allen BDF4836B, Safety & Operation Manual

Page 1: ...SAFETY OPERATIONS MANUAL Manual Part 050362 Revision C Language English Original Instructions B R I D G E D E C K F I N I S H E R S BDF4836B ...

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 050362 Page 2 ...

Page 3: ...19 050690 Bridge Deck Finisher Basic 24 067419 Bridge Deck Finisher Basic 24 T4 Diesel Engine 066700 Bridge Deck Finisher Basic 24 Diesel Engine with Vibrator Tubes 068091 Bridge Deck Finisher Basic 30 050695 Bridge Deck Finisher Basic 36 Bridge Deck Finisher Basic 36 T4 Diesel Engine 4836B Bridge Deck Finisher 050362 Page 3 ...

Page 4: ...al Regulations 17 1 1 General Safely Precautions 18 1 2 Engine Safety 20 2 0 Operations 23 2 1 Machine Component Overview 24 2 2 Machine Control Detail 25 2 3 Lifting the Machine 28 2 4 Pipe Rail Setup 30 2 5 Machine Setup 31 2 6 Power Crown Option 40 2 7 Paving Operations 42 3 0 Service 51 3 1 General Maintenance 52 3 2 Shifting Mechanism Adjustment 55 3 3 Trouble Shooting 57 ...

Page 5: ...050362 Page 5 Table of Contents continued ...

Page 6: ...dification 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 existence on ...

Page 7: ...Automatic paving carriage travel reversal Adjustable Drag Pan and Texturing Drag Roller Tamper Vibration System Power Unit Kohler Gasoline 25 HP OPTIONAL ACCESSORIES Extension Inserts 18 Ft 5 49 M 15 Ft 4 57 M 12 Ft 3 65 M 6 Ft 1 83 M and 3 Ft 0 91 M Power Assist Crown Adjustment Four Wheel Transport Dolly Adjustable Towing Tongue Skew Bar Kit Swing Out Legs Roller Tamper Vibration System Auxiliar...

Page 8: ...rame Clearance Above Screed Rail 47 In 119 38 Cm 6 Minimum Frame Clearance Above Screed Rail 15 In 38 10 Cm 7 Frame Clearance Above Finished Concrete 58 In 91 44 Cm 8 Height to Top of Leg 103 In 2 62 M 9 Height of framework 36 In 91 44 Cm 10 Leg Center Spacing 67 3 8 In 1 71 M 11 Drag Pan Length 33 In 83 82 Cm 12 Burlap Drag Length 19 In 48 26 Cm 13 Finishing Roller Length 46 In 116 84 Cm 14 Auger...

Page 9: ...ansfer Weight 175 175 Live Loads Basic Carriage Weight 2371 4 593 593 Carriage Accessories 900 4 225 225 Operator Weight 200 4 50 50 Total Weight 9102 1367 1717 Your Machine Total Weight LBS of Wheels Idler LBS per Wheel Power Unit End LBS Per Wheel Standard Machine Weight 8 Extra Inserts 8 Accessories 8 Machine Transfer Weight Live Loads Basic Carriage Weight 4 Carriage Accessories 4 Operator Wei...

Page 10: ...eg Rail 620 lbs 281 Kg 15 Ft Section With Leg Rail 868 lbs 394 Kg 15 Ft Section Without Leg Rail 732 lbs 332 Kg 18 Ft Section With Leg Rail 1023 lbs 464 Kg 18 Ft Section Without Leg Rail 889 lbs 403 Kg Determine the number of each length and type of insert section that are going to be added to the basic machine Add the weights of those sections to get the total weight of extra sections Example 2 3...

Page 11: ...accessory replaced Unfortunately not all accessory weights are currently available If your accessory is not included in the list below contact the Allen Engineering Service Department Auxiliary Internal Vibrator 285 lbs 129 Kg Carriage Spray System Includes the weight of 50 Gallons of water 900 lbs 408 Kg Skew Bar Kit 237 lbs 107 Kg Weight Transfer of Power Units with Diesel and Gasoline Engines T...

Page 12: ...ier than 200 lbs enter the appropriate weight If other people other than the operator are required to be on the machine their weights should be included Divide the weight by the number of wheels Write the wheel loads of your machine into the weight per wheel columns Example 200 lbs 4 50 lbs PER WHEEL THE 4836 IS SUPPORTED BY 8 WHEELS WITH 4 WHEELS TO EACH SIDE AS SHOWN ABOVE 050362 Page 12 Machine...

Page 13: ...inees should have normal depth perception field of vision reaction time manual dexterity coordina tion and no tendencies to dizziness or similar characteristics In addition to the above listed requirements the operator shall 1 Demonstrate the ability to understand and interpret all labels operator manuals safety codes and other information relevant to the operation of the paver 2 Possess knowledge...

Page 14: ...050362 Page 14 Notes ...

Page 15: ...SECTION 1 SAFETY 050362 Page 15 SECTION 1 SAFETY ...

Page 16: ...ting 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 containi...

Page 17: ...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 result in ...

Page 18: ...ediately Serious infections or toxic reaction can develop from hydraulic fluid penetrating the skin The safety alert symbol recognizes important safety messages written on the paver decals as well as in this manual When you see this symbol be alert to possible danger that could result in serious injury or death Note the use of key signal words in association with the safety alert symbol DANGER An ...

Page 19: ... and on coming traffic STORAGE PRECAUTIONS 1 Store paver in an area away from human activity 2 Do not permit children to play on or around the stored paver 3 Make sure the unit is stored in an area that is firm level and free of debris 4 Store the paver inside a building or cover securely with a weatherproof tarpaulin SAFETY DECALS 1 Keep Safety Decals and signs clean and legible at all times 2 Re...

Page 20: ...l before servic ing equipment NEVER run engine without an air filter or with a dirty air filter Severe engine damage may occur Service air filter frequently to prevent engine malfunction NEVER tamper with the factory settings of the engine or engine governor Damage to the engine or equipment can result if operating in speed ranges above the maximum allowable ALWAYS use extreme caution when working...

Page 21: ...SECTION 1 SAFETY 050362 Page 21 PAGE LEFT BLANK INTENTIONALLY ...

Page 22: ...Notes SECTION 1 SAFETY 050362 Page 22 ...

Page 23: ...SECTION 2 OPERATIONS 050362 Page 23 SECTION 2 OPERATIONS ...

Page 24: ...arriage B Stationary Power Unit Power is supplied by a 25 HP Kohler Gasoline Engine The machine is equipped with a 12 volt electric starting system All power functions are hydraulically driven The stationary power unit drives the Bogie Travel Wheels and the Carriage Travel Speed and Direction IDLE END C Paving Carriage Power is supplied by a 25 HP Kohler Gasoline Engine and with a 12 Volt electric...

Page 25: ...N THE PAVE POSITION B THE MACHINE TRAVEL DIRECTION CONTROLS ARE ENGAGED AND C THE MACHINE TRAVEL SPEED CONTROL IS NOT SET AT ZERO B Power Selection Control The power selection valve has three functions Pave Stop and Travel To avoid erratic carriage travel slowly ease the control to each new position In the Pave position the carriage will move back and forth through the machine truss The Pave posit...

Page 26: ...age Manual Mode 1 The carriage speed control setting should be at the 10 location on the scale 2 BOTH machine direction controls need to be in either the forward or reverse location 3 The power selector control should be in the Travel location 4 When the machine travel speed control is eased off of the 0 location the machine will start to move Automatic Mode 1 The carriage speed control should be ...

Page 27: ...sing position left the directional valves will continue to control the direction of the roller rotation When the handle is turned to the reversing position right the rollers will reverse their rotation just before the carriage ends its pass and reverse its direction on the truss I Carriage Lift Valve Option Lifts and lowers carriage J Roller Tamper Speed Control Located on the roller tamper frame ...

Page 28: ...t allow the weight of the machine to rest on the carriage or the paving rollers Damage to the carriage or the paving rollers could result 36 to 48 Machine Appx Weight 6 500 to 10 500 Lbs 84 to 108 Machine Appx Weight 10 000 to 13 500 Lbs WARNING Use extreme caution when lifting the Concrete paving machine All lifting devices must meet or exceed the required capacity to lift the weight of the machi...

Page 29: ...does not set on the paving rollers Cut two 4 x 4 wood blocks approximately 3 feet long Place the blocks under the end panels of the carriage and nail them to the deck of the truck bed With the carriage frame now setting on the blocks readjust the hold down rollers located on the carriage hanger frame at the top of the carriage to the down position Using the leg cranks lower the machine just enough...

Page 30: ...ed to conform to the longitudinal profile This can be accomplished many different ways You can use an instrument to measure from quarter points on the deck to the top of the screed rail using a level and rule then pulling a stringline between the two points or measuring from the grade line on the form to the top of the screed rail SCREED RAIL AND PAVING FORMS The screed rail and paving form setup ...

Page 31: ...of the machine frame to the travel bogies on the idler end of the machine and store them by the power unit insert Remove the car riage reversing paddles from the carriage rail for re installation after the carriage travel limits have been determined Truss frame inserts are added to the machine by splitting the machine at the hinge point of the power unit insert section Support the power unit inser...

Page 32: ...ting on blocks remove the carriage hanger frame and install the frame into truss Move the machine over the top of the paving carriage so that the paving carriage is centered under the machine truss Using the leg cranks lower the machine down until the carriage hanger frame can be bolted back on to the carriage Position the carriage in the middle of the machine and connect the travel chain Adjust t...

Page 33: ...d in the opposite direction Tighten jam nuts to hold bolts 7 AUGER INSTALLATION Slide the augers onto the lower car riage auger shafts Facing the lower 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 auger guard assembly Turn the auger adjusting crank and set the augers 1 8 to 1 4 above the b...

Page 34: ...usted and is straight re tighten all of the carriage rail locknut Repeat the procedure on the oppo site side of the machine 10 SQUARE CARRIAGE Before squaring the paving carriage make sure that the lower carriage slide blocks make contact with the upper carriage skew ring If your machine is equipped with a carriage lift option make sure that it is in the down position If contact is not made turn t...

Page 35: ...e back of the lower carriage Do not remove the bolts Using a tape or carpenters rule measure down from the string line to the top of the straight edge At this point the distance is arbi trary but must be the same at all four corners Adjust the distance of each roller end by turning its adjuster bolt clockwise to raise the roller and counter clockwise to lower the roller When all four corners are o...

Page 36: ...ned rollers are set to grade The Roller Tamper finned rollers are vertically adjustable from 1 2 inch above concrete grade to 3 4 inch below concrete grade The depth of penetration can vary according to job require ments Pitching the front end of the rollers allows the Roller Tamper to remain parallel to the concrete grade when the rear of the machine is raised with the leg cranks Maximum recommen...

Page 37: ...er pivot device slide a reversing paddle onto the carriage rail When it makes contact with the paving roller revers ing valve shift rod push the paddle approximately 1 1 2 inches or until the rod spring shifts the reversing valve Lock the reversing paddle in place by tightening the set screw Move the carriage to the opposite direction reversal point and repeat the procedure on the other side of th...

Page 38: ...14 CHAIN TENSION Use the chain tightener on the paving car riage to equalize the tension of each carriage travel chain See Figure 28 Be careful to verify that the carriage is square with the carriage rails For dual chain machines run the carriage to the drive end of the machine and verify that the distance between the carriage frame and the carriage travel shaft Dimension A B is the same at each c...

Page 39: ...or to become familiar with the controls and the operation of the machine If any corrections or adjustments need to be made it is usually done by adjustments in the screed pipe 17 PRE POUR INSPECTION Thoroughly inspect the machine before pouring concrete For best performance lubricate all mov ing parts Be sure to coat any part that might be exposed to wet concrete with oil Make sure that all engine...

Page 40: ...Power Crown Lever Nut A SECTION 2 OPERATIONS 050362 Page 40 2 6 Power Crown Option ...

Page 41: ...crowning shaft to turn freely STEP 2 Crown the machine using the power crown lever on the control panel Push the lever up to crown the machine and pull the lever down to lower the machine STEP 3 After desired crown is achieved tighten nut A to ensure that the crown will stay and the possibility of the crown slipping does not occur SECTION 2 OPERATIONS 050362 Page 41 2 6 Power Crown Option continue...

Page 42: ... so that the drag is not so heavy If the burlap does not seem to drag enough increase the length of the burlap so that it hangs down more NOTE If the drag pan H Frame is too high or the chains are hooked too tight the pan will have a tendency to hop as it is being dragged across the deck SECTION 2 OPERATIONS 050362 Page 42 2 7 Paving Operations ...

Page 43: ...he left roller turns counter clockwise This allows the leading roller to consolidate the concrete and the trailing roller to pave the surface Normally when pouring a flat bridge deck or slab this roller rotation will provide the best overall production and sealed finish However due to mix slump and other concrete variables one roller rota tion option may work better than another The paver s automa...

Page 44: ...no more than 6 to 8 feet in front of the machine Normal advancement of the machine will vary from 3 to 6 inches up to 12 inches for each carriage pass This will insure that fresh concrete will move into the paving rollers before dehydration of the concrete occurs This is particularly true in hot windy weather The decking and sub base material should also be kept wet in hot windy weather to aid in ...

Page 45: ... MACHINE THE DIAGONAL ANGLE BRACES IN THE SECTION BEING CROWNED When the 4836 Paver is skewed to pave skewed decks with a crown each carriage travel rail must be crowned exactly above the crown line on the deck The lower carriage must be skewed so that the paving rollers are parallel to the centerline of the deck The carriage wheels on the upper carriage must be repositioned so that they are cente...

Page 46: ...Skew Clamp Skew Cylinder SECTION 2 OPERATIONS 050362 Page 46 2 7 Paving Operations continued ...

Page 47: ...o skew the paving rollers follow the steps below 1 Manually disconnect the skew cylinder if it is installed on the machine and tie it back or remove it from the carriage 2 Loosen the skew stop clamps and rotate the paving rollers to the desired skew angle 3 Use the roller directional valves and position the two valve levers in the same direction Facing the augers both rollers turn clockwise when t...

Page 48: ...ed and vibrated with hand vibrators The setup time the time it takes for the film or latex skin to form on the surface is 10 to 15 minutes with a normal slump of 4 1 2 to 7 inches It is important that the finishing process be completed within ten minutes This will give adequate time for hand finishing along curb edges and for the surface texturing required before the surface film or skin forms Bec...

Page 49: ...SECTION 2 OPERATIONS 050362 Page 49 PAGE LEFT BLANK INTENTIONALLY ...

Page 50: ...SECTION 2 OPERATIONS 050362 Page 50 Notes ...

Page 51: ...SECTION 3 SERVICE 050362 Page 51 SECTION 3 SERVICE ...

Page 52: ...y replace oil filter with a 10 micron filter element after the first 50 hours and every 250 hours thereafter Engine Crankcase 1 Inspect Engine Oil SAE 30 MS SD or SE Add oil if necessary POWER UNIT Check Hydraulic Oil Reservoir 1 Inspect 68 Hydraulic Oil Add hydraulic oil if necessary Engine Crankcase 1 Inspect See Engines Add oil if necessary LEGS AND TRAVEL BOGIES Check Power Leg Screws 4 Lubric...

Page 53: ...ge to power the paving rollers augers and various optional carriage accessories Consult your Engine Owner s Manual for recom mended service procedures To insure the best engine performance and life a strict schedule of routine service and maintenance is recommended Change the engine oil after the first 5 Hours of operation and every 25 Hours thereafter Kohler API Service Classifications SF SG SH K...

Page 54: ... oil is replaced Before paving or transporting the machine secure all hoses to keep them away from sharp edges and moving parts Before con necting hoses clean the quick disconnects and fittings SHIFTING MECHANISM ADJUSTMENT The shifting mechanism automatically decelerates reverses and accel erates the carriage each time the carriage makes a pass and allows the operator to manually start or reverse...

Page 55: ...s greater than C D length F linkage 4 If A B is less than C D shorten F linkage TROUBLE SHOOTING SYMPTOM CAUSE REMEDY While in the pave position the carriage doesn t reverse direction and the machine will continue to travel The reversing valve on the shifting mechanism is not completely shifted Check the adjustment of the adjustable linkage assembly Use the formula provided SECTION 3 SERVICE 05036...

Page 56: ...s to slow motion the machine moves forward and the carriage travel reverses and accelerates smoothly If the carriage does not slow but goes in and out too fast during travel reversal the cam arm needs to be adjusted The cam arm is provided with a slot to fine tune the carriage travel shift speed Adjust the cam arm clockwise relative to the valve shift to reduce the travel speed and counter clockwi...

Page 57: ...move some or all of the added weight usually concrete from the pan The pan is not being pulled straight Adjust and hook the chains to the pan so that all the chains are hooked the same number of links from the pan The pan is being pulled at a point to high by the pan hanger frame Adjust the height of the hanger frame distance to the top of the pan to approximately 6 inches The total finished surfa...

Page 58: ... Check valve is stuck Lightly tap check valve Replace valve if malfunc tion recurs Valve is located beneath Power Unit See Parts Book Speed and power loss for carriage travel drive motor when carriage return direction is normal Clevis end or rear spool stop is unscrewing from reversing valve spool Clean oil from clevis end threads Assemble and loctite Carriage travel reversing valve is worn or fau...

Page 59: ...ore reas sembling Speed and power loss for paving roller and auger Worn hydraulic pump Replace hydraulic pump AUTOMATIC REVERSING VALVE Carriage rollers only work in Non Reversing Mode and will not go into Auto Reversing Mode after shifting the selector handle to Auto Reversing Mode Both the MV1 and MV2 Cartridge Valves are stuck and not shifting Replace both Cartridges Carriage rollers only work ...

Page 60: ...p the nozzle at least 1 foot 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 hardened concrete It is NOT recommended to use chemicals such as Muriatic Acid Hydrochloric Acid Hydrofluoric Ac...

Page 61: ...ccess the Parts Decals Manual Mobile 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 concrete equipment service concrete equipment manuals 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 ...

Page 62: ...ISION DETAIL REVISION REVISION DATE REVISION REFERENCE REVISION BY 06 2009 Initial Release AW A 07 2009 AW B 07 2018 MN 18 047 18 064 MW C 01 2022 Updated Covers MK SECTION 4 PARTS 050362 Page 62 Revision Detail ...

Page 63: ...ny errors or inaccuracies that may appear in this man ual 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 61...

Page 64: ...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 ...