN

LUBRICATION POINTS

10 Hours

4. TRENCHER BOOM MOUNT FITTING

B4032290

1. STEERING BRAKE LEVER (4)

BD01F318

5. TRENCHER SHAFT FITTINGS (2)

100 Hours

B4032190

2. TRENCHER CLUTCH YOKE FITTING

AU103168 C7B

B4034490

6. TRENCHER DRIVE CHAIN

B4022588

LUBRICATION

FLUID LEVELS

BASIC MACHINE

2 250 Hours

1

3

1. GEAR REDUCTION LEVEL

2. BATTERY LEVEL

10 Hours

BC01C152

3. TRANSMISSION OIL LEVEL

3. TRANSMISSION OIL LEVEL

B4033690

50 Hours

ENGINE OIL LEVEL

BD01F324

HYDRAULIC OIL LEVEL

BACKFILL BLADE - 3 Fittings

10 Hours

BD01F329

2. BATTERY LEVEL

BD01F315

B4028690

AU103168 C7B

LUBRICATION

ENGINE LUBRICATION

Engine Oil Selection

Astec Engine Oil is recommended for use in your engine.

Astec Engine Oil will lubricate your engine correctly under all operating conditions

Use a SAE 30W Single Grade Engine Oil when operating in temperatures over 5°C (40°F). If Astec Multi-Viscosity is not available, for cold weather operation, Astec Single

Grade Engine Oil can be used. If Astec engine oil is not available, use only oil meeting API engine oil service category SF or SG.

IMPORTANT: Air cooled engines run hotter. The use of non-synthetic multi-viscosity oils in temperatures above

5°C (40°F) will result in higher than normal oil consumption. When using a multi-viscosity oil, check oil level more frequently.

NOTE: DO NOT put Performance Additives or other oil additive products in the engine crankcase. The oil change intervals given in this manual are according to tests with

Astec lubricants.

RH99K130

See the following chart for recommended viscosity at ambient air temperature ranges.

OIL VISCOSITY/TEMPERATURE USAGE CHART

BC01C159

AU103168 C7B 34

LUBRICATION

Engine Oil Level

DIPSTICK

OIL FILL

CAP IN

COVER

OIL

FILTER

BD01F324

NOTE: Check the engine oil every 10 hours of operation or once every day, whichever occurs first.

Make sure the engine is not running and the machine is parked on a level surface when you check the oil level.

NOTE: If the engine has been running, wait 2 or 3 minutes before you check the oil level.

1. Raise the engine service hood. Stand on the right side of the machine and locate the engine oil dipstick (1).

2. Pull out the dipstick and wipe with a clean cloth.

3. Push the dipstick completely in and remove.

4. The oil level must be between the ADD and FULL marks on the dipstick.

5. If the oil level is below the ADD mark, add oil through the oil filler cap (2), located in the valve cover at the front of the engine. Raise the oil level to the FULL mark. Do not raise the oil level above the FULL mark.

6. Install the oil filler cap, if removed

7. Install the dipstick. Make sure the dipstick is fully seated in the dipstick tube. Lower the engine service hood.

NOTE: See Engine Lubrication chart for the engine oil specifications.

Engine Oil and Filter Change

Change the engine oil after the first 5 to 8 hours of operation and then every 50 hours of operation. Replace the engine oil filter every 50 hours or operation.

Change the oil more often if the engine is operated in dirty or dusty conditions or if engine is operated under heavy loads or in high ambient air temperatures.

If possible, change the oil when the oil is warm. Warm oil drains quickly and completely.

OIL DRAIN

VALVE

1/2 - 3/4

TURN

RT160044

1. Park the machine on a level surface and stop the engine. Remove the key.

2. Move the Steering Brake Levers all the way

REARWARD to lock the brakes.

3. Open the hood. Loosen and remove the dipstick.

4. Place a drain pan that will hold 1.9 L (2 U.S. Qts.) under the engine drain plug and remove the plug.

5. Allow the used oil to drain completely, then reinstall the drain bolt, and tighten it securely.

6. Standing on the right side of the unit, reach around the rear of the engine with a filter strap wrench and remove and discard the oil filter.

7. Clean the gasket seal surface on the filter head with a clean cloth.

8. Apply a thin layer of clean grease or oil to the gasket seal of the new oil filter.

IMPORTANT: DO NOT use a filter strap wrench to install the new oil filter. An oil filter strap wrench can cause a leak if the filter is dented.

9. Install the filter. Use your hands to tighten the filter until the filter seal makes contact with the filter mounting base. Then tighten the filter an additional

1/2 to 3/4 turn.

10. Fill the crankcase with the specified amount of the recommended oil. See Engine Lubrication in this manual.

11. Install the filler cap and the dipstick. Check the oil level.

12. Start the engine. Run the engine at idle for approximately 2 minutes. Check for oil leaks.

13. Stop the engine.

35 AU103168 C7B

LUBRICATION

14. Wait approximately 5 minutes and check the oil level. If the oil level is below the FULL mark, add oil to raise the oil to the FULL mark. Do not fill the crankcase above the FULL mark.

WARNING: Never drain oil or remove oil filter while engine is running.

Engine Oil Cooler Maintenance

The TF300B V-Twin engine is equipped with an external engine oil cooler. The cooler is mounted in front of the engine blower intake. Filtered oil is routed through the oil cooler through two hoses from the oil filter adapter.

Fresh air is drawn across the oil cooler fins dissipating heat from the engine oil.

The oil cooler fins must be checked periodically and cleaned with compressed air or a soft bristle brush every

100 hours. Remove the air intake housing to perform this task. The air intake housing must be reinstalled prior to machine operation.

INTAKE SHROUD

BD01H265

AIR FILTERING SYSTEM

A dirty air filter will restrict air flow to the carburetor, reducing engine performance. If you operate the machine in very dusty areas, clean the air filter more often.

The air filter element should be checked every day or 10 hours of operation, cleaned every season or 25 hours of operation, and replaced once a year or every 50 hours of operation.

Check and Clean

1. Park the machine on a level surface and stop the engine. Remove the key.

2. Move the Steering Brake Levers all the way

REARWARD to lock the brakes.

3. Open the engine hood to access the Air Filter.

4. Remove the cover assembly and knob that holds the cover plate down.

5. Remove the foam pre-cleaner and wash it in liquid detergent and water

6. Squeeze the pre-cleaner dry with a clean cloth or paper towel.

7. Saturate the pre-cleaner in engine oil. Wrap it in a clean absorbent cloth and squeeze to remove excess oil.

8. Reinstall the pre-cleaner over the air filter cartridge

9. Replace the knob that holds the cover plate down and close the cover assembly.

10. Close and secure the engine hood.

Replace Air Filter

To replace the Air Filter element follow the procedure above but replace the old filter with a new one. Use a damp cloth and wipe all the excess dirt from around the cover housing and under the cover.

NOTE: Be careful not to knock loose dirt or debris down into the engine while the filter and covers are removed .

IMPORTANT: Never operate this engine with the air cleaner assembly or air cleaner removed.

AU103168 C7B

COOLER

BD01H263

LUBRICATION

Cleaning the Element

Check the dirty element for damage. Replace the element as necessary.

WARNING: Always wear face protection when using compressed air.

Wear face protection.

Remove the loose dirt with compressed air at 207 kPa, 2 bar (30 psi) maximum.

Hold the nozzle at least 25 mm (one inch) from the element.

2. Mix 2 tablespoons of D1400 Detergent, available from your dealer, with 7.5 litres (2 gallons) of water.

3. Soak the element in the detergent solution for 15 minutes and then move the element up and down rapidly to loosen as much dirt as possible.

4. Use a water hose without a nozzle and pressure less than 275 kPa, 2.8 bar (40 psi) to remove all detergent from the element.

5. Allow the element to air dry. If you use a drier, do not exceed 71°C (160°F) and make sure the air is circulating in the drier.

6. Use a light and inspect the element for holes or splits in the pleats. Check for damage to the metal parts and rubber gaskets. Replace the element as necessary.

NOTE: If the element is not to be used for some time, cover the element with paper for storage .

FUEL SYSTEM

WARNING: Engine fuel is flammable and can cause a fire or an explosion. Do not fill the fuel tank or service the fuel system near an open flame,welding, burning cigars, cigarettes, etc.

WARNING: Never refuel the machine when the engine is hot or running. Never smoke while refueling.

WARNING: Fluid under pressure can pierce skin and cause injury or death. Stay away.

Lead-Free Gasoline Fuel

Use lead-free gasoline with a minimum average octane rating of 85 or higher.

NOTE: Do not use gasoline that contains more than 10% ethanol. If you use gasoline that contains methanol, the gasoline must contain cosolvents and corrosion inhibitors.

Never use gasoline containing more than 5% methanol.

Fuel Storage

If you keep fuel in storage for a period of time, you can get foreign material or water in the fuel storage tank.

Many engine problems are caused by water in the fuel.

Fuel Tank Filler Cap

Fill the tank at the end of each day. A full tank will prevent water condensation.

BD01C056

1. FUEL FILLER CAP

Always stop the engine and let cool before adding fuel.

When adding fuel to the machine, remove the fuel cap

SLOWLY to reduce any air pressure build up.

In-Line Fuel Filter

The fuel filter should be checked every 6 months or every

500 hours of operation. Replace the fuel filter every 250 hours of operation or every year.

1. Park the machine on a level surface and stop the engine.

2. Move the Steering Brake Levers all the way

REARWARD to lock the brakes.

3. Open the engine access hood.

4. Clean the area around the filter.

37 AU103168 C7B

LUBRICATION

BD01C055

5. Remove the in-line fuel filter element clamps.

Remove old filter from fuel lines and install new filter. Inspect fuel lines during replacement. Install clamps.

6. Inspect routing of fuel lines to prevent rubbing on any moving components or sharp objects.

HYDRAULIC OIL SYSTEM

BD01F329

WARNING: Fluid under pressure can pierce skin and cause injury or death. Stay away.

HYDRAULIC RESERVOIR DIPSTICK AND FILL TUBE

BD01F328

Hydraulic Filter Change

WARNING: Shut off engine and remove key before performing maintenance or repair work.

Hydraulic Oil Level

Check the hydraulic reservoir oil level every 10 hours of operation or one time each day, whichever occurs first.

1. Park the machine on a level surface.

2. Stop the engine and remove the key.

3. Open the hood.

4. Loosen and remove the dipstick (1) to check the hydraulic oil level in the hydraulic reservoir.

5. If the oil level is below the ADD mark, add oil until the oil level is at the FULL mark.

6. Install the dipstick after checking the oil level.

BD01C057

HYDRAULIC FILTER

1. Park the machine on a level surface and stop the engine. Remove the key.

2. Move the Steering Brake Levers all the way

REARWARD to lock the brakes.

3. Remove the seat and seat plate.

AU103168 C7B 38

LUBRICATION

4. Use a strap wrench to remove the old hydraulic filter

(1). Turn the filter counterclockwise to remove.

Discard the filter in a proper manner. Consult local oil product disposition regulations. It may be necessary to loosen the front battery bolt to remove filter.

5. Lubricate the gasket on the new filter with clean engine oil. Turn the new filter onto the filter head until the gasket makes contact with the filter head.

Continue to tighten the filter by hand 1/2 to 3/4 of a turn. If front battery tie-down bolt was loosened, tighten after filter replacement.

IMPORTANT: Do not use a filter wrench to tighten the filter. A wrench can damage the housing of the filter.

Hydraulic Oil Change and Hydraulic

Reservoir Suction Screen Cleaning

6. Check the oil level in the hydraulic reservoir. Add oil if necessary.

7. Start and run the engine at idle speed for two minutes. Check for leaks around the filter.

8. Stop the engine, remove the key and check the oil level in the hydraulic oil reservoir. Add oil as necessary.

9. Install dipstick after checking hydraulic oil level and close hood.

10. Install seat and seat plate.

Hydraulic Reservoir Breather

BD01F328

BD01F319

RESERVOIR BREATHER

1. Open the hood. Remove and clean the breather each time the hydraulic oil is changed.

2. Install the breather after cleaning.

B4033590

1. Make sure the hydraulic oil is at operating temperature.

2. Park the machine on a level surface and stop the engine. Remove the key.

3. Move the Steering Brake Levers all the way

REARWARD to lock the brakes.

4. Put a drain pan below the hydraulic reservoir drain plug. The hydraulic reservoir holds approximately

26.5 litres (7 U.S. Gallons) of oil.

5. Remove the drain plug (1) and drain the oil from the hydraulic reservoir.

6. Loosen the clamp (2) that fastens the hose to the suction screen (3). Disconnect the hose from the suction screen.

7. Loosen and remove the suction screen from the hydraulic reservoir.

8. Clean the suction screen in cleaning solvent.

9. Apply sealant to the threads on the suction screen.

10. Install the suction screen, connect the hose and tighten the hose clamp. Apply sealant to the threads on the drain plug.

11. Install the drain plug.

12. Fill the hydraulic reservoir with oil, see Hydraulic

System Service Specifications in this manual for reservoir capacity.

13. Start and run the engine at idle for 2 minutes.

14. Stop the engine and check for leaks, check the oil level in the hydraulic reservoir. Add oil as necessary.

AU103168 C7B

LUBRICATION

TRANSMISSION AND GEAR

REDUCTION HOUSING

Transmission Oil Level

The transmission oil level should be checked every 250 hours of operation.

Transmission Oil Change

The transmission oil should be changed every 1,000 hours of operation.

B4040990

B4033690

Check the transmission oil level with the engine stopped, key removed and the machine parked on a level surface.

Loosen and remove the level plug (1). The oil must be even with the hole for the level plug. Add oil as necessary.

Gear Reduction Housing Oil Level

The gear reduction housing oil should be replaced every

1,000 hours of operation.

B4040890

Check the housing oil level with the engine stopped, key removed and the machine parked on a level surface.

Loosen and remove the level plug (2). The oil must be even with the hole for the level plug. Add oil as necessary.

B4033690

1. Make sure the transmission oil is at operating temperature.

2. Park the machine on a level surface, stop the engine and remove the key.

3. Move the Steering Brake Levers all the way

REARWARD to lock the brakes.

4. Put a drain pan below the transmission. The transmission holds approximately 0.95 L (1 U.S. Qt.) of oil.

5. Loosen and remove the lowest bolt (1) on the LEFT side of the transmission housing to drain the oil.

6. When all the oil is drained from the transmission, install and tighten the bolt.

7. Fill the transmission through the level plug hole (2) until the oil is even with the bottom of the hole.

8. Install and tighten the level plug.

AU103168 C7B 40

Gear Reduction Housing Oil Change

LUBRICATION

TRENCHER DRIVE CHAIN

LUBRICATION

B4034690

B40330909

2 2

B4040890

1. Make sure the gear reduction housing oil is a operating temperature.

2. Park the machine on a level surface, stop the engine and remove the key.

3. Move the Steering Brake Levers all the way

REARWARD to lock the brakes.

4. Put a drain pan below the gear reduction housing.

The gear reduction housing holds approximately 0.25

L (0.25 U.S. Qt.) of oil.

5. Remove the drain plug (1) and drain the oil from the gear reduction housing.

6. When all the oil has been drained from the gear reduction housing, install and tighten the drain plug.

7. Fill the gear reduction housing through the level plug hole (2) until the oil is even with the bottom of the hole.

8. Install and tighten the level plug.

B4022588

1. Park the machine on a level surface, stop the engine and remove the key.

2. Move the Steering Brake Levers all the way

REARWARD to lock the brakes.

3. Remove the chain cover (1) and lubricate the trencher drive chain (2) with Case Chain Lubricant.

Case Chain Lubricant is available from your dealer.

4. After lubrication is complete, install the chain cover.

IMPORTANT: Always replace chain cover after servicing the machine. NEVER operate the machine without covers or guards in place.

WARNING: Replace all covers or guards after servicing or cleaning the machine. NEVER operate the machine with covers or guards removed

41 AU103168 C7B

LUBRICATION

NOTES

AU103168 C7B 42

ADJUSTMENT/MAINTENANCE

TRENCHER DRIVE BELT TENSION

WARNING: Rotating belts. Contact with rotating belts can cause serious injury or death.

Always stop the engine and remove the key before working in this area.

Check the trencher drive belt tension every 50 hours of operation. Adjust as necessary. If the drive belt is new, check and adjust the belt every 30 minutes until the tension remains constant.

Replace the trencher drive belt if you see any of the following: cuts, cracks, loose cords, grease, oil or twisting.

BD01H264

7. Loosen the lock nuts on the two adjustment bolts.

8. Turn the adjustment bolts to adjust the tension of the trencher drive belt. Make sure you keep the engine in alignment with the jackshaft.

9. After the tension is correct, tighten the lock nuts on the adjustment bolts and tighten the four engine mounting bolts.

10. Close the hood.

TRENCHER CLUTCH

BD01F316 WARNING: Rotating belts. Contact with rotating belts can cause serious injury or death.

Always stop the engine and remove the key before working in this area.

WARNING: Shut off engine and remove key before performing maintenance or repair work.

1. Park the machine on a level surface, stop the engine and remove the key.

2. Move the Steering Brake Levers all the way

REARWARD to lock the brakes.

3. Open the hood.

4. Check the deflection of the trencher drive belt between the engine pulley and trencher clutch. The belt deflection must be 6 mm (1/4 inch) with approximately 9 kg (20 pounds) of force.

5. If the belt needs adjustment, do the following steps.

6. Loosen the four engine mounting bolts.

1

B1582A88

AU103168 C7B

ADJUSTMENT/MAINTENANCE

The adjustable clutch of the trencher protects the trencher drive components. When correctly adjusted, the clutch will slip just enough to stall the engine if the digging chain becomes jammed. The service life of the clutch will be reduced if the clutch is adjusted too loose. If the clutch is adjusted too tight, the digging chain or drive belt can be damaged.

1. To tighten the clutch, pull out the locking pin (1) and rotate the adjusting yoke clockwise until the locking pin engages the next hole in the clutch plate.

2. To loosen the clutch, pull out the locking pin and rotate the adjusting yoke counterclockwise until the locking pin engages the next hole in the clutch plate.

NOTE: If the clutch does not release after several adjustments, the six release springs behind the clutch plate can be weak and must be replaced. See your dealer.

3. When the clutch is adjusted correctly, the clutch will rotate 1-1/2 to 2 revolutions before stalling the engine if the digging chain becomes jammed.

TRENCHER DRIVE CHAIN TENSION

WARNING: Rotating chains. Contact with rotating chains can cause serious injury or death.

Always keep the cover in place while you operate the machine. Stop the engine and remove the key before working in this area.

WARNING: Replace all covers or guards after servicing or cleaning the machine. NEVER operate the machine with covers or guards removed.

Check the trencher drive chain tension every 50 hours of operation. Adjust as necessary. If the drive chain is new, check and adjust the chain every 2 hours until the tension remains constant.

1. Park the machine on a level surface, stop the engine and remove key.

2. Move the Steering Brake Levers all the way

REARWARD to lock the brakes.

3. Remove the trencher drive chain cover.

IDLER

SPROCKET

CHECK

TENSION

HERE

B4033090

4. Move the bottom of the chain up and down to check movement. Total movement must be 12 mm (0.5

inch).

AU103168 C7B

BD01F318

B4033190

5. Adjust the idler sprocket as necessary to get the correct chain tension.

6. Install the trencher drive chain cover after adjustment is complete.

ADJUSTMENT/MAINTENANCE

TRENCHER DIGGING CHAIN TENSION

WARNING: Rotating chains. Contact with rotating chains can cause serious injury or death.

Always keep the cover in place while you operate the machine. Stop the engine and remove the key before working in this area.

Check the tension of the digging chain frequently. The tension specifications are for normal soil conditions.

Change the tension according to your soil conditions.

Increase tension in hard rocky soils and decrease the tension in loose soils. Do not overtighten the chain.

Operating the trencher with the chain too tight will increase the wear and decrease the service life of the digging chain, sprockets and boom.

NOTE: A digging chain tension set too tight will decrease productivity .

3. Loosen the two boom mounting bolts.

B4033290

B4034790

1. Park the machine on a level surface. Lower the trencher boom into a horizontal position, stop the engine and remove the key.

B4033390

4. Turn the adjusting screw at the bottom of the boom to adjust the tension of the digging chain.

5. See the illustration below and on the following page for correct chain tension in normal soil conditions.

6. Tighten the two boom mounting bolts after correct tension procedure is complete.

BD01F318

2. Move the Steering Brake Levers all the way

REARWARD to lock the brakes.

45 AU103168 C7B

ADJUSTMENT/MAINTENANCE

25 mm (1 inch)

TRACK ADJUSTMENTS

Steel Track Machine

NOTE: Only make track tension adjustment when track is too loose or too tight. Track tension must always be correct.

Check the track tension every 50 hours of operation.

To adjust track, do the following:

1. Park the machine on a level surface, stop the engine and remove the key.

DIGGING CHAIN TENSION FOR SPROCKET BOOM

RH97G038

38 to 63.5 mm

(1-1/2 to 2-1/2 inch)

B4032790

2. Pull up the track at the center of the track frame.

Measure the deflection between the top of the track frame and the bottom of the track. The deflection must be 50 mm (2 inches).

DIGGING CHAIN TENSION FOR CHANNEL BOOM

RH97G037

B4032590

3. If the deflection is not correct, loosen the four transmission mounting bolts.

AU103168 C7B 46

B4032690

4. To Tighten the track or Decrease the deflection remove the cap (2) from the grease fitting in the track adjusting cylinder.

ADJUSTMENT/MAINTENANCE

7. When the track tension is correct tighten the grease fitting.

NOTE: If grease does not start to drain, SLOWLY rotate the track .

WARNING: The grease in the hydraulic track tensioner is pressurized. NEVER loosen grease valve more than one turn. NEVER remove the grease fitting. If the valve is loosened too much or if fitting is removed, grease will be released under pressure causing serious injury.

B4032890

5. Add grease to the track adjusting cylinder until the track tension is correct.

B4032590

8. After adjustment of the track tension is complete tighten the four transmission mounting bolts.

Rubber Track Machine

Check the track tension every 50 hours of operation.

1. Park the machine on a level surface, stop the engine and remove the key.

2. Measure the distance between the top of the track and the bottom of the track frame. Record this measurement.

3. Add 12 mm (1/2 inch) to the measurement found in

Step 2. The answer is the correct track deflection. Do the procedure in Steps 4 through 9 to check and adjust the deflection.

4. Raise the machine until the track is above the ground.

MEASURE THIS

DISTANCE

B4032690

6. To Loosen the track, turn grease valve (3) counterclockwise NO MORE THAN ONE TURN. One turn of the valve will release grease and loosen the track.

B4022890

5. Measure the distance between the track frame and the top of the track. This measurement must equal the measurement calculated in Step 3.

AU103168 C7B

ADJUSTMENT/MAINTENANCE

ROLL-OVER PROTECTION

STRUCTURE

If your machine is equipped with a ROLL-OVER

PROTECTIVE STRUCTURE (ROPS). A ROPS certification label is fastened to the structure with the following information: ROPS Serial Number, maximum gross machine weight, machine model number, and ISO number.

WARNING: Do not modify ROPS in any manner.

Unauthorized modifications such as welding, drilling, cutting or adding attachments can weaken the structure and reduce your protection.

Replace ROPS if subjected to roll-over or damage.

Do not attempt to repair.

B4032590

6. If the deflection is not correct, loosen the four transmission mounting bolts (1).

7. To Tighten the track ( Decrease the deflection), do the following steps:

A. Remove the cap from the grease fitting in the track adjusting cylinder.

B. Add grease to the track adjusting cylinder.

8. To Loosen the track ( Increase the deflection), do the following steps:

A. Slowly loosen the grease fitting in the track adjusting cylinder until grease starts to flow from the track adjusting cylinder. As the grease flows from the track adjusting cylinder the deflection will increase.

NOTE: If grease does not start to drain, SLOWLY rotate the track .

B. When the track deflection is correct, tighten the grease fitting.

9. Tighten the four transmission mounting bolts, when adjustment is completed.

WARNING: If you try to operate this machine without a ROPS and the machine rolls over, you can be injured or killed. Remove the ROPS only for service or replacement.

WARNING: Adding additional weight

(attachments, etc). to the machine can cause injury or death. Do not exceed the gross weight printed on the ROPS label.

WARNING: Improper ROPS inspection or maintenance can cause injury or death. Do the recommended ROPS inspection shown in this manual. If you must replace the ROPS, ROPS parts, or ROPS mounting hardware, use only the replacement parts shown in the Astec parts catalog for this machine.

WARNING: You are protected by the ROPS

(Roll-Over Protective Structure) system on this machine. The seat belt is an important part of that ROPS system. Before you operate this machine, always fasten the seat belt. If the machine rolls over and you DO NOT have the seat belt fastened, you can be crushed by the ROPS or the machine.

Maintenance and Inspection of ROPS

Do the following items every 500 hours of operation or when the ROPS has been in an accident (for example, hitting an overhead object, or the machine rolling over).

IMPORTANT: If the ROPS part is damaged, you must replace the ROPS before you operate the machine.

AU103168 C7B 48

ADJUSTMENT/MAINTENANCE

Check the operators seat and the mounting parts for the seat belt. Tighten the bolts to the correct torque. See

Operators Seat Torque Specifications in this manual.

Replace the parts that have wear or damage.

Check for cracks, rust or holes in the ROPS and ROPS parts. Age, weather and accidents will cause damage to the ROPS and ROPS parts. If you have any doubt about the ROPS system, see your dealer.

Damage to the ROPS

If the machine has rolled over or the ROPS has been in some other type of accident (such as hitting an overhead object during transport), you MUST replace the damaged

ROPS component parts.

After an accident, check the following for damage:

1. The ROPS enclosure.

2. The Lower ROPS frame.

3. The Operator’s seat

4. The seat belt mounting and seat belt.

Before you operate the machine replace all ROPS components that are damaged.

See your dealer for replaceable components.

IMPORTANT: Do not try to weld or straighten the ROPS.

SEAT BELT

The seat belts are an important part of your ROPS. You must wear the seat belt at all times when you operate the machine

Before you operate this machine always make sure that the ROPS and operators seat belts are correctly installed.

Inspection and Maintenance

1. Keep sharp edges and items that can cause damage away from the belts.

2. From time to time, check belts, buckles, retractors, tethers, slack take-up system and mounting bolts for damage.

3. Check the seat belts for damage. Replace all parts that are damaged.

4. Replace belts that have cuts that can make the belt weak.

5. Make sure the mounting bolts for the seat belts are tight.

6. Keep the seat belts clean and dry.

7. Keep the seat belts clean. Wash the seat belts only in soap and water.

DO NOT put the seat belts in bleach or dye. This procedure will weaken the seat belt material.

FIRE EXTINGUISHER

Type of Fire Extinguisher

It is recommended that you have a fire extinguisher on your machine. The fire extinguisher of the type shown is available from your dealer and can be installed on the machine.

Contact your Astec Dealer for proper installation.

BS01H293

49 AU103168 C7B

ADJUSTMENT/MAINTENANCE

153L95

This dry chemical fire extinguisher has a 5 pound capacity and is approved for Class A, B and C type fires. The operating temperature is from -54 to 49°C (-65 to 120°F).

NOTE: See your Astec dealer for the proper type and installation of fire extinguisher.

IMPORTANT: DO NOT mount the Fire Extinguisher on any part of the ROPS structure, unless the mounting is a part of the original design of the ROPS. DO NOT make any modifications to the ROPS structure.

Inspection and Care

EVERY MONTH: It is recommended that you inspect the fire extinguisher once each month for damage and to insure that the gauge is working correctly.

EVERY 6 MONTHS: Have the dry chemical removed and refilled by a fire equipment technician.

ONCE EACH YEAR: Have the fire equipment technician inspect the fire extinguisher.

AU103168 C7B 50

BATTERY

ELECTRICAL

Battery Connections

WARNING: Before you service a battery, always wear face protection, protective gloves and protective clothing. Battery acid or battery explosion can cause serious injuries.

WARNING: 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. DO NOT induce vomiting. Seek medical attention immediately. BATTERIES

PRODUCE EXPLOSIVE GASES. Keep sparks, flame, lit cigars and cigarettes away. Ventilate when charging or using in enclosed area. Always wear eye protection when working near batteries.

Wash hands after handling. KEEP OUT OF REACH

OF CHILDREN.

1. NEGATIVE TERMINAL (-)

2. POSITIVE TERMINAL (+)

BD01F315

WARNING: 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.

WARNING: Sparks or flame can cause hydrogen gas in a battery to explode. To prevent an explosion, do the following:

1. When you disconnect the battery cables, always disconnect the negative (-) battery cable first.

2. When you connect the battery cables, always connect the negative (-) cable last.

3. Do not short circuit the battery posts with metal items.

4. Do not weld, grind, or smoke near a battery.

Battery Service

NOTE: The electrical system in this machine is 12 volts.

Before you service components in the electrical system, always disconnect the negative (-) battery cable.

Do not run the engine with the battery disconnected or the alternator wires disconnected.

Do not use a steam cleaner or cleaning solvent to clean the alternator.

RT160033

BATTERY TERMINALS

Battery Fluid Level

Check the fluid level in the battery every 50 hours of operation. Add clean drinking water or distilled water to each cell until the fluid level is at the split ring in each cell opening.

IMPORTANT: If the temperature is 0 C (32 F) or below and you have added water to the battery do the following: Connect a battery charger to the battery or run the engine for two hours to mix the water with the electrolyte.

Cleaning the Battery

Check the battery regularly for dirt, corrosion and damage. Dirt, mixed with electrolyte or moisture on the top of the battery, can cause a discharged condition in the battery. Use one of the following methods to clean the battery.

1. Use Astec Battery Saver, Astec part number REN280.

Follow the instructions on the container. This cleaner does not need water.

2. Use baking soda or ammonia and flush the outside of the battery with water. If you do not have Astec

Battery Saver, use other special cleaners to prevent corrosion on the battery terminals.

51 AU103168 C7B

ELECTRICAL

OVERLOAD PROTECTION

A 30 ampere fuse protects the electrical system from a circuit overload. It is located in the engine compartment near the relay panel.

If there is a problem in the electrical system, check the 30 ampere fuse. Replace as needed.

SEAT INTERLOCK SYSTEM

Your Trencher may be equipped with a SEAT INTERLOCK

SYSTEM which requires the operator to be seated in the operator’s seat when starting or operating this machine. If the operator does not remain seated when the ground drive and the digging chain clutch levers are NOT in

NEUTRAL or DISENGAGE position, the system will stop the engine in 2 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.

The relays for the SEAT INTERLOCK SYSTEM are located on the side of the engine. Make sure the INTERLOCK

SYSTEM is working properly at all times. New relays are available from your dealer if replacement is needed.

WARNING: The operator presence/seat interlock system provides protection from injury.

Do not disable the system.

AU103168 C7B 52

MACHINE STORAGE

Storage Preparation

If the machine is stored for more than 30 days, it is recommended that the machine be parked inside a building. If a building is not available, park the machine in a dry area on wooden planks and cover the machine with a waterproof covering.

Removal from Storage

DO NOT start the engine until all of the following steps have been completed.

1. Remove the drain plug from the engine to drain any condensation from the engine crankcase.

1. Wash the machine.

2. Lubricate all grease fittings.

3. Paint any areas where the paint has been damaged.

4. Coat hydraulic cylinder rods, valve spools, and control shafts with Astec Rust and Corrosion Preventive.

Astec Rust and Corrosion Preventive is available from your dealer.

2. Install and tighten the drain plug. Fill the engine with oil. See Engine Lubrication in this manual.

3. Make sure the battery is fully charged. Install the battery

4. Fill the fuel tank with gasoline. See Fuel System in this manual.

5. Check the hydraulic oil level.

6. Check the Reduction Gearbox oil level.

5. Clean or replace the element for the air filter.

6. Drain the fuel tank. Engines stored over 30 days need special attention. To prevent gum from forming in fuel system or on essential carburetor p a r t s : I f f u e l t a n k c o n t a i n s ox y g e n a t e d o r reformulated gasoline (gas blended with an alcohol or ether), run engine until it stops from a lack of fuel, or if fuel tank contains gasoline, either run engine until it stops from a lack of fuel, or add a gasoline additive (such as Stabil) to the gasoline in the tank. If you use a gasoline additive, run the engine for several minutes to circulate the additive throughout the carburetor.

7. To prevent rust damage to the internal components of the engine, do the following steps:

A. Stop the engine and remove the key.

B. While the engine is warm, drain the engine oil.

Reinstall the drain plug.

C. Remove the spark plugs and pour 30 ml (1 oz.) of clean engine oil into each cylinder. Install the spark plugs and crank slowly to distribute the oil.

8. Move all hydraulic controls to release any pressure in the hydraulic system.

9. Remove the battery from the machine. Charge the battery and store the battery on a wood pallet in a cool dry area. If possible, keep the battery charged during the storage period.

10. Put a Do Not Operate tag on the key switch.

7. Lubricate the machine at all grease fittings.

8. Use petroleum base solvent to remove the Astec Rust and Corrosion Preventative from the hydraulic cylinder rods and control valve spools.

9. Remove the Do Not Operate tag

10. Start the engine. It is important that you use the correct procedure. See Starting the Engine in this manual.

11. If the cylinders were coated with oil during storage preparation, the engine may smoke briefly at startup.

This is normal.

NOTE: Check the battery periodically for the correct electrolyte level. Test the electrolyte with a hydrometer.

When the hydrometer reading is near 1.215 charge the battery.

53 AU103168 C7B

MACHINE STORAGE

NOTES

AU103168 C7B 54

SPECIFICATIONS

Boom Identification

SPROCKET BOOM, ONE SPROCKET

BOOM LENGTH

SPROCKET BOOM, TWO SPROCKETS

BOOM LENGTH

CHANNEL BOOM, TWO SPROCKETS

BOOM LENGTH

RB97F026

Boom Length in Inches

Boom

Part No.

Chain

Pitch

Maximum Dig

Depth in Inches

Maximum Dig

Width in Inches

SPROCKET BOOM - One Sprocket, 164 and 165 Digging Chain

28.6

H560565 56 26 16*

45.6

52.2

78.6

H560573

H560938

SPROCKET BOOM - Two Sprockets, 164 and 165 Digging Chain

62.5

H567818 96 54 8

H567826

116

CHANNEL BOOM - 164 and 165 Digging Chain

29.2

45.8

52.2

H615559

H615492

H615419

16*

* NOTE: Requires special boom mounting for 28,000 and 34,000 pound four pitch chain. Maximum width cut for

28,000 and 34,000 pound two pitch digging chain is 10 inches. Contact your dealer for additional information.

55 AU103168 C7B

SPECIFICATIONS

ENGINE DATA

Make and Model...................................Briggs & Stratton

Model ..........................................Vanguard 3814479214

Type of Fuel..................................................... Gasoline

Cooling System ..............................................Air Cooled

Number of Cylinders ....................................................2

Displacement .................................. 627 cc (38.2 cu. in.)

Bore ................................................. 75.5 mm (2.97 in.)

Stroke ................................................. 70 mm (2.76 in.)

Horsepower .......................................... 18.5@3100 rmp

Engine Speed

Low Idle ......................................................1000 rpm

High Idle (no load) .......................................3100 rpm

Electrical System ............................ 12 Volt, Electric Start

Alternator ......................................................... 16 Amp

Routine Maintenance Parts

(Purchase from your Astec Dealer)

Oil Filter ........................................................ 416409A1

Air Intake Precleaner ...................................... 416420A1

Air Intake Main Element.................................. 416419A1

In-Line Fuel Filter ........................................... 416421A1

Spark Plug .................. Briggs & Stratton Resistor 496018

Spark Plug .....................Briggs & Stratton Platinum 5066

Spark Plug ........................................ Champion RC14YC

OPERATING DATA AND DIMENSIONS

Operating Weight

Basic Machine with Trencher and Backfill Blade

..................................................... 1.050 kg (2315 lbs.)

Dimensions

A. Trench Depth ...................See Trencher Digging Depth

B. Trench Width ................... See Trencher Digging Width

C. Boom Travel - Total ................................ 130 Degrees

D. Trencher Chain Shaft Height ..... 358.6 mm (14-1/8 in.)

E. Length of Basic Unit ........................ 2159 mm (85 in.)

F. Length with Blade, no Trencher......2743.2 mm (108 in)

G. Width - Transport..........................1028 mm (40.5 in.)

H. Height - Transport (Digging Boom)... 1828 mm (72 in.)

J. Length of Track on Ground .............. 914.4 mm (36 in.)

K. Tread Width................................. 787.4 mm (31 inch)

L. Centerline - Trench to Outside of Machine

.............................................. 520.7 mm (20-1/2 in.)

M. Height - Backfill Blade....................... 406 mm (16 in.)

N. Backfill Blade Travel - Above Ground .. 254 mm (10 in.)

O. Backfill Blade Travel - Below Ground..... 102 mm (4 in.)

P. Width - Backfill Blade ....................... 1422 mm (56 in.)

Q. Backfill Blade Travel - Left or Right............ 40 Degrees

R. Centerline - Machine to Outside of Backfill Blade - Fully

Angled Right or Left .......................... 991 mm (39 in.)

AU103168 C7B 56

RH97G036

SPECIFICATIONS

TORQUE SPECIFICATIONS - DECIMAL HARDWARE

Use the torques in this chart when special torques are not given.

These torques apply to fasteners with both UNC and UNF threads as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphites, Molydisulfide greases, or other extreme pressure lubricants are used.

Grade 5 Bolts, Nuts, and Studs

Grade 8 Bolts, Nuts, and Studs

Size

1/4 inch

5/16 inch

3/8 inch

7/16 inch

1/2 inch

9/16 inch

5/8 inch

3/4 inch

7/8 inch

1.0 inch

1-1/8 inch

1-1/4 inch

1-3/8 inch

1-1/2 inch

Newton metres

10 to 12

21 to 24

38 to 43

61 to 69

94 to 104

132 to 149

183 to 210

325 to 370

530 to 595

790 to 890

980 to 1100

1385 to 1555

1810 to 2030

2400 to 2700

Pound-

Inches

91 to 103

188 to 212

336 to 378

Pound-

Feet

45 to 51

68 to 76

98 to 110

138 to 155

242 to 270

390 to 435

585 to 655

725 to 805

1020 to 1145

1335 to 1495

1770 to 1990

Size

1/4 inch

5/16 inch

3/8 inch

Newton metres

15 to 16

30 to 34

54 to 60

Pound-

Inches

130 to 145

268 to 301

474 to 534

Pound-

Feet

7/16 inch

1/2 inch

9/16 inch

5/8 inch

3/4 inch

7/8 inch

1.0 inch

1-1/8 inch

86 to 97

132 to 149

191 to 213

260 to 293

480 to 515

745 to 835

1120 to 1280

1585 to 1785

63 to 71

96 to 110

140 to 155

190 to 215

340 to 380

550 to 615

825 to 925

1170 to 1315

1-1/4 inch

1-3/8 inch

2215 to 2235

2930 to 3295

1650 to 1855

2160 to 2430

1-1/2 inch 3895 to 4375 2870 to 3225

NOTE: Use thick nuts with Grade 8 bolts.

57 AU103168 C7B

SPECIFICATIONS

M10

Size

TORQUE SPECIFICATIONS - METRIC HARDWARE

Use the following torques when specifications are not given.

These values apply to fasteners with both coarse and fine threads as received from supplier, plated or unplated, or when lubricated with engine oil. These values do not apply if graphite or Molydisulfide grease or oil is used. Use of a click type torque wrench, or better is required.

Grade 8.8 Bolts, Nuts, and Studs

M12

M14

M16

M20

M24

M30

M36

8.8

Newton metres

3 to 4

5 to 6

10 to 11

23 to 26

46 to 51

80 to 90

128 to 145

200 to 220

400 to 450

690 to 780

1375 to 1545

2400 to 2700

Pound-

Inches

31 to 35

49 to 55

84 to 94

229 to 277

408 to 460

Pound-

Feet

59 to 66

94 to 106

149 to 161

293 to 330

510 to 575

1010 to 1140

1770 to 1990

Grade 10.9 Bolts, Nuts, and Studs

M10

M12

M14

M16

M20

M24

M30

M36

Size

10.9

Newton metres

5 to 6

8 to 9

14 to 15

33 to 37

65 to 74

114 to 128

183 to 205

285 to 320

555 to 620

955 to 1075

1900 to 2140

3315 to 3730

Grade 12.9 Bolts, Nuts, and Studs

12.9

Pound-

Inches

44 to 49

71 to 79

120 to 136

293 to 329

Pound-

Feet

48 to 54

85 to 94

136 to 153

208 to 235

406 to 460

705 to 790

1400 to 1580

2445 to 2750

Usually the torque values specified for grade 10.9 fasteners can be used satisfactorily on grade 12.9 fasteners.

AU103168 C7B 58

Nom. SAE

Dash Size

-2

-3

-4

-5

-6

-8

-10

-12

-14

-16

-20

-24

SPECIFICATIONS

Nom. SAE

Dash Size

-2

-3

-4

-5

-6

-8

-10

-12

-14

-16

-20

-24

TORQUE SPECIFICATIONS - STEEL HYDRAULIC FITTINGS

Tube OD/Hose ID

37 Degree Flare Fitting

6.4 mm (1/4 inch)

7.9 mm (5/16 inch)

9.5 mm (3/8 inch)

12.7 mm (1/2 inch)

15.9 mm (5/8 inch)

Thread Size

5/16 - 24

3/8 - 24

7/16 - 20

1/2 - 20

9/16 - 18

3/4 - 16

7/8 - 14

Newton metres

8 to 9

11 to 12

14 to 16

18 to 21

27 to 33

46 to 56

77 to 85

19.0 mm (3/4 inch)

22.2 mm (7/8 inch)

25.4 mm (1.0 inch)

31.8 mm (1-1/4 inch)

38.1 mm (1-1/2 inch)

1-1/16 - 12

1-3/16 - 12

1-5/16 - 12

1-5/8 - 12

1-7/8 - 12

107 to 119

127 to 140

131 to 156

197 to 223

312 to 338

Pound-Inches

72 to 84

96 to 108

120 to 144

156 to 192

240 to 300

408 to 504

684 to 756

Pound-Feet

79 to 88

94 to 103

97 to 117

145 to 165

230 to 250

Straight Threads with O-ring

Tube OD/Hose ID

6.4 mm (1/4 inch)

7.9 mm (5/16 inch)

9.5 mm (3/8 inch)

12.7 mm (1/2 inch)

Thread Size

5/16 - 24

3/8 - 24

7/16-20

1/2-20

9/16-18

3/4-16

Newton metres

8 to 9

11 to 12

20 to 25

27 to 33

43 to 54

73 to 90

15.9 mm (5/8 inch)

19.0 mm (3/4 inch)

22.2 mm (7/8 inch)

25.4 mm (1.0 inch)

31.8 mm (1-1/4 inch)

38.1 mm (1-1/2 inch)

7/8-14

1-1/16-12

1-3/16-12

1-5/16-12

1-5/8-12

1-7/8-12

100 to 124

138 to 173

173 to 216

203 to 253

308 to 357

492 to 542

Pound-Inches

72 to 84

96 to 108

180 to 228

240 to 300

384 to 480

648 to 804

Pound-Feet

74 to 92

102 to 128

128 to 160

150 to 187

227 to 264

363 to 400

59 AU103168 C7B

SPECIFICATIONS

Size

5/16-18

3/8-16

7/16-14

1/2-13

5/8-11

Split Flange Mounting Bolts

Newton metres

20 to 27

27 to 34

47 to 61

74 to 88

190 to 203

Pound-Inches

180 to 240

240 to 300

420 to 540

Pound-Feet

55 to 65

140 to 150

Nom. SAE

Dash Size

-4

-6

-8

-10

-12

-16

-20

-24

O-Ring Face Seal End

Tube OD

6.4 mm

(1/4 inch)

9.5 mm

(3/8 inch)

12.7 mm

(1/2 inch)

15.9 mm

(5/8 inch)

19.0 mm

(3/4 inch)

25.4 mm

(1.0 inch)

31.8 mm

(1-1/4 inch)

38.1 mm

(1-1/2 inch)

Thread Size

9/16-18

11/16-16

13/16-16

1-14

1-3/16-12

1-7/16-12

1-11/16-12

2-12

Newton metres

23 to 26

34 to 40

52 to 57

81 to 90

117 to 128

152 to 174

179 to 201

213 to 235

Pound-Inches

204 to 228

O-Ring Boss End

Fitting or Lock Nut

Thread Size

Newton metres Pound-Inches

300 to 348

456 to 504

720 to 792

Pound-Feet

86 to 94

112 to 128

132 to 148

157 to 173

9/16-18

3/4-16

7/8-14

1-1/16-12

1-5/16-12

48 to 54

70 to 78

102 to 114

142 to 160

237 to 254

432 to 480

612 to 684

Pound-Feet

75 to 84

105 to 117

175 to 187

AU103168 C7B 60

SPECIFICATIONS

Pipe fittings

Nom. SAE

Dash Size

-2

-3

-4

-5

-6

-8

-10

-12

-14

-16

-20

-24

-32

Thread Size

1/8 - 27

1/4 - 18

3/8 - 18

1/2 - 14

3/4 - 14

1 - 11 1/2

1 1/4 - 11 1/2

1 1/2 - 11 1/2

2 - 11 1/2

TFFT (Turns For Finger Tight)

2.0 - 3.0

1.5 - 3.0

2.0 - 3.0

1.5 - 2.5

NOTE: Apply sealant/lubricant to male pipe threads. The first two threads should be left uncovered to avoid system contamination. Screw pipe fitting into female pipe port to the finger tight position. Wrench tighten fitting to the appropriate turns from finger tight (TFFT) shown in table above, making sure the tube end of an elbow or tee fitting is aligned to receive incoming tube or hose fitting.

61 AU103168 C7B

SPECIFICATIONS

NOTES

AU103168 C7B 62

INDEX

A

Access Covers .......................................................... 30

After Delivery Check ...................................................1

Air Filter Cleaning ..................................................... 37

Air Filter Service ....................................................... 36

Air Filter Service Specifications .................................. 36

Air Filter System ....................................................... 36

Air System Element .................................................. 36

L

Lubrication - Maintenance Chart ................................ 29

Lubrication Points ..................................................... 32

M

Machine Components ................................................. 4

Machine Maintenance Safety ....................................... 8

Machine Operation Safety ........................................... 7

Maintenance Parts .................................................... 56

B

Backfill Blade Controls .............................................. 14

Backfill Blade Operation ............................................ 25

Battery .................................................................... 51

Battery Cover ........................................................... 31

Blade Operation - Backfill .......................................... 25

Boom Position When Digging .................................... 23

Boom Types ............................................................. 22

Booster Battery Connections ..................................... 19

C

Capacities - Lubricant Specifications ........................... 28

Chain Types ............................................................. 23

Cutting a Curved Trench ........................................... 25

Cutting a Straight Trench .......................................... 25

O

Operating Data Dimensions ....................................... 56

Operating in Cold Weather ........................................ 18

Operating in Hot Weather ......................................... 17

Operating Instructions .............................................. 17

Operation Safety ........................................................ 7

Operator Positions .................................................... 21

P

Parking The Machine ................................................ 20

Parking the Machine ................................................... 7

Personal Safety .......................................................... 5

Pressurized Hydraulic Fluid Safety ............................... 8

E

Engine Hourmeter .................................................... 27

Engine Oil Change .................................................... 35

Engine Oil Cooler Maintenance .................................. 36

Engine Service Specifications ..................................... 34

Engine Speed ........................................................... 19

F

Filter - Air ................................................................ 37

Fire or Explosion Safety ..............................................9

Fluid Levels .............................................................. 33

Fuel System ............................................................. 37

Fuel Tank Cover ....................................................... 31

S

Safety

Utility Safety .......................................................... 5

Safety Decals ........................................................... 10

Seat Belt ................................................................. 15

Seat Interlock System ............................................... 52

Selecting Job Tools ................................................... 22

Specifications ........................................................... 36

Speed - Engine ........................................................ 19

Starting The Engine .................................................. 18

Stopping The Engine ................................................ 20

G

Gear Reduction Housing Oil Change ........................... 41

Gear Reduction Housing Oil Level .............................. 40

H

Hydraulic Filter Change ............................................. 38

Hydraulic Oil Change ................................................ 39

Hydraulic Reservoir Breather ..................................... 39

Hydraulic Reservoir Suction Screen Cleaning .............. 39

Hydraulic SystemService Specifications ...................... 28

Hydraulic System Oil Level ........................................ 38

T

Transmission Oil Change ........................................... 40

Transmission Service SpecificationsOil Level ............... 40

Transporting Machine ............................................... 26

Trench - Curved ....................................................... 25

Trench - Straight ...................................................... 25

Trencher Digging Width - Depth ................................ 55

Trencher Drive Chain Cover ...................................... 31

Trencher Drive Chain Lubrication ............................... 41

Trencher Operation .................................................. 21

Trencher Teeth ........................................................ 23

U

Utility Safety .............................................................. 5

I

Identification - Serial Numbers ....................................3

In-Line Fuel Filter ..................................................... 37

Instruments and Controls .......................................... 13

Interlock System - Seat ............................................. 52

W

Weight - Operating ................................................... 56

A1 AU103168 C7B

INDEX

AU103168 C7B A2

AFTER DELIVERY CHECK

AFTER DELIVERY CHECK

After First 100 Hours of Operation of New Machine

Date of Check________________Hourmeter Reading__________________________________________ hours

MACHINE: Product Identification Number ________________________________________________________

OWNER: Name ______________________________________________________________________________

Address ______________________________________________________________________________

DEALER:Name ______________________________________________________________________________

Address ______________________________________________________________________________

AXLES

[ ] Check axle oil levels.

BRAKES

[ ] Check operation of parking/emergency brake.

ELECTRICAL SYSTEM

[ ] Check battery fluid level.

[ ] Check operation of starter, alternator, instruments and warning lamps.

ENGINE

[ ] Check engine speed at idle and at full throttle.

FUEL SYSTEM

[ ] Drain water and sediment from the fuel system.

HYDRAULIC SYSTEM

[ ] Change the hydraulic filters.

[ ] Check the reservoir fluid level.

LUBRICATION

[ ] Lubricate all pivot points.

[ ]

SAFETY

Check condition of safety decals and information decals.

[ ] Check the torque of ROPS and seat belt mounting bolts.

[ ] Make sure the Operators Manual and Safety Manual are in the manual storage box.

TRANSMISSION

[ ] Check fluid level of the transmission.

BOLT TORQUE

[ ] See Bolt Torque in this manual and check the torque of the bolts shown.

DEALER: Make sure the new owner/operator understands all the safety and information decals, the service information, and the service procedures in this operator’s manual.

Technician (signature) ___________________________________________ Date ________________________

Dealer (signature) ______________________________________________ Date ________________________

Owner (signature) _____________________________________________ Date ________________________

Dealer Copy

B1 AU103168 C7B

AFTER DELIVERY CHECK

NOTES

AU103168 C7B B2

AFTER DELIVERY CHECK

AFTER DELIVERY CHECK

After First 100 Hours of Operation of New Machine

Date of Check________________Hourmeter Reading__________________________________________ hours

MACHINE: Product Identification Number ________________________________________________________

OWNER: Name ______________________________________________________________________________

Address ______________________________________________________________________________

DEALER:Name ______________________________________________________________________________

Address ______________________________________________________________________________

AXLES

[ ] Check axle oil levels.

BRAKES

[ ] Check operation of parking/emergency brake.

ELECTRICAL SYSTEM

[ ] Check battery fluid level.

[ ] Check operation of starter, alternator, instruments and warning lamps.

ENGINE

[ ] Check engine speed at idle and at full throttle.

FUEL SYSTEM

[ ] Drain water and sediment from the fuel system.

HYDRAULIC SYSTEM

[ ] Change the hydraulic filters.

[ ] Check the reservoir fluid level.

LUBRICATION

[ ] Lubricate all pivot points.

[ ]

SAFETY

Check condition of safety decals and information decals.

[ ] Check the torque of ROPS and seat belt mounting bolts.

[ ] Make sure the Operators Manual and Safety Manual are in the manual storage box.

TRANSMISSION

[ ] Check fluid level of the transmission.

BOLT TORQUE

[ ] See Bolt Torque in this manual and check the torque of the bolts shown.

[ ]

DEALER: Make sure the new owner/operator understands all the safety and information decals, the service information, and the service procedures in this operator’s manual.

Technician (signature) ___________________________________________ Date ________________________

Dealer (signature) ______________________________________________ Date ________________________

Owner (signature) _____________________________________________ Date ________________________

Customer Copy

B3 AU103168 C7B

AFTER DELIVERY CHECK

NOTES

AU103168 C7B B4

AFTER DELIVERY CHECK

ASTEC TECHNICAL MANUALS

Manuals are available from your dealer for the operation, service, and repair of your machine. For prompt convenient service, contact your dealer for assistance in obtaining the manuals for your machine.

Your dealer can expedite your order for operator’s manuals, parts catalogs, and maintenance records.

Always give the machine name, model, and P.I.N. (Product Identification Number) or S.N. (Serial Number) for your machine so your dealer can provide the correct manuals for your machine.

CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known to the

State of California to cause cancer, birth defects, and other reproductive harm.

Astec reserves the right to make improvements in design or changes in specifications at any time without incurring any obligation to install them on units previously sold.

B5 AU103168 C7B

AFTER DELIVERY CHECK

NOTES

AU103168 C7B B6

Key features

Powerful engine for superior performance
Durable construction for long-lasting use
Intuitive controls for easy operation
Comfortable operator's seat for all-day comfort
Safety features for operator and machine protection

Frequently asked questions

The TF300B is ideal for a variety of trenching applications, including: * Installing underground utilities * Repairing water and sewer lines * Creating drainage ditches * Landscaping projects

The TF300B offers a number of benefits, including: * Increased productivity * Reduced labor costs * Improved safety * Versatility

To maintain the TF300B, you should follow the maintenance schedule in the operator's manual. This schedule includes tasks such as: * Changing the oil and filter * Greasing the fittings * Inspecting the belts and hoses * Checking the fluid levels

TF300B Trencher

Operator’s Manual

AU103168

TABLE OF CONTENTS

TO THE OWNER

TF300B TRENCHER

AFTER DELIVERY CHECK

RIGHT, LEFT, FRONT AND REAR OF MACHINE

IDENTIFICATION NUMBERS

TF300B Trencher

MACHINE COMPONENTS

SAFETY/DECALS/HAND SIGNALS

SAFETY MESSAGE

PERSONAL SAFETY

UTILITY SAFETY

BEFORE OPERATIONS

FAILURE IN OPERATION

MACHINE OPERATION

PARKING THE MACHINE

CAST DUCTILE IRON

MAINTENANCE

BURN PREVENTION

PRESSURIZED HYDRAULIC

FLUID AND GREASE

HAZARDOUS CHEMICALS

FIRE EXTINGUISHER

Type of Fire Extinguisher

FIRE OR EXPLOSION

PREVENTION

READ OPERATOR’S MANUAL

SAFETY DECALS

HAND SIGNALS

INSTRUMENTS AND CONTROLS

INSTRUMENT PANEL AND CONTROLS

BACKFILL BLADE CONTROLS

SEAT BELT

NOTES

OPERATING INSTRUCTIONS

ENGINE OPERATION

Before Starting The Engine

Walk-Around Inspection

Run-In Procedure For a New Machine

RUN-IN MAINTENANCE SCHEDULE

OPERATING IN HOT WEATHER

OPERATING IN COLD WEATHER

STARTING THE ENGINE

ENGINE SPEED

BOOSTER BATTERY CONNECTIONS

PARKING AND STOPPING THE

ENGINE

MACHINE OPERATION

STEP AND HAND RAIL

Backfill Operating Position

OPERATOR POSITION

Trencher Driving, Transport Position

TRENCHER OPERATION

TRENCHER BOOM TYPES

Sprocket Boom (if equipped)

Selecting Correct Tools for the Job

Channel Boom (if equipped)

Boom Position When Digging

TRENCHER CHAIN AND TEETH

Chain Types

Standard Digging Chain

Anti-Backflex Digging Chain

Teeth

BEFORE YOU OPERATE

Cutting a Trench

Cutting A Straight Trench

Cutting A Curved Trench

BACKFILL BLADE OPERATION

TRANSPORTING THE MACHINE ON

A TRAILER

LUBRICATION

GENERAL SAFETY BEFORE

SERVICING MACHINE

PLASTIC AND RESIN PARTS

ENVIRONMENT

ENGINE HOURMETER/TACHOMETER

CAPACITIES AND LUBRICANT SPECIFICATIONS