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053016

Page 2

SECTION 1

INTRODUCTION

Section 1

Table of Contents

Sect No. 

Title 

Page

1.0 Introduction

 

Table of Contents   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 2

 

Limited Warranty & Limitation of Liability   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 3

 Specifications  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 4
 Introduction    .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 6
 

Federal / State Warning Regulations   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 9

 

Manual Tag Safety Detail   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 10

 

Spark Arrestor Notice   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 11

 

Operating Safety  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 12

 

Engine Safety   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 13

 

Service Safety    .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 14

 

Lifting Safety    .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 15

 

Dealer Information and Ordering Parts    .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 16

2.0 Controls  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

 Components   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 17
 Control   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 18

3.0 Operations  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

 

When Lifing Your Machine    .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 20

 

When Loading & Transporting Your Machine  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 21

 

Placeing Screed Rail & Paving Forms   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 22

 

BDF Assembly & Set-up   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 23

 

Paving Operation

   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 30

 Maintenance   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 33
 

Lubricaton Maintenance    .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 34

 Troubleshooting  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 35
 

Cleaning Procedure   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 36

 

Revision Detail  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 37

Summary of Contents for BDF6048B

Page 1: ...SAFETY OPERATIONS MANUAL Manual Part 053016 Revision B Language English Original Instructions B R I D G E D E C K F I N I S H E R S BDF6048B ...

Page 2: ...ail 10 Spark Arrestor Notice 11 Operating Safety 12 Engine Safety 13 Service Safety 14 Lifting Safety 15 Dealer Information and Ordering Parts 16 2 0 Controls 17 Components 17 Control 18 3 0 Operations 20 When Lifing Your Machine 20 When Loading Transporting Your Machine 21 Placeing Screed Rail Paving Forms 22 BDF Assembly Set up 23 Paving Operation 30 Maintenance 33 Lubricaton Maintenance 34 Trou...

Page 3: ...o product alterations or repairs made to the product without the written approval of Allen Allen specifically excludes from warranty any damage to any trowels resulting from an impact to the rotors 7 Impact damage to gear boxes is not covered under the Allen warranty and is deemed customer abuse 8 Allen will pay shop labor on warranty items at the Allen Shop Labor Rate in existence on the date of ...

Page 4: ...ance per Carriage Pass 0 to 15 Inches 0 to 38 1 Cm Battery 12 Volt Power Unit Engine 23 5 HP Kohler Gasoline Engine PAVING CARRIAGE Turntable mounting to allow for skewed decks Independently adjustable dual augers Five foot long dual rollers Independent roller rotation with automatic roller reversing or non roller reversing Automatic cushioned paving carriage travel reversal Adjustable Drag Pan an...

Page 5: ... 4 66 M E Maximum Frame Clearance Above Screed Rail 47 In 119 38 Cm F Minimum Frame Clearance Above Screed Rail 15 In 38 10 Cm G Frame Clearance Above Finished Concrete 37 In 91 44 Cm I Height to Top of Leg 111 In 2 82 M J Height of framework 48 In 121 92 Cm K Leg Center Spacing 90 3 4 In 2 31 M L Drag Pan Length 33 In 83 82 Cm M Burlap Drag Length 19 In 48 26 Cm N Finishing Roller Length 60 In 15...

Page 6: ...e these conditions Operators and operator trainees should have normal depth perception field of vision reaction time manual dexterity coordination and no tendencies to dizziness or similar characteristics In addition to the above listed requirements the operator shall 1 Demonstrate the ability to comprehend and interpret all labels operator manuals safety codes and other information pertinent to t...

Page 7: ...fety glasses and any other protective gear that is warranted by the work environment Introduction 5 Keep work area organized and clean Wipe up oil spills of any kind Keep tools and parts off floor Eliminate the possibility of a fall which could result in serious injury 6 Be sure to reinstall safety devices guards or shields after ad justing and or servicing the machine 7 After servicing be sure th...

Page 8: ...d 2 Always comply with local regulations regarding moving equip ment on public roads and highways 3 Make sure that all lights and reflectors comply with state and local regulations Make sure that they are clean in good working order and can be seen clearly by all overtaking and on coming traffic STORAGE PRECAUTIONS 1 Store paver in an area away from human activity 2 Do not permit children to play ...

Page 9: ...ng cutting drilling of masonry concrete metal and other materials can generate dust mists and fumes con taining chemicals known to cause serious or fatal injury or illness such as respiratory disease cancer birth defects or other reproductive harm SILICOSIS WARNING Grinding cutting drilling of masonry concrete metal and other materials with silica in their composition may give off dust or mists co...

Page 10: ...igh light that contains useful or important information EMERGENCY is used for the identification of safety equipment first aid or emergency egress locations NOTICE used to convey safety information on labels and signs CAUTION is indicative of a potentially hazardous situation which if not avoided may result in minor or moderate injury WARNING Indicative of a potentially hazardous situations that c...

Page 11: ...e engine exhaust It is often required when operating equipment on forested land to prevent the risk of fires Consult the engine distributor or local authorities and make sure that you comply with regulations regarding spark arrestors Potential hazards associated with the operation of this equipment will be referenced with haz ard symbols which may appear throughout this manual in conjunction with ...

Page 12: ... with it NEVER touch the engine or muffler while the engine is on or immediately after it has been turned off These areas get hot and may cause burns NEVER use accessories or attachments that are not recommended by AEC Damage to equipment and injury to the user may result NEVER operate the machine with the belt guard missing Exposed drive belt and pulleys create potentially dangerous hazards that ...

Page 13: ...ses is provided Exhaust gas from the en gine contains poisonous carbon monoxide gas exposure to carbon monoxide can cause loss of consciousness and may lead to death DO NOT smoke while operating the machine DO NOT smoke when refueling the engine DO NOT refuel a hot or running engine DO NOT refuel the engine near an open flame DO NOT spill fuel when refueling the engine DO NOT run the engine near o...

Page 14: ...pairs ALWAYS handle blades carefully The blades can develop sharp edges which can cause serious cuts ALWAYS keep the area around the muffler free of debris such as leaves paper cartons etc A hot muffler could ignite the debris and start a fire ALWAYS replace worn or damaged components with spare parts designed and recommended by AEC Corporation ALWAYS disconnect the spark plug on machines equipped...

Page 15: ...orth guidelines which detail the use of Rigging Equipment for Material handling This guideline is found under OSHA Standard Number 1926 251 Please read and follow all guidelines found in this standard Removal from service Synthetic web slings shall be immediately removed from service if any of the following conditions are present OSHA 1926 251 e 8 Lifting Safety ...

Page 16: ...n address 4 DO NOT return parts to AEC without receiving written authorization from AEC All authorized returns must be shipped pre paid 5 When placing an order please contact the AEC dealer nearest you ALL INFORMATION SPECIFICATIONS AND ILLUSTRATIONS IN THIS MANUAL ARE SUBJECT TO CHANGE WITHOUT NOTICE AND ARE BASED ON THE LATEST INFORMATION AT THE TIME OF PUBLICATION Your Dealer has Allen Engineer...

Page 17: ... moves forward after each pass of the paving carriage B Stationary Power Unit Power is supplied by a 23 5 HP Kohler Gasoline Engine The machine is equipped with a 12 volt electric starting system All power functions are Components hydraulically driven The stationary power unit drives the Bogie Travel Wheels and the Carriage Travel Speed and Direction C Paving Carriage Power is supplied by a 23 5 H...

Page 18: ... Carriage Direction Power Selector Valve Machine Travel Speed Machine Travel Direction Controls Carriage Travel Speed Controls actuated each time the carriage automatically reverses direction CAUTION Before engaging carriage travel be sure that all personnel are clear of the paving carriage The paving carriage will not automatically reverse direction of travel when it reaches the end of the ma chi...

Page 19: ...s on the Ma chine Travel Speed Control setting The automatic machine advancement is variable from 0 to 15 inches with each car riage pass F Carriage On Off Valve The hydraulic power required to drive the rollers and the augers is controlled by the Carriage On Off Valve The Valve is located on the Carriage Control Console See Figure 3 G Roller Direction Valves The Directional Valves will allow the ...

Page 20: ... the machine as they could roll causing an unbalanced load and personal injury ALLOWING the weight of the machine to rest on the carriage paving rollers WILL cause damage to the carriage or the paving rollers ALWAYS place blocks under end frame ALWAYS attach LONG safety ropes or tag lines to the ends of the machine prior to lifting Position the paving carriage opposite the power unit end to provid...

Page 21: ...es on both ends of the machine SEE PICTURE 5 Secure the wood by screwing or nailing it to the truck bed When loading the machine with the Paving Carriage attached block the carriage so that the machine or carriage weight does not rest on the paving rollers Place the blocks under the end frames of the carriage and nail them to the deck SEE PICTURE 6 With the carriage frame now setting on the blocks...

Page 22: ...T UP When the machine is riding on bridge girders you will need to fabricate a screed chair stand that will be epoxied or welded to the beam or a girder plate SEE PICTURE 7 We recommend you tie the vertical tube to the rebar mats for stability The top of the vertical tube will be below the finished surface grade The screed rail needs to be adjusted to conform to the longitudinal profile which can ...

Page 23: ...procket roll up the chain to keep from tangling and place it near the paving carriage Roll up the hydraulic hoses that stretch across the top of the machine for the travel bogies power legs on the idler end of the machine and place near the power unit end Additional frame inserts are added to the machine after splitting the machine at the hinge point of the power unit section The power unit end ne...

Page 24: ... side of the machine The power bogie drive chain protection shield should be on the outside but can be placed on the inside depending on clearance PLEASE MAKE SURE all hoses are connected so that the direction of machine travel is as indicated on the control console It may be necessary to reverse the hose connections to correct the direction of travel MACHINE LEG ADJUSTMENT Adjust the machine leg ...

Page 25: ... augers onto the shafts Looking at the front of the carriage slide the clockwise auger onto the right hand shaft and the counter clockwise auger onto the left hand shaft Tighten auger hardware and mount the safety auger guard assembly SEE PICTURE Turn the auger adjusting crank and set the augers 1 8 to 1 4 above the bottom of the paving rollers as a starting point NOTE Grease the auger shafts STRA...

Page 26: ...re are no gaps shut off the engine and replace the cotter pin in the castle nut Align the paving rollers so that they are parallel with the upper carriage Use a level metal bar or string line across the top of each side of the upper carriage from carriage rail to carriage rail Place a 4 6 long straight edge or level across the top or the bottom of both ends of the paving rollers Measure the distan...

Page 27: ...he idle end slide a striker target or shifter paddle onto the carriage rail at the desired point the carriage needs to shift After the shifting rod makes contact with target the paving roller reversing valve will not engage at this time TO ENGAGE the shift in the reversing valve move the paddle approximately 1 2 until the rod spring shifts the reversing valve and the lower carriage shifts Tighten ...

Page 28: ...hain sag position the carriage to one end of the machine and measure the space between the bottom and top chain in the center of the machine on both sides SEE PICTURE Our recommendation is the chain sag should not be less than the distance for dimensions 1 and or 2 shown below Too tight and excessive chain wear may result Too slack and excessive sprocket wear and or improper carriage reversal may ...

Page 29: ...n any part that will come in contact with wet concrete DO NOT USE FORM OIL OR DIESEL Use clean designated containers to add hydraulic fluid to the hydraulic tanks and keep any dirt or contaminates from getting into the hydraulic system also take care and clean all hydraulic fittings quick dis connects components before any work performed Follow MFG guidelines for engine services or maintenance SET...

Page 30: ... carriage travel for which lever will be adjusted When putting the automatic roller reversing valve in the Non Reversing position causes no change to the roller direction with each pass of the carriage Facing the front of the carriage the left roller turns counter clockwise and the right roller turns clockwise The leading roller will consolidate the concrete allowing the trailing roller to pave th...

Page 31: ...aving up a grade or slope Turn the leg crank 1 2 turn counter clockwise to raise the back of the machine 1 8 of an inch With the back of the machine raised the augers may need to be adjusted lower watch the amount of concrete the rollers are carrying Use the hand crank on the sides of the carriage to adjust the auger elevation These adjustments will counteract the tendency of excess concrete from ...

Page 32: ...chine travel advancement to coincide with the placement of the concrete Place concrete no more than 5 to 8 feet in front of the machine Average advancement of the machine can vary from 3 to 8 inches for each carriage pass In hot windy weather this will insure fresh concrete will move into the paving rollers before any drying occurs Always keep the deck wet CARRIAGE TRAVEL SPEED Slower carriage tra...

Page 33: ...ith the machine The drag pan and burlap astrograss H frames will need to be turned so that they are parallel to the carriage rail This allows the pan and the texturing cloth to follow the skew angle as the carriage travels across the deck or slab At this point the paving rollers need to be stringlined to the carriage rail so that the rollers are parallel to the carriage rail Follow the standard se...

Page 34: ...t for the installation of additional inserts It is important that you know and have available the following information before ordering the optional skew bar kit 1 What is the skew angle 2 Is the skew angle measure from a line parallel to or perpendicular to the centerline of the bridge deck Note For consistency ACP measures from perpendicular 3 Is the skew clockwise or counter clockwise from a li...

Page 35: ...wer unit to power machine travel and paving carriage travel The other is mounted on the paving carriage to power the paving rollers augers and various optional carriage accessories Consult your Owner s Manual for recommended service procedures To insure the best engine performance and life a strict schedule of routine service and maintenance is recommend ed Change the engine oil after the first 50...

Page 36: ...n main controller rail and striker arms Apply to finishing roller reversing rod Idler Sprocket Bearings Lubricate NLGI 2 Lithium Base Grease Lubricate slowly until excess lubricant is observed EVERY 25 HOURS POWER UNIT Engine Crankcase Replace Engine Oil SAE 30 MS SD or SE Add oil if necessary PAVING CARRIAGE Engine Crankcase Replace Engine Oil SAE 30 MS SD or SE Add oil if necessary LEGS TRAVEL B...

Page 37: ...ehind tubes Carriage bouncing caused by too much space between carriage pivot blocks and ring Tighten pivot nut or shim wear blocks until contact is made with ring MACHINE OPERATION With machine in Pave mode the engine loads up and carriage does not move Hoses on shifter mechanism are not connected correctly Connect hoses correctly on shifter Cam arm follower on shifter is not in Pave position Che...

Page 38: ...ng is malfunc tioning Change quick disconnect Tubes are operating under load but augers are not Augers are seeing too much concrete Lessen amount of concrete in front of augers Motor for auger is damaged Change auger motor Quick disconnect is faulty on auger hose Change quick disconnect fitting There is noise coming from tube bearings and bearings are extremely hot Tubes may be stopping under load...

Page 39: ...arriage only works in one direc tion in auto reverse move the MV1 or MV2 cartridge is stuck Remove the 9 16 Vent Cap on both the MV1 and MV2 Cartridges Insert a small screw driver or allen wrench into the vent cap holes The cartridge with the shallowest hole is the cartridge that is stuck To get by until part is available use small screw driver or allen wrench to manually push the cartridge spool ...

Page 40: ... 300mm away from the machine Keep a perpendicular angle 90 when cleaning over a decal Holding nozzle of a pressure washer at an angle different from 90 may lift the decal from the machine Recommended using a safe cement dissolver BACK SET or similar to remove hard ened concrete It is NOT recommended to use chemicals such as Muriatic Acid Hydrochloric Acid Hydrofluoric Acid Sulfuric Acid Phosphoric...

Page 41: ...053016 Page 41 Revision Detail MANUAL REVISION DETAIL REVISION REVISION DATE REVISION REFERENCE REVISION BY Initial Release AW A 03 20 Update to Machine Standard MW B 01 22 Updated Covers MK ...

Page 42: ...E T P A R A G O U L D A R K A N S A S 7 2 4 5 0 8 7 0 2 3 6 7 7 5 1 8 0 0 6 4 3 0 0 9 5 T O L L F R E E U S A O N LY MAILING P O B O X 8 1 9 P A R A G O U L D A R K A N S A S 7 2 4 5 1 A L L E N E N G C O M C O N N E C T W I T H U S O N S O C I A L ...

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