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allen BDF4836B Safety & Operation Manual

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B R I D G E D E C K F I N I S H E R S
BDF4836B
SAFETY &
OPERATIONS MANUAL
Man ual Par t #: 05 036 2 | R evis io n : C
Languag e: E n g lish | O r igin a l In stru cti on s

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  • Page 1 B R I D G E D E C K F I N I S H E R S BDF4836B SAFETY & OPERATIONS MANUAL Man ual Par t #: 05 036 2 | R evis io n : C Languag e: E n g lish | O r igin a l In stru cti on s...
  • 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. Page 2 050362...

  • Page 3: Safety & Operations

    4836B B ridge inisher SAFETY & OPERATIONS MANUAL This manual covers the products listed below: Part No. Description 067210 Bridge Deck Finisher, Basic, 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’...
  • Page 4 Table of Contents Page 4 050362...
  • Page 5 Table of Contents, continued 050362 Page 5...

  • Page 6: Limited Warranty

    Allen reserves the choice to repair or replace. 2. If Allen chooses to replace the part, it will be at no cost to the customer and will be made available to the Allen Distributor, Dealer, or Rental Center from whom the End User purchased the product.

  • Page 7: Product Specifications

    Product Specifications STANDARD UNIT • Steel construction • Crown changes at all hinge points or carriage rail. • Machine automatically moves forward (0 to 12 Inches) at the end of each carriage pass. • Machine Width ................36 Ft - (10.97 M) Can be extended to 90 Ft (27.43 M) •...
  • Page 8 Specifications, continued DESCRIPTION MEASUREMENT Overall Machine Length 36 Ft 6 In 11.12 M Leg Span - Independently Adjustable Jack Mounts 33 Ft 3 In 10.15 M Finishing Width 31 Ft 4 In 9.55 M Maximum Leg Travel -Independently Adjustable Jack Mounts 15 Ft 3 In 4.66 M Maximum Frame Clearance Above Screed Rail...

  • Page 9: Machine Weights

    Machine Weights Example Total Weight Power Unit End (LBS Per # of Wheels Idler (LBS per Wheel) (LBS) Wheel Standard Machine Weight 4376 Extra Inserts 1016 Accessories Machine Transfer Weight Live Loads Basic Carriage Weight 2371 Carriage Accessories Operator Weight Total Weight 9102 1367...
  • Page 10 Unfortunately, not all accessory weights are currently available. If your accessory is not included in the list below, contact the Allen Engineering Corporation Service Department. • 4 Inch Swing Legs (2 Ends - Set of 4) ..........................480 lbs (218 Kg) •...
  • Page 11 Weight of Carriage Accessories (These weights take into consideration any basic carriage parts that the 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) •...
  • Page 12 Machine Weights, continued Determine the number of accessories being added to the basic carriage. Add the additional weights of those accessories to get the total additional weight of the accessories. Example: Carriage Spray System = 900 lbs. Write this weight into the total weight column. Divide the total weight by 4 to obtain the weight per wheel on the idler end and the driver end of the machine.

  • Page 13: Operator Information

    If you require any additional information or Understand responsibility for maintenance requirements. service do not hesitate to call the Allen Paver Service Department. (Tel: 800-643-0095 - Fax: 800-643-0097) Understand the operating procedures as outlined by the man- ufacturer.
  • Page 14 Notes Page 14 050362...
  • Page 15 SECTION 1 SAFETY SECTION 1 SAFETY 050362 Page 15...

  • Page 16: Silicosis Warning

    Federal / State Warning Regulations SECTION 1 SAFETY 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.
  • Page 17 Manual Tag Safety Detail SECTION 1 SAFETY Safety-Alert Signs This manual contains Safety-Alert Signs, as defined below, which must be followed to reduce the possibility of improper servi ce damage to the equipment or personal injury. Read and follow all Safety-Alert Signs included in this manual. NOTE defines an operating procedure, condition, etc.

  • Page 18: General Safety Precautions

    YOU are responsible for the safe operation and maintenance of your Replace any worn, cut, abraded, flattened or crimped hoses Allen Paver. You must ensure that you and anyone else who is going and metal lines. to operate, maintain or work around the machine be familiar with the...
  • Page 19 Check all lifting cables, chains, clevises, cable clamps and spreader beams for any damage. Use ropes Obtain Safety Decals or signs from the Allen Parts and Service tied to the ends of the machine to prevent the machine from Department.

  • Page 20: Engine Safety

    1.2 - Engine Safety SECTION 1 SAFETY • DO NOT place hands or fingers inside engine compartment when engine is running. • NEVER operate the engine with heat shields or guards removed. • Keep fingers, hands hair and clothing away from all moving parts to prevent injury. •...
  • Page 21 SECTION 1 SAFETY PAGE LEFT BLANK INTENTIONALLY 050362 Page 21...
  • Page 22 Notes SECTION 1 SAFETY Page 22 050362...
  • Page 23 SECTION 2 OPERATIONS SECTION 2 OPERATIONS 050362 Page 23...
  • Page 24 2.1 - Machine Component Overview SECTION 2 OPERATIONS POWER UNIT DRIVE END CONTROL PANEL INSERTS IDLE END DRAG PAN IDLE END POWER UNIT INSERT ROLLER TAMPER PAVING CARRIAGE BOGIE WHEEL ASSEMBLY PAVER COMPONENTS A. Machine Frame The 4836B Paver Frame is constructed from welded steel for maximum strength and light weight.

  • Page 25: Section Iii - "Set-Up" Instructions

    2.2 - Machine Control Detail SECTION 2 OPERATIONS Carriage Travel Speed Machine Travel Speed ACC Power Manual Carriage Direction Power Crown (Option) Power Selector Valve Water Spray (Option) Machine Travel Direction Controls PAVER CONTROLS BEFORE STARTING ENGINES READ THE ENGINE STARTING INSTRUCTIONS AND ALL WARNING DECALS LOCATED ON THE OPERATORS CONSOLE AND AT OTHER KEY POINTS ON THE MACHINE.
  • Page 26 2.2 - Machine Control Detail, continued SECTION 2 OPERATIONS C. Carriage Speed Control Automatic Mode: The carriage speed control establishes the speed of both the The carriage speed control should be off the “0” location. The paving carriage and any accessories installed on the unit. This valve higher the setting the faster the paving carriage will travel through regulates the amount of hydraulic oil going to any one of the control the machine truss.
  • Page 27 2.2 - Machine Control Detail, continued SECTION 2 OPERATIONS Roller Directional Valves G. Roller Direction Valves The directional valves will permit the rollers to rotate forward, remain in neutral or rotate in reverse. The operator should choose the favored setting before the initial carriage pass and push the levers to the up, middle or down locations.

  • Page 28: Lifting The Machine

    2.3 - Lifting the Machine SECTION 2 OPERATIONS WARNING! Use extreme caution when lifting the Use the lifting straps provided with the paving machine. The straps are rated at 28,000 lbs. when used in the basket configuration. Concrete paving machine. All lifting devices must meet or exceed the required capacity to lift the Attach ropes to each end of the machine to help preventing the machine weight of the machine.

  • Page 29: Loading The Machine

    2.3 - Lifting the Machine, continued SECTION 2 OPERATIONS Loading With Carriage - If the machine is to be loaded with the LOADING THE MACHINE carriage still in the machine, you will need to block the carriage Before loading the machine. Check the height of the flat bed trailer to so that the machine or carriage weight does not set on the paving make sure that the machine not be too tall for transport.

  • Page 30: Towing The Machine

    2.4 - Pipe Rail Setup SECTION 2 OPERATIONS 30 inches). The screed chairs should not interfere with support studs. The rails and chairs should be double checked after the positioning of CAUTION! Do not allow the weight of the machine to the machine.

  • Page 31: Machine Setup

    2.5 - Machine Setup SECTION 2 OPERATIONS Paving forms must have a good solid sub base to sit on to keep the paving forms from sinking. ACP recommends metal forms made especially to carry the weight of the paver. The 6036 Paver will be equipped with flat flange bogie wheels that are 3 inches in width to ride on top of the paving form.
  • Page 32 2.5 - Machine Setup, continued SECTION 2 OPERATIONS Chain Tensioner the machine is split the power unit section is self supporting and stable. Hook up the idler end of the machine to a lifting device. Remove the crown bolts at the top of the truss frame and the hinge Hold Down Roller pins on the lower end of the truss frame.
  • Page 33 2.5 - Machine Setup, continued SECTION 2 OPERATIONS 5. SQUARING TRUSS - After the machine has been placed on the deck, center the paving carriage in the truss. All four corners of the machine must be set to the same height to assure that the truss does not have a twist.
  • Page 34 2.5 - Machine Setup, continued SECTION 2 OPERATIONS at each carriage rail adjuster. Turn the carriage rail adjuster up or down so that the string line just touches the top of the wood block. After the carriage rail has been adjusted and is straight, re-tighten all of the carriage rail locknut.
  • Page 35 2.5 - Machine Setup, continued SECTION 2 OPERATIONS Physically align the paving rollers so that they are parallel with the upper carriage. Stretch a string line across the top of each side of the upper carriage. Make sure that the string line contacts the inner flange of the carriage rail.
  • Page 36 2.5 - Machine Setup, continued SECTION 2 OPERATIONS Roller Tamp Speed 11. ROLLER TAMPER The Roller Tamper finned rollers are vertically adjustable - The ACP Roller Tamper is an option that from 1/2 inch above concrete grade to 3/4 inch below concrete provides a means of achieving a more uniform concrete surface grade.
  • Page 37 2.5 - Machine Setup, continued SECTION 2 OPERATIONS ing valve shift rod, push the paddle approximately 1-1/2 inches or 12. CARRIAGE TRAVEL - The carriage travel distance can be until the rod spring shifts the reversing valve. Lock the reversing adjusted to suit the job requirements by strategically positioning paddle in place by tightening the set screw.

  • Page 38: Chain Tension

    2.5 - Machine Setup, continued SECTION 2 OPERATIONS the desired grade slope. It is recommended that the crown bolts be adjusted 1/2 inch at a time and alternated sequentially. This permits the crown bolt nuts to shift slightly to compensate for the angle change and requires less adjustment effort.
  • Page 39 2.5 - Machine Setup, continued SECTION 2 OPERATIONS To determine the amount of chain sag needed, move the carriage to 16. DRY RUN - The machine is now ready for a “Dry Run” of one end of the machine and measure the distance between the top the entire deck or slab.

  • Page 40: Power Crown Option

    2.6 - Power Crown Option SECTION 2 OPERATIONS Nut (A) Power Crown Lever Page 40 050362...
  • Page 41 2.6 - Power Crown Option, continued SECTION 2 OPERATIONS The Power Crown (Optional) is an assisted system to help in the crowning of the bridge deck finisher. To operate the the power crowner follow the instructions below. STEP 1) Loosen nut (A) off to allow the crowning shaft to turn freely. STEP 2) Crown the machine using the power crown lever on the control panel.
  • Page 42 2.7 - Paving Operations SECTION 2 OPERATIONS The texture given by the burlap can be easily adjusted. If the burlap is dragging to hard, remove one of the retaining tubes and roll up the burlap 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.
  • Page 43 2.7 - Paving Operations, continued SECTION 2 OPERATIONS 2. ROLLER ROTATION - The two paving rollers can rotate in the same direction (either clockwise or counter clockwise) or they due to “mix”, slump and other concrete variables, one roller rota- can rotate in opposite directions.
  • Page 44 2.7 - Paving Operations, continued SECTION 2 OPERATIONS 4. PAVING UP & DOWN GRADES 7. CARRIAGE TRAVEL SPEED - When paving up a grade, - At times it may be advanta- the rear of the paving rollers may need to be raised higher geous to slow down the carriage travel speed.
  • Page 45 2.7 - Paving Operations, continued SECTION 2 OPERATIONS 9. PAVING SKEWED DECKS riage wheels by means of the Optional Carriage Skew Bar Kit. The - BASIC MACHINE skew bar kit offsets the carriage wheels so that when the carriage Follow the standard machine setup instructions, initial roller and passes through the crown the paving rollers pass over the crown drag pan adjustments and roller rotation.
  • Page 46 2.7 - Paving Operations, continued SECTION 2 OPERATIONS Skew Cylinder Skew Clamp Page 46 050362...
  • Page 47 2.7 - Paving Operations, continued SECTION 2 OPERATIONS Skew Bar Tube Chain Tensioner Extension Carriage Wheel Mount Tube Mount Adjustable Tube Mount To skew the paving rollers follow the steps below: Manually disconnect the skew cylinder, if it is installed on the machine, and tie it back or remove it from the carriage.
  • Page 48 2.7 - Paving Operations, continued SECTION 2 OPERATIONS 12. PAVING THIN BONDED CONCRETE OVERLAYS The setup time, the time it takes for the film or latex skin to form It is very important that the machine has a straight and solid set on the surface, is 10 to 15 minutes with a normal slump of 4-1/2 of screed rails.
  • Page 49 SECTION 2 OPERATIONS PAGE LEFT BLANK INTENTIONALLY 050362 Page 49...
  • Page 50 Notes SECTION 2 OPERATIONS Page 50 050362...
  • Page 51 SECTION 3 SERVICE SECTION 3 SERVICE 050362 Page 51...

  • Page 52: General Maintenance

    3.1 - General Maintenance SECTION 3 SERVICE MAINTENANCE For maximum performance we recommend that you service and maintain your 4836 Paver on a regular basis. Do not hesitate to call the ACP Service Department if, at any time, you have a question about the service and maintenance of your machine.
  • Page 53 3.1 - General Maintenance, continued SECTION 3 SERVICE LUBRICATION CHART (cont’d) EVERY 100 HOURS LEGS AND TRAVEL BOGIES Check NLGI-2 Lithium Base Grease - Lubricate slowly until Drive Bogie Axle Bearings (4) Lubricate excess lubricant is observed. Bogie Drive Chains (2) Lubricate CONTROLLER Check...
  • Page 54 3.1 - General Maintenance, continued SECTION 3 SERVICE SHIFTING MECHANISM ADJUSTMENT HYDRAULIC OIL AND OIL FILTERS The shifting mechanism automatically decelerates, reverses and accel- Check the level of hydraulic oil in the oil reservoir on a daily basis. erates the carriage each time the carriage makes a pass and allows Check the oil before starting the engine.

  • Page 55: Troubleshooting

    3.2 - Shifting Mechanism Adjustment SECTION 3 SERVICE ADJUSTABLE LINKAGE ADJUSTMENT CHECK 1. Using a tape measure, measure and record the dimensions A, B, C, and D. You will have to shift the valve once to measure both A and B. 2.
  • Page 56 3.2 - Shifting Mechanism Adjustment, SECTION 3 continued SERVICE Periodically, check the fit of the controller cam rollers between the upper and lower rails. Occasionally the upper rail needs to be adjust- ed downward to compensate for the wear of the cam rollers and rail edges.
  • Page 57 3.3 - Trouble Shooting SECTION 3 SERVICE Problem Cause Solution Finishing Paving rollers are carrying to much concrete Adjust the augers lower to leave a golf ball (the roll of concrete on the side of the rollers size roll at the front edge of the leading roller is to large) Open or pitted surface left by the rollers (the rollers are plowing concrete)
  • Page 58 3.3 - Trouble Shooting, continued SECTION 3 SERVICE Problem Cause Solution Carriage does not move when power is applied. Carriage Shifting Mechanism cam arm follower is Check cam arm follower tension and verify that Engine is under strain. not in “pave” position. cam arm movement is not obstructed.
  • Page 59 Remove the 9/16 Hex Vent Cap on both the MV1 and MV2 Cartridge Valves. Insert a small screw- driver or allen wrench into the vent cap holes. The cartridge with the shallowest hole is the cartridge If the carriage works in all modes except for one that is stuck.

  • Page 60: Cleaning Procedure

    Cleaning Procedure SECTION 3 SERVICE Machine Cleaning Procedure When cleaning the machine, please adhere to the following information to ensure proper cleaning and to keep the machine in the best condition possible. Power Washing Procedure: • Ensure that the water pressure is below 2000 PSI (14 MPa) •...
  • Page 61 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. Allen Engineering P.O.

  • Page 62: Manual Revision Detail

    Revision Detail SECTION 4 PARTS MANUAL REVISION DETAIL REVISION # REVISION DATE REVISION REFERENCE # REVISION BY 06/2009 Initial Release 07/2009 07/2018 MN 18-047, 18-064 01/2022 Updated Covers Page 62 050362...
  • Page 63 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 in this man- ual.
  • Page 64 AEC FACTORY & HEADQUARTERS 8 1 9 S . 5 T H S T R E 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 .

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