allen HDX605 Page 5 Safety & Operation Manual Download

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068356

Page 5

GENERAL

INFORMATION

2.0 Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Introduction to HDX605 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Start-up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Machine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Trowel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Engine Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Customer Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

3.0 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Customer Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

4.0 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Popular Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Parts Manual (Where to find) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Revision Detail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Copyright Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Table of Contents

Sect No.

Title

Page

Summary of Contents for HDX605

Page 1: ...SAFETY OPERATIONS MANUAL HDX605 RIDING TROWEL Manual Part 068356 Revision ...

Page 2: ...This manual or a copy of it must be kept with the machine at all times There is a manual storage container located on the machine for your convenience 068356 Page 2 ...

Page 3: ...SAFETY OPERATOR MANUAL This manual covers the products listed below Part No Description 060500 HDX605 Riding Trowel Riding Trowel 068356 Page 3 ...

Page 4: ...r Codes 12 Unit Identification 13 Technical Specifications 14 Machine Dimension Specifications 15 Engine Specifications 16 Engine Parts 18 1 0 Safety 19 Federal State Warning Regulations 20 Manual Tag Safety Detail 21 Spark Arrestor Notice 22 Operating Safety 23 Engine Safety 24 Service Safety 25 Lifting Safety 26 Transportation Safety 28 Pan Installation Safety Lifting Bridle 29 Pan Installation ...

Page 5: ...wel Operation 36 Engine Control Unit 40 Customer Notes 44 3 0 Service 45 Maintenance Schedule 46 Filter Replacement 47 Fault Codes 48 Cleaning Procedure 53 Customer Notes 54 4 0 Accessories 55 Popular Accessories 56 Parts Manual Where to find 59 Revision Detail 60 Copyright Information 61 Table of Contents Sect No Title Page ...

Page 6: ...product modification to 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 exi...

Page 7: ...ns Complete any warranty requirements as specified by the engine manufacturer in their instructions found inside the manual box located on the back of the riding trowel operator s seat Your engine and clutch is not manufactured by Allen Engineering Corporation Inc and therefore is not covered under Allen Engineering Corporation Inc warranty Your engine manufacturer should be contacted if you wish ...

Page 8: ...PENDING CE DECLARATION AT THIS TIME 068356 Page 8 GENERAL INFORMATION CE Declaration ...

Page 9: ...e velocity value obtained at the handle grip while operating the ride on trowel on curing concrete in a manner most often experienced in normal circumstances Values were obtained from all three axes of motion The values shown represent the maximum RMS value from these measure ments Summary Data Of Sound And Vibration Testing for CE Marking Operator Ear SPL Seat Vibration Average Left Hand Vibratio...

Page 10: ...rained mechanics and original Allen replacement parts Always contact the Allen Dealer who sold you this machine for Allen Certified repairs and replacement parts Place Allen Dealer information below for future reference Dealer Name Phone Address City State Zip Salesman Mobile Phone Additional Comments ...

Page 11: ...tion and part number from the PARTS DECALS MANUAL 3 Specify exact shipping instructions including the preferred routing and complete destination 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 THI...

Page 12: ... characters of the Model Number and Serial Number codes Model Number HDX 605 Series Hydra Drive Extreme Serial Number The serial number found on the identification plate is a ten digit format The model number identifies your machine and will ensure that you receive the correct replacement parts Serial Number Example 605 01 19 001 Series Sequence Number Month Year 068356 Page 12 GENERAL INFORMATION...

Page 13: ...o Figure 1 for serial number and model number location This plate should not be removed at any time Please record the information found on this plate below so it will be available should the identification plate become lost or damaged When ordering parts or requesting service information you will always be asked to specify the model and serial numbers of the machine FILL IN FOR FUTURE REFERENCE 06...

Page 14: ...ower Hydraulic Fluid Capacity 15 gal 56 8L Number of Operating Lights 6 Height 60 3 8 1533 1 mm Length 108 5 8 2759 1 mm Width 52 1 8 1324 0 mm Dry Weight 2049 lb 929 4 kg Panning Width 101 5 2578 1mm Rotor Center Distance 55 5 1409 7mm Rotor Diameter 46 1168 4mm Idle RPM 1200 Full RPM 3400 Lifting 2 point Top Mounted 068356 Page 14 GENERAL INFORMATION Technical Specifications ...

Page 15: ...108 5 8 2759 1 52 1 8 1324 0 60 3 8 1533 1 068356 Page 15 GENERAL INFORMATION Machine Dimension Specifications ...

Page 16: ...on Ratio 9 1 1 Governor Type Electronic Cooling System High Capacity Liquid Direction of Rotation Rev Counter Clockwise view from Flywheel Oil Pan Capacity in gal L 1 59 6 0 Starter Capacity V kW 12V 1 0 kW Alternator Capacity 12V 40A Dry Weight lbs kg 264 6 120 Dimensions Length in mm 23 3 591 3 Width in mm 18 8 478 7 Height in mm 25 7 652 3 Emission Certifications EPA Non Road LSI Tier 2 Certifi...

Page 17: ...Dimensions mm in 068356 Page 17 GENERAL INFORMATION Engine Specifications ...

Page 18: ...V Valve 6 Engine Hook 7 Oil Level Gauge 8 Exhaust Manifold 9 Starter 10 Alternator 11 Coolant Drain Shutoff Valve 12 Oil Filter Cartridge 13 Oil Pressure Switch 14 Electronic Control Throttle REF PART NAME 15 Injector 16 Gas Mixer 17 Pressure Regulator 18 Intake Manifold 19 Cooling Fan 20 Fan Belt 21 Fan Drive Pulley 22 Oil Drain Plug 23 Oil Pan 24 Flywheel 25 ECU Engine Control Unit 068356 Page 1...

Page 19: ...SECTION 1 SAFETY SECTION 1 SAFETY 068356 Page 19 ...

Page 20: ...RESPIRATORY HAZARDS Grinding 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...

Page 21: ... is essential to highlight 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 ...

Page 22: ...s a device designed to prevent the discharge of spark or flames from the 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 SECTION 1 SAFETY 068356 Page 22 ...

Page 23: ...eate potentially danger ous hazards that can cause serious injuries NEVER leave machine running unattended DO NOT run the machine indoors or in an enclosed area such as a deep trench unless adequate ventilation through such items as exhaust fans or hoses is provided Exhaust gas from the engine contains poisonous carbon monoxide gas exposure to carbon monoxide can cause loss of consciousness and ma...

Page 24: ...s from the engine 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 open flames ALWAYS refill th...

Page 25: ...especially in enclosed areas Fumes from fuels and solvents can become explosive ALWAYS turn engine off and remove key from machine before performing maintenance or making repairs 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 ...

Page 26: ...ail 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 SECTION 1 SAFETY 068356 Page 26 ...

Page 27: ...tional lifting harness is available for purchase Part number 064798 Place slings chains or hooks through each lifting point on the machine Use a sling or chains connected to a central lifting device Ensure that all lifting devices have sufficient weight bearing capacity ALWAYS shutdown engine before transporting LIFTING POINT Lifting Safety SECTION 1 SAFETY 068356 Page 27 ...

Page 28: ...owing Connect and test electric brake operation Secure portable power cables in cable tray with tie wraps The maximum speed for highway towing is 55 MPH unless posted otherwise Recommended off road towing is not to exceed 15 MPH or less depending on type of terrain Avoid sudden stops and starts This can cause skidding or jack knifing Smooth gradual starts and stops will improve towing Avoid sharp ...

Page 29: ...ly lower the machine down onto the pans Make sure the blades are going into the proper gaps Typically the pans can only be installed one way 6 Once the machine is on securely on the ground with the pans underneath remove the lifting bridle from the machine 7 Start the machine and slowly increase the throttle until the blades begin turning and engaging the pans The machine is now ready to finish th...

Page 30: ...slide the pans under the machine making sure that you are aware of the corners of the blades as they are sharp 5 Align the pans so that the clips will not be crushed when the machine is lowered back down 6 Slowly lower the machine down onto the pans Make sure the blades are going into the proper gaps Typically the pans can only be installed one way 7 Remove the dolly jacks from the machine 8 Start...

Page 31: ...SECTION 2 OPERATION SECTION 2 OPERATIONS 068356 Page 31 ...

Page 32: ...rn high production machine Finishing rate will vary depending on the operators skill and job conditions This riding trowel has ten finishing blades The Super Heavy Duty SHD Gearboxes are designed to provide exceptional performance with low maintenance and trouble free use under some of the worst conditions All Allen Engineering HDX605 Riders are equipped with a safety shutdown switch and a low oil...

Page 33: ... blades 6 Verify that daily maintenance of grease points have been performed Starting Procedures Turn ignition switch key to the start position immediately release key when engine starts Allow engine to warm up for 5 minutes before operating riding trowel Operating the starter for more than 5 seconds can damage the starter or engine If engine fails to start release the switch and wait 15 seconds b...

Page 34: ...Operator Detail 8 1 3 2 5 4 7 6 9 10 11 13 14 15 16 20 17 18 19 22 21 12 23 26 27 29 24 30 28 25 34 32 33 31 Machine Components SECTION 2 OPERATIONS 068356 Page 34 ...

Page 35: ... 16 Idle Full Throttle Switch Controls engine RPM 17 Warning Light Red LED Hydraulics Over Heated 18 Warning Light Green LED Control weather start ready 19 Warning Light Yellow LED Change hydraulic filter 20 Cruise Control Switch Turns the machine cruise control on off 21 Tool Holder Store hand tools here 22 Cup Holder Holds your favorite beverage 23 Engine Module Controls engine RPM shows fuel le...

Page 36: ... a 180 degree turn and repeat the straight line of direction to the other end of the slab To familiarize a new operator with the riding trowel the following steps should be taken All items in this manual are describe from the operator Sitting On Machine or SOM for short 1 Location of all Operating Controls A Right Pitch Control B Joystick Forward Reverse C Joystick Left Right Forward Reverse D Lef...

Page 37: ...s B and C They will return to their neutral position Also release pressure on the right foot pedal E This machine is equipped with a seat kill switch mechanism If in need of an emergency stop simply turning the key off or raising off the seat even while holding the right foot pedal down will stop the engine from running Steering Control Diagram Position Action 1 Forward 2 Reverse 3 Rotate Clockwis...

Page 38: ...RPM Full 3400 RPM The engine will start at idle speed This machine is equipped with a Cold Weather Start circuit meaning that the engine RPM will not increase above idle speed until the hydraulic oil has reached an optimum temperature The operator can activate the RPM toggle to FULL during this period however the RPM will not increase until that optimum temperature is achieved There is a seat sens...

Page 39: ...tor will use the rocker switch located at the top of either joystick By pressing the rocker switch towards the inside the pitch will decrease pressing the switch toward the outside of the joystick will increase the pitch level see Figure 2 5 8 Enable Machine Blades The machine trowel blades are enabled by the foot pedal E Hold down the pedal to enable the rotors to begin turning release pressure o...

Page 40: ...c graphics designate screen layout and define custom parameters The PV380 is equipped with five tactile push buttons to quickly access a convenient menu In addition a back lit and heated graphic display with LEDs indicate alarm or shutdown status Flat Screen Display A 3 8 QVGA monochrome LCD screen displays gauges soft key commands and fault messages as well as menu options for setup and configura...

Page 41: ...D Resolution QVGA 320 x 240 Pixels Orientation Landscape Back lighting LED White Flash Memory 2Mb RAM 256kb Operating Voltage 6 36 VDC Power Consumption 10 Watt Communications CAN 2 0B RS485 Modbus Engine Control Unit ECU SECTION 2 OPERATIONS 068356 Page 41 ...

Page 42: ... button 1 to move the selection UP use button 2 to move the selection DOWN button 3 will verify the selection use button 5 to return to the home screen BUTTON FOUR Directs you to the Service Reminder screen The first screen will give an overview of the current state of all the service reminders that are set To cycle through reset the reminders press OK button 3 then press the down arrow button 1 a...

Page 43: ...he operator stands up while in run RPM the machine will return to IDLE RPM The status of this function can be viewed in the IO STATUS screen under SEAT SW Run Light When the oil temp has reached an acceptable temp the green light to the right of the operator will illu minate Lift Off When lifting the machine off the slab with no operator in the seat someone can hold the Run Idle Rocker to achieve ...

Page 44: ...Customer Notes SECTION 2 OPERATIONS 068356 Page 44 ...

Page 45: ...SECTION 3 SERVICE SECTION 3 SERVICE 068356 Page 45 ...

Page 46: ...nspect for Leaks X Check poly V belt X Inspect all Hardware X Inspect Belts X Inspect Wiring X Inspect Battery X Inspect Exhaust X Inspect Coolant Hoses X Inspect Catalyst X ACTION Control Linkage Lubrications X Change Engine Oil X Change Hydraulic Oil X Change Fuel Filters X Change Oil Separator Element X Change Air Filters X Drain Water Separator X Replace Fan Belt X Clean Entire EGR System X Ch...

Page 47: ...cription Filter Fuel For Kubota WG1605 Filter Replacement Part 069428 Description Filter Air Primary For Kubota WG1605 Part 069249 Description Filter Air Safety For Kubota WG1605 Part 049801 Description Filter Hydraulic Spin On 10 micron SECTION 3 SERVICE 068356 Page 47 ...

Page 48: ...5 Engine Coolant Temperature Abnormality High Side Stage 1 0 Engine Coolant Temperature Abnormality High Side Stage 2 Intake Air Temperature 105 3 Sensor or Wiring Harness Open or Short to Power Sensor Malfunction 4 Sensor or Wiring Harness Short to Ground Sensor Malfunction 15 Engine Coolant Temperature Abnormality High Side Stage 1 0 Engine Coolant Temperature Abnormality High Side Stage 2 Knock...

Page 49: ...r Short or Damage FPP Malfunction Engine Speed 515 15 Engine Over Speed Condition Stuck Throttle Large Vacuum Leak Into Intake Manifold After Throttle Blade 16 Engine Over Speed Condition Faulty Crank Sensor or Input 0 Engine Over Speed Condition Faulty Crank Sensor or input Oil Pressure 100 1 Low Oil Pressure Adaptive Learn 4237 0 Exhaust Leaks Upstream or Near the HEGO Sensor Reduced Fuel Supply...

Page 50: ...Inoperative sensor 3227 Injectors 651 5 Loss of 12 V feed to injector Open injector coil Open or shorted to ground injector driver circuit in engine harness 6 Injector coil shorted internally Injector driver circuit shorted to voltage between injector and ECM 652 5 Loss of 12 V feed to injector Open injector coil Open or shorted to ground injector driver circuit in engine harness 6 Injector coil s...

Page 51: ...Pump Relay Control Coil 1348 4 Relay pull in coil shorted internally Relay driver circuit shorted to ground in wire harness 5 Open coil in relay Open in relay driver circuit in engine harness 3 Shorted relay pull in coil Relay driver circuit shorted to voltage in wire harness Power Relay Control Coil 1485 4 Short to Ground in Relay Pull in Coil Short to Ground in Relay Driver Circuit in Wire Harne...

Page 52: ...s in Wrong Connector Terminal Slot 4 Loss of feed voltage to Cam sensor Loss of signal or ground circuits Faulty sensor Internal Processor Diagnostics 628 13 Faulty ECU 629 31 Faulty ECU 630 12 Faulty ECU 1634 2 Faulty ECU J1939 Network 695 9 Fault Codes This is only a partial list of the most common error codes that are available If an alternate code is shown that is not on this list please conta...

Page 53: ...m 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 hardened concrete It is NOT recommended to use chemicals such as Muriatic Acid Hydrochloric Acid Hydrofluoric Acid Sulfuric Acid Phosphoric Acid ...

Page 54: ...Customer Notes SECTION 3 SERVICE 068356 Page 54 ...

Page 55: ...SECTION 4 ACCESSORIES SECTION 4 ACCESSORIES 068356 Page 55 ...

Page 56: ...6094V 4 Trowel Blade Finish 6 X 18 VP Silver Series only sold as set of 4 Part Number 015695V 4 Float Pan Clip On 46 5 O D Universal Flat 80 Lip Angle 5 Blade Part Number 051552 Float Pan Safety Catch 46 5 O D Universal Flat 80 Lip Angle 5 Blade Part Number 051553 SECTION 4 ACCESSORIES 068356 Page 56 ...

Page 57: ...ke mobilization easier These tires are foam filled to help support the added weight of the machine and to help prevent flats Comes in set of 2 Part Number 048770 F Lifting Bridle 6 000 Pound Max 2 Point x 3 Foot Part Number 064798 SECTION 4 ACCESSORIES 068356 Page 57 ...

Page 58: ...PAGE LEFT BLANK INTENTIONALLY SECTION 4 ACCESSORIES 068356 Page 58 ...

Page 59: ...ile Device Scan this QR code with a compatible device cellular phone tablet etc Computer Click the link or go to the following website https alleneng com images manuals 068356P 20 20HDX605 20 20Parts 20and 20 Decal 20Manual pdf Mail A physical copy of the parts manual can also be mailed to you upon request Please contact Allen Engineering service department and one can be sent to you Allen Enginee...

Page 60: ...Revision Detail MANUAL REVISION DETAIL REVISION REVISION DATE REVISION REFERENCE REVISION BY 06 19 Initial Release MW 068356 Page 60 ...

Page 61: ...inaccuracies that may appear in this manual Allen Products are covered under one or more of the following patent numbers U S Design Patents 344 736 400 542 400 544 402 998 402 999 403 332 404 041 404 042 410 931 413 127 416 564 465 897 466 909 474 203 U S Utility Patents 5 108 220 5 238 323 5 328 295 5 352 063 5 405 216 5 476 342 5 480 257 5 480 258 5 533 831 5 562 361 5 567 075 5 613 801 5 658 08...

Page 62: ...CONNECT WITH US ON P O BOX 819 PARAGOULD AR 72451 USA 800 643 0095 USA ONLY 870 236 7751 FAX 800 643 0097 USA ONLY 870 236 3934 WWW ALLENENG COM ...

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