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allen BDF6048B 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
BDF6048B
SAFETY &
OPERATIONS MANUAL
Man ual Par t #: 05 301 6 | R evis io n : B
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 BDF6048B SAFETY & OPERATIONS MANUAL Man ual Par t #: 05 301 6 | R evis io n : B Languag e: E n g lish | O r igin a l In stru cti on s...
  • Page 2 Table of Contents SECTION 1 INTRODUCTION Page 2 Section 1 053016...

  • Page 3: Limited Warranty And Limitation Of Liability

    . 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 4: Specifications

    Specifications SECTION 1 INTRODUCTION BASIC UNIT • All welded steel construction that creates strength with a minimum of weight . • Crown may be changed at any hinge point or at travel rail adjuster . • Machine Length: ..................36 Ft - (10.9 M) Can be extended to 160 Ft (Consult Factory) (48.77 M) •...
  • Page 5 Specifications - Continued SECTION 1 INTRODUCTION 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...

  • Page 6: Operator Qualification

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

  • Page 7: Introduction Section

    YOU are responsible for the safe operation and maintenance of your If injured by concentrated high pressure steam or hydraulic Allen Paver . You must ensure that you and anyone else who is going to fluid, seek medical attention imedi ately . Serious infections or...
  • Page 8 Always disconnect the battery ground cable before working on sure to replace the decal as well . the electrical system . Obtain Safety Decals or signs from the Allen Parts and Service Do not tip battery more than 45 degrees to avoid electrolyte loss . Department .

  • Page 9: Silicosis Warning

    Federal / State Warning Regulations SECTION 1 INTRODUCTION 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 10 Manual Tag Safety Detail SECTION 1 INTRODUCTION 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 11 Spark Arrestor Notice SECTION 1 INTRODUCTION Some states require that in certain locations arrestors be used on internal combustion engines . A spark arrester is 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 .

  • Page 12: Operating Safety

    Operating Safety SECTION 1 INTRODUCTION Familiarity and proper training are required for the safe operation of this equipment! Equipment operated improperly or by untrained personnel can be dangerous! Read the operating instructions contained in both this manual and the engine manual and familiarize yourself with the location and proper use of all controls .
  • Page 13 Engine Safety SECTION 1 INTRODUCTION Internal combustion engines present special hazards during operation and fueling . Read and follow the warning instruc- tions in the engine owner’s manual and the safety guidelines below . Failure to follow the warnings and safety guidelines could result in severe injury or death .

  • Page 14: Service Safety

    Service Safety SECTION 1 INTRODUCTION 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 . •...
  • Page 15 Lifting Safety SECTION 1 INTRODUCTION ALWAYS DO A THOROUGH INSPECTION OF THE SLINGS, CHAINS, AND HOOKS BEFORE ATTEMPTING TO LIFT THE MACHINE! OSHA has set forth 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 .
  • Page 16 Your Dealer has Allen Engineering Corporation trained mechanics and original Allen replacement parts . Al- ways contact the Allen Dealer who sold you this machine for Allen Certified repairs and replacement parts . Place Allen Dealer information below for future reference .
  • Page 17 Components SECTION 2 CONTROLS POWER UNIT DRIVE END CONTROL PANEL INSERTS DRAG PAN IDLE END POWER UNIT INSERT ROLLER TAMPER PAVING CARRIAGE BOGIE WHEEL ASSEMBLY PAVER COMPONENTS A. Machine Frame hydraulically driven . The stationary power unit drives the Bogie Travel The 6048 Paver Frame is constructed from welded steel for maximum Wheels and the Carriage Travel Speed and Direction .
  • Page 18 Controls SECTION 2 CONTROLS Carriage Travel Speed Machine Travel Speed Manual Carriage Direction Power Selector Valve Machine Travel Direction Controls PAVER CONTROLS actuated each time the carriage automatically reverses direction . Before starting engines read the engine starting instructions and all warning decals located on the CAUTION: Before engaging carriage travel be sure operators console and at other key points on the that all personnel are clear of the paving carriage.
  • Page 19 Controls, continued SECTION 2 CONTROLS carriage . advancement is variable from 0 to 15 inches with each car- riage pass . Manual Mode: The Carriage Speed Control setting should be at the 10 posi- F. Carriage On/Off Valve - The hydraulic power required to drive the tion on the scale .

  • Page 20: Operation

    When Lifting Your Machine SECTION 3 OPERATION WARNING under end-frame • Please use extreme caution when lifting the BDF. Make sure crane or lifting equipment has enough capacity • ALWAYS attach LONG safety ropes or tag lines to the to lift the weight of the machine . Please make sure all ends of the machine prior to lifting .
  • Page 21 When Loading & Transporting Your Machine SECTION 3 OPERATION • CHECK all height restrictions prior to loading the machine as all Drop-Deck trailers and flat-bed trailers have different dimensions . Paving Carriage may need to be removed for legal transport . Tighten the leg clamps on the four legs (SEE PICTURE 2) .
  • Page 22 . (Special situations may have a maximum 30 inches). • Allen recommends our Steel Forms or forms designed and engineered to carry the weight and load of the The rails and chairs should be double checked paver.

  • Page 23: Insert Assembly

    Your BDF assembly process can be performed by a 2-3 the truss frame and the hinge pins on the bottom person crew with the help of an Allen Field Technician . of the truss frame and can be placed out of the Typically: one operator and two ground people .
  • Page 24 BDF Assembly & Set-up SECTION 3 OPERATION INSTALLING/REMOVING THE PAVING CARRIAGE – At that the direction of machine travel is as indicated on the control console. times it is necessary for transport, different paving direction or winter storage to remove the carriage from the •...

  • Page 25: Auger Installation

    BDF Assembly & Set-up SECTION 3 OPERATION DRAG PAN INSTALLATION STRAIGHTENING THE MACHINE • Attach the drag pan hanger bracket to the upper • When the attachments have been installed on the carriage mount on the top of the paving carriage paving carriage, maximize machine weight by filling the gas and hydraulic tanks .
  • Page 26 BDF Assembly & Set-up SECTION 3 OPERATION STRAIGHTENING CARRIAGE RAIL • Align the paving rollers so that they are parallel with the upper carriage . • For string-lining the carriage rail, use nylon masonry line . • Use a level, metal bar or string-line across the top of each side of the upper carriage from carriage rail to carriage rail .
  • Page 27 BDF Assembly & Set-up SECTION 3 OPERATION • The depth and penetration required will vary according to until the rod spring shifts the reversing valve and the lower job specifications. carriage shifts . • Pitching the front end of the drum higher allows the roller •...

  • Page 28: Chain Tensioning

    BDF Assembly & Set-up SECTION 3 OPERATION CHAIN TENSIONING • When determining the amount of chain sag, position the carriage to one end of the machine and measure • The chain tightener on the paving carriage is used the space between the bottom and top chain in the to equalize the tension of each the 2 carriage travel center of the machine on both sides (SEE PICTURE) .
  • Page 29 BDF Assembly & Set-up SECTION 3 OPERATION SETTING THE MACHINE GRADE the hydraulic tanks and keep any dirt or contaminates from getting into the hydraulic system, also, take care and clean • Position the machine so the carriage paving rollers are over all hydraulic fittings, quick dis-connects &...
  • Page 30 Paving Operation SECTION 3 OPERATION ROLLER ROTATION • When putting the automatic roller reversing valve in the “Non- Reversing” position causes no change to the • Paving roller rotation can turn either clockwise or roller direction with each pass of the carriage . counter clockwise or they can rotate in opposite •...
  • Page 31 Paving Operation SECTION 3 OPERATION SUPER ELEVATIONS • Turn the leg crank 1/2 turn counter clockwise to raise the back of the machine 1/8 of an inch . • For super elevated bridge decks, skewed decks • With the back of the machine raised, the augers or slabs, the roller rotation must be turning in the may need to be adjusted lower, watch the amount same direction with the valve lever set in the “Non-...
  • Page 32 Paving Operation SECTION 3 OPERATION PAVING CURVES MACHINE ADVANCEMENT • Mark an equal number of spaces on the inner curve (1 • The operator will pace the machine travel to 2 feet spacing), know the length or distance of the advancement to coincide with the placement of the inside .
  • Page 33 Paving Operation SECTION 3 OPERATION BEFORE PAVING SKEWED DECKS Paving Skewed Decks - Basic Machine • Before paving skewed decks it is essential that you Follow the standard machine setup instructions, initial determine all of the job specifications and special roller and drag pan adjustments and roller rotation .
  • Page 34 Paving Operation SECTION 3 OPERATION Paving Skewed Decks with Crown Skew Bar Kit Installation • Review the project specifications and requirements. 1 . Remove the carriage assembly from the machine and When determining machine lengths for skewed decks block up the carriage so that the carriage weight does with a crown, remember all lengths start with the crown not rest on the paving rollers .

  • Page 35: Maintenance Section

    . Take every precaution, to avoid Engine Service: contaminating the oil in the system . Thoroughly clean all Allen Bridge Deck Finishers use two engines . One engine hydraulic components before loosening or removing for is mounted on the stationary power unit to power machine repairs .

  • Page 36: Lubrication Maintenance

    Lubrication Maintenance SECTION 3 OPERATION LUBRICATION SCHEDULE Reversing Valve Slide NLGI-2 Lithium Base Grease - Lubricate slowly until excess lubricant is observed, approximately Lubricate Bracket 5-6 pumps . 68 Hydraulic Oil - Add hydraulic oil if necessary. Replace oil filter with a 10μm filter element after Hydraulic Oil Reservoir Inspect the first 50 hours and every 250 hours thereafter.

  • Page 37: Troubleshooting Section

    Troubleshooting SECTION 3 OPERATION SYMPTOM CAUSE REMEDY FINISHING Too much concrete in front of tubes Lower Augers Concrete is pitting behind roller tubes (Tubes plowing Slow the concrete delivery in front of machine Concrete is drying out concrete) to allow machine to keep up . Concrete is pitting behind Augers are to low, starving the roller Raise the augers to allow more concrete to...

  • Page 38: Troubleshooting

    Troubleshooting SECTION 3 OPERATION SYMPTOM CAUSE REMEDY Cam arm on shifter is not adjusted Adjust cam arm or upper rail correctly Carriage slows and stops but Check reversing valve for proper function and Reversing valve not shifting correctly will not regain speed correct if needed Distortion in valve body could restrict Loosen bolts one at a time...
  • Page 39 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 Carriage blower over relief if the carriage only works in one direc- cartridge that is stuck .

  • Page 40: Cleaning Procedure

    Cleaning Procedure 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 41: Manual Revision Detail

    Revision Detail MANUAL REVISION DETAIL REVISION # REVISION DATE REVISION REFERENCE # REVISION BY Initial Release 03/20 Update to Machine Standard 01/22 Updated Covers 053016 Page 41...
  • Page 42 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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