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Poorly maintained equipment can become a safety hazard! In order for the equipment to operate safely and properly

over a long period of time, periodic maintenance and occasional repairs are necessary.

• ALWAYS

disconnect the battery before servicing the equipment.

• DO NOT

attempt to clean or service the machine while it is running. Rotating parts can cause severe

injury.

• DO NOT

crank a flooded engine with the spark plug removed on gasoline-powered engines. Fuel trapped

in the cylinder will squirt out the spark plug opening.

• DO NOT

test for spark on gasoline-powered engines if the engine is flooded or the smell of gasoline is

present. A stray spark could ignite the fumes.

• DO NOT

use gasoline or other types of fuels or flammable solvents to clean parts, 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 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 with gasoline engines, before servicing, to avoid acci-

dental start-up.

• ALWAYS

relieve all pressure in the air, oil and cooling systems before disconnecting any lines, fittings or

related items. Escaping fluid under pressure has sufficient force to penetrate skin causing serious person-
al injury, DO NOT check for leaks your hands.

• ALWAYS

switch off the power supply at the battery disconnect before adjusting or maintaining the electrical equip-

ment.

• ALWAYS

keep the machine clean and labels legible. Replace all missing and hard-to read labels. Labels provide

important operating instructions and warn of dangers and hazards.

• ALWAYS

wear rubber gloves to avoid personal injury, when you treat fluids used in machine. In case of

contact with skin, immediately wash off.

SECTION 1

SAFETY

069971

Page 18

Service Safety

Содержание 069600

Страница 1: ...SAFETY OPERATIONS MANUAL HDX780 RIDING TROWEL Manual Part 069971 Revision Language English Original Instructions ...

Страница 2: ...al are subject to change without notice and are based on the latest information at the time of publication No part of this manual may be reproduced or transmitted in any form or by any means electronics or mechanical for any purpose without the express written permission of Allen Engineering Corporation AEC AEC assumes no responsibility or liability for any errors or inaccuracies that may appear i...

Страница 3: ...ct 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 the war...

Страница 4: ...ations 13 Manual Tag Safety Detail 14 Spark Arrestor Notice 15 Operating Safety 16 Engine Safety 17 Service Safety 18 Lifting Safety 19 Transportation Safety 21 Pan Installation Safety 22 Safety Decals 24 2 0 Operations 25 Introduction to HDX780 26 Start up Procedure 27 Machine Components 28 Trowel Operation 30 Engine Control Unit 33 3 0 Service 37 Maintenance Schedule 38 Engine Filter Replacement...

Страница 5: ...rouble free operation This manual is divided into the following sections 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 ...

Страница 6: ...d at the operators ear position while the ride on trowel is operating at full throttle on concrete in a manner most often experienced in normal circumstances Sound pressure may vary depending upon the condition of the concrete Hearing protection is always recommended Vibration Level Information The vibration level indicated is the maximum RMS Root Mean Square velocity value obtained at the handle ...

Страница 7: ...ss 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 Engineering Cor...

Страница 8: ...ive the correct replacement parts Serial Number Example 780 01 20 001 Model Sequence Number Month Year Unit Identification Plate Location An identification plate listing the model number and the serial number is attached to each unit and is located on the rear lower left side of mainframe Refer below for serial number and model number location This plate should not be removed at any time Please re...

Страница 9: ...ring System Hydraulic Hydraulic Capacity 20 25 Gal Number of Operating Lights 6 Height 64 1 4 Length 147 3 4 Width 68 1 4 Dry Weight 2836 lbs Panning Width 140 Rotor Center Distance 79 5 Rotor Diameter 60 Rotor Speed 10 135 RPM Lifting 2 point Top Mounted Technical Specifications Machine Dimension Detail 147 3 4 62 1 8 68 1 4 ...

Страница 10: ...n3 119 10 Injection System Direct Injection Injection Pressure PSI 26 100 0 Compression Ratio 17 5 1 Cooling System Liquid Direction of Rotation Rev Clockwise Engine Oil Capacity in gallons 1 85 Dry Weight lbs 562 Dimensions Length in mm 36 5 Width in mm 27 0 Height in mm 31 8 Emission Certifications EPA Non Road LSI Tier 4 Certified EU Stage IIIB Certified 069971 Page 10 GENERAL INFORMATION Engin...

Страница 11: ...Low Mounting Position 11 Dipstick 12 Oil Filler Plug Bottom Option 13 Oil Filler Plug Middle Option 14 Crankcase Ventilation Intake Side REF PART NAME 1 Lifting Eyes 2 DPF System TICD Model Only 3 Turbocharger 4 Engine Foot 5 Diesel Oxidation Catalytic Converter TIC Model 6 Exhaust Outlet 7 Starter High Mounting Position 8 Three Phase Alternator 9 Poly V Belt 10 Oil Drain Screw Front 11 Fan Exhaus...

Страница 12: ...SECTION 1 SAFETY SECTION 1 SAFETY 069971 Page 12 ...

Страница 13: ...ng 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 containing...

Страница 14: ...t 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 could res...

Страница 15: ...en 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 safety notes SECTION 1 SAFETY 069971 Pag...

Страница 16: ...r 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 can cause serious injuries NEVER leave ma...

Страница 17: ...ine 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 the fuel tank in...

Страница 18: ... 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 with gasoline engines before servicing ...

Страница 19: ...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 069971 Page 19 Lifting Safety ...

Страница 20: ...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 SECTION 1 SAFETY 069971 Page 20 Lifting Safety ...

Страница 21: ... 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 turns to prevent rolli...

Страница 22: ...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 the concrete utilizing the pans NOTE Utilizing the lifting slin...

Страница 23: ... of the corners of the blades as they are sharp 4 Align the pans so that the clips will not be crushed when the machine is lowered back down 5 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 6 Remove the dolly jacks from the machine 7 Start the machine and slowly increase the throttle until the blades ...

Страница 24: ... Ports PART 070129 QTY 1 DECAL Tie Down PART 068459 QTY 4 DECAL Lifting Point PART 065653 QTY 2 DECAL Pinch Hazard PART 065917 QTY 2 DECAL Grease PART 066103 QTY 2 DECAL Drop Hazard PART 065656 QTY 2 DECAL Hydraulic Fluid PART 065668 QTY 2 DECAL PROP 65 PART 069225 QTY 1 DECAL Diesel Only PART 069104 QTY 1 DECAL Retardant Only PART 065655 QTY 1 DECAL T4 Compliant PART 070658 QTY 1 DECAL HYDR PRESS...

Страница 25: ...SECTION 2 OPERATION SECTION 2 OPERATIONS 069971 Page 25 ...

Страница 26: ...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 HDX780 Riders are equipped with a safety shutdown switch and a low oil...

Страница 27: ...ed control operation before and after starting engine for proper operation 11 Check the steering left and right for proper operation 12 Check for any hydraulic leaks 13 Remove any loose objects that could interfere with the operation of the trowel Note If there is any indication that faulty equipment exists shutdown safely inform the proper authority and DO NOT operate the riding trowel until the ...

Страница 28: ...Machine Components Operator Detail 1 20 11 23 3 2 4 31 12 7 8 33 6 9 10 1 7 21 22 13 14 15 19 18 17 5 16 8 24 25 26 28 29 30 32 27 34 SECTION 2 OPERATIONS 069971 Page 28 ...

Страница 29: ...the pitch of the right blades 16 Engine Speed Switch Changes the engine speed from Idle to Full 17 Light Switch Turns the machine LED lights on or off 18 Cruise Control Switch Turns the machine cruise control on off 19 High Oil Pressure When lit change oil filter 20 Tool Holder Store hand tools here 21 Cup Holder Holds your favorite beverage 22 Engine Module Controls engine RPM shows fuel level co...

Страница 30: ... 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 Left Pitch Control E Right Foot Pedal F Retardant Spray Pushbutton 2 Steering the Riding Trowel A slight feathering motion forward ...

Страница 31: ...achieved at full engine RPM After starting engine fully engage the throttle This allows the engine to warm up quicker and also engages the torque converter At this time the machine s rotors will begin turning so long as foot pedal E is engaged DO NOT use excessive pressure on the joysticks Excessive pressure does not increase the reaction time of the machine and can damage steering controls 5 Engi...

Страница 32: ...es of the concrete When changing or setting pitch angle of trowel blades slow the machine down set the desired degree of pitch on the left side of the machine and then adjust the right side to match To change the pitch the operator 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...

Страница 33: ...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...

Страница 34: ...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 069971 Page 34 ...

Страница 35: ...lection 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 and select button 3 This ...

Страница 36: ... unless the seat switch is made If the 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 Lift Off When lifting the machine off the slab with no operator in the seat someone can hold the Run Idle Rocker to achieve a higher Engine RPM for 5 seconds and press the foot pedal while the machine is being...

Страница 37: ...SECTION 3 SERVICE 069971 Page 37 SECTION 3 SERVICE ...

Страница 38: ...ect 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 Filter 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 ...

Страница 39: ...05S Page 1 from 2 Replacement Filters Item Part Description Qty 1 065851 Pre Fuel Filter 1 2 065852 Fuel Filter 1 3 065853 Oil Seperator 1 4 065854 Oil Filter 1 5 065855 Air Filter Secondary 1 6 065856 Air Filter Primary 1 SECTION 3 SERVICE 069971 Page 39 ...

Страница 40: ... used with your engine 2 Attach one end of the positive booster cable red to the positive ter minal of the booster battery Attach the other end to the terminal of your engine battery 3 Attach one end of the negative booster cable black to the negative terminal on the booster Attach the other end of the negative cable to your engine battery 4 Jump starting in any other manner may result in damage t...

Страница 41: ...The steps below descried the general procedure to remove the trowel arms to be aligned 1 Block up pressure plate A using a wooden block 2 Remove stabilizer ring from spider assembly only on available models 3 Remove blades from trowel arms 4 Loosen hex head cap screw B and remove it and the external star washer from the spider boss 5 Remove trowel arms from spider boss with lift levers in place 6 ...

Страница 42: ...l filter blocked wiring harness or pre supply pump itself defective 97 15 Water in Fuel Detected Water in Fuel Detected 17 Fuel Level Un plausible Wiring Harness or Component 100 0 Maximum Oil Pressure Error in Plausibility Check The oil temperature Oil_tSwmp is equal to or greater than the limit Oil_ tLimP_C and the oil pressure Oil_pSwmp is greater than the threshold Oil_pMaxP_mp 1 Minimum Oil P...

Страница 43: ... Sensor 4 Fault Check Min Signal Range Violated for Ambient Air Pressure Sensor 110 0 Physical Range Check High for CEngDsT The sensed sensor signal CEngDsT_tSens is greater than CEngDsT_ PhysRng Max_C 1 Physical Range Check Low for CEenDst The sensed sensor signal CEngDsT_tSens is less than CEngDsT_Phys Rng Min_C 3 The Sensor Raw Signal CEngDst_uRaw Voltage is Above CEngDst_SRC uMa x_C 4957mV The...

Страница 44: ...d with Low Fuel Level and High Ambient Temperature 1 Physical Range Check Low for Fuel Temperature The sensed sensor signal FuelT_tSens is less than FuelT_PhysRng Min_C Very Cold Ambient Temperature 3 SRC High for Fuel Temperature Sensor The sensor raw signal voltage FuelT_uRaw is above FuelT_SRC uMax_C 4933mV Wiring Harness or Component 4 SRC Low for Fuel Temperature Sensor The sensor raw signal ...

Страница 45: ...aft revolutions there is not any camshaft edge present The defect debounce counter EpmCaS_ctNoSig reaches the threshold EpmCaS_numNoSigDef_C If the monitoring range is left the debounce counter is reseted Wiring Harness or Component 652 3 General Short Circuit Short Circuit of an Injector Wiring Harness or Injector Cylinder 653 3 5 Open Load Open Load Error of an Injector Interruption of an electr...

Страница 46: ...Fault 1109 11 Injection Cut Off Demand ICO for Shut Off Coordinator The un debounced defect detection takes place in the standard ICO mode EngICO_stMode_C 0 with an ICO Mo_stICOMsg requested and an engine speed Epm_nEng greater than EngICO_nCtOffStdICO_C 1700rpm The un debounced defective detection takes place in the comfortable ICO mode EngICO_stMode_C 1 with requested ICO Mo_stICOMsg and an engi...

Страница 47: ...e Position Sensor Physical SRC High EGRVlv_SensCal uRawMaxOpn_C EGRVlv_SensCal uRawMaxClsd_C EGRVlv_uRaw EGRVlv_SensCal uMax_C EGRVIv Mis sadjusted or Dirty 21 DFC for Valve Position Sensor Physical SRC Low EGRVlv_SensCal uRawMinClsd_C EGRVlv_SensCal uRawMinOpn_C EGRVlv_uRaw EGRVlv_SensCal uMin_C 2802 11 EEP Read Error Based on the Error for more Blocks If Selector Erase Only Flash Cannot be perfo...

Страница 48: ...fect detection 20222 11 Diagnostic Fault Check to Report Errors in SPI Communication If there is no active shut off path test MoCSOP_stRdyMsg TRUE and the error counter MoCCom_ctErrMM or MoCCom_ctErrFC is MOCCOM_MM_STATUS_LIMIT_ERRORS 5 there is an undebounced defect detection 20223 11 Diagnostic Fault Check to Report Multiple Error While Checking the Complete ROM Memory If multiple errors are det...

Страница 49: ...ported by the level 1 The error is reported after a debounce time MoFRailP_ctDebGrad Max_C 2550ms Additionally the error will be reported after a debounce time MoFRailP_ctDebGradMax_C if level 2 detects a gradient error and level 1 is not reporting it 20233 11 Diagnostic Fault Check to Report the Error Due to Torque Comparison FStSys_stStrtRlsCAN_mp TRUE 20234 11 Diagnosis of Curr Path Limitation ...

Страница 50: ...ltage values ADC_ VAL1 ADC_VAL2 detected by the accelerator pedal are not plausible to each other If RMTAPP with LIS is used defect is detected if there is a implausibilty with LIS and RMTAPP1 voltage 20282 3 Short Circuit to Battery on Out1 Error for H Bridge Short Circuit to Battery at Out1 of TLE7209 CJ230 Error Wiring Harness or Component Short Circuit to Battery on Out2 Error for H Bridge Sho...

Страница 51: ... 1 set in MoCSOP_st for example counter MoCSOP_ ctDebSOPTst MoCSOP_ctDebSOPTst_C 66 Events or MoCSOP_ct DebPSDia MoCSOP_ctDebPSDia_C 2 Events AND MoCSOP_ctCyl Num MoFInjDat_numCyl_C 4 during the MM SOP test 25 OS Timeout in the Shut Off Path Test Failure Setting the Alarm Task Period Irreversible error bit 7 set in MoCSOP_st counter MoCSOP_ctErrOSTim eout MOCSOP_MM_OSTIMEOUT_RESET_ERRORS 2 within ...

Страница 52: ...o the threshold Rail_MeUnMon dvolSetMin_C an error will be detected 1 Metering unit is stuck in open position 2 Zero delivery throttle clogged up 3 Metering unit without power due to electrical error 4 Pressure after zero delivery throttle too high 2 If the rail pressure RailP_pFlt exceeds the limiting value Rail_MeUnMon pFltMax_C 1 750 000 hPa an error will be detected If the rail pressure RailP_...

Страница 53: ...n at least one injector checkpoint has exceeded the admissible limits or no injector adjustment values could be read due to faulty EEPROM access IMA not pro grammed 23896 13 Check Of Missing Injector Adjustment Value Programming IMA Not Pro grammed 23897 13 23898 13 23906 3 Short Circuit to Battery of Pre Supply Pump Output Wiring Harness or Component 4 Short Circuit to Ground of Pre Supply Pump O...

Страница 54: ...hine 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 To prevent build up...

Страница 55: ...SECTION 4 ACCESSORIES SECTION 4 ACCESSORIES 069971 Page 55 ...

Страница 56: ...el Blade Finish 6 X 23 Gold Series only sold as set of 4 Part Number 047973G 4 Trowel Blade Finish 6 X 23 Plastic Steel Reinforced only sold as set of 4 Part Number 048342 4 Trowel Arm Alignment Jig Part Number 016863 Puller Spider Service Tool 6 Boss Part Number 048360 SECTION 4 ACCESSORIES 069971 Page 56 ...

Страница 57: ...le 6 Blade Part Number 047438 Dolly Jacks are available for HDX riders to make 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 039578 F Lifting Bridle 6 000 Pound Max 2 Point x 3 Foot Part Number 064798 Popular Accessories 069971 Page 57 ...

Страница 58: ... ways to access the Parts Decals Manual Mobile Device Scan this QR code with a compatible device cellular phone tablet etc Computer Click the link below HDX780 Parts and Decals Manual 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 Engineering P O Box 819 Paragould Ar 72451 USA Phon...

Страница 59: ...Revision Detail 069971 Page 59 MANUAL REVISION DETAIL REVISION REVISION DATE REVISION REFERENCE REVISION BY 02 20 Initial Release MW ...

Страница 60: ...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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