Curb Roller Manufacturing BADGER CURB MAKER CM4600 User manual

www.curbroller.com
785-467-3132
MODEL CM4600
OWNER’S MANUAL

Table of Contents
Introduction ........................................................................................... 1
Upon Receipt ........................................................................................ 1
Manufacturer’s Notice ......................................................................... 1
Specifications ....................................................................................... 2
Badger Curb Maker Package .......................................................... 2
Safety ..................................................................................................... 3
Assembly ............................................................................................... 5
Operation .............................................................................................. 6
Preparing the Concrete for the Curb Maker ....................... 6
Preparing the Curb Maker ....................................................... 6
Operating the Curb Maker ....................................................... 7
Cleanup and Maintenance ............................................................... 8
Cleanup ......................................................................................... 8
Maintenance ................................................................................ 8
Troubleshooting .................................................................................. 8
Curb Maker Drum Does Not Spin .......................................... 8
Curb Maker Is Hard To Pull ...................................................... 8
Curb Maker Will Not Stay On Forms ..................................... 9
Access Door Won’t Stay Closed ............................................. 9
Frequently Asked Questions ........................................................... 9
What are the drums made out of? ......................................... 9
Can I pour just one curb shape with the Curb Maker? ...... 9
What drives the Curb Maker? ................................................. 9
Can I use the Curb Maker for catch or spill curb? ............. 9
How do I change the direction of the Curb Maker? ......... 10
How do I adjust the speed of the Curb Maker? ................ 10
Can I change the drum profile on a Curb Maker? ............ 10
Can the Curb Maker power curb and gutter drums? ....... 10
Can the Curb Maker be converted to a roller screed? ..... 10
Parts ........................................................................................................ 11
Curb Maker Warranty ........................................................................ 17
Unit Identification ............................................................................... 19

Introduction
Congratulations on your purchase
of the Badger Curb Maker.
The Curb Maker is proudly
manufactured in the USA by Curb
Roller Manufacturing. The Curb
Maker has been manufactured to
provide years of service.
Before using the Curb Maker you
must read and follow this manual
for proper use and set up. You
must also read the DeWalt DCD460
manual.
Upon Receipt
Carefully examine your equipment
upon receipt to verify all the
components of your order have
been shipped to you and arrived
undamaged. Report any damage
immediately to the freight carrier
and register any claim. If any
material or manufacturing defects
are discovered, contact a Curb
Roller Mfg. representative at
785-467-3132.
Manufacturer’s Notice
Information provided in this manual
was current as of the issue date.
Curb Roller Mfg. reserves the right
to make design changes without
notice or liability.
Information furnished in this manual
does not include all of the details
of design, production, or variations
of the equipment. It does not cover
all of the possible contingencies
which may emerge during
operation. If special problems arise
or further information is desired,
please contact a Curb Roller Mfg.
representative at 785-467-3132.
This owner’s manual does not
replace, nor does its use release
the owner/operator from observing
all safety codes or operating
limitations as well as any applicable
federal, state, provincial or local
regulations.
1

2
Badger Curb Maker Package
This package includes:
A. Drive Unit
B. Idle Frame Assembly
C. Two (2) DeWalt Batteries
D. Adjuster Boot
E. DeWalt FLEXVOLT Charger
F. Operator’s Belt
*Drums for the Badger Curb Maker are
sold separately. To order, contact
Curb Roller Manufacturing or Dealers
in the Curb Roller Manufacturing
network.
Specifications
Length
28” (711 mm)
Width
32” (813 mm)
Weight
105 lbs (48 kg)

Observe all federal, state,
provincial, and local safety codes
and regulations that apply to the job
site.
Personal Protective Equipment
(PPE) must be worn to operate the
Curb Maker. Necessary PPE for this
machine includes safety glasses,
steel toed boots, gloves, ear
protection, and hardhat.
Individuals under the age of
eighteen should not operate the
Curb Maker.
Do not operate, work on/or around
this machine while under the
influence of alcohol, drugs, or if
feeling ill.
Never attempt to clean or service
the Curb Maker while machine is
running.
Safety
Before assembling and operating
this equipment you must read,
understand, and follow the
instructions and safety warnings in
this manual.
If you have any safety concerns or
questions that are not covered in
this manual, please contact a Curb
Roller Mfg. representative at
785-467-3132.
Failure to read and obey the
following safety warnings may
result in serious injury or death.
The use of the Badger Curb Maker
may be hazardous. The Curb Maker
has rotating parts and lithium-ion
battery power.
Do not alter, change, or modify the
Curb Maker. Altering, changing,
or modifying the equipment may
cause unsafe conditions or damage
the equipment, and may void the
manufacturer’s warranty.
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
3

Always clean, maintain, and
transport the Curb Maker with the
batteries removed from the drill to
avoid accidental rotation.
The Curb Maker is designed to run
with the drill on low speed. Do not
under any circumstance take apart
the drive unit and change the speed
on the drill.
Do not install battery until the Curb
Maker is in place ready to run.
Make sure all bystanders around
the machine are aware the drum is
about to spin.
Entanglement Hazard. Keep away
from moving parts.
Do not wear loose clothing. Long
hair must be tied back or netted.
Do not wear jewelry, headsets
with dangling wires, or coats with
dangling hood strings.
Never operate machine with
missing guards, shields, bolts, pins,
or any missing part.
The Curb Maker weighs approx 160
lbs. (48 kg.) with a drum installed.
Plan a safe handling procedure
before lifting. Individuals should not
attempt to lift the Curb Maker alone.
Before each use inspect all moving
parts for concrete or other debris
that can hinder operation.
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
4

Assembly
1. Pin the drum shaft into the drive
unit’s chuck.
2. Slide the idle frame assembly
into the drive unit.
3. Verify that the idler bearing on
the idle frame assembly slips
over the end of the drum shaft
opposite the chuck.
4. Use the two black pins and snap
rings to fasten the idle frame
assembly into the drive unit.
5. Pin the drum shaft opposite
from the chuck through the idler
bearing.
6. Fasten the adjusting boot into
the idle frame assembly with the
threaded knob.
5

Operation
Preparing the concrete for the
Curb Maker
1. Make sure the tops of the
stakes and pins used to support
the form board are below the
top of the form board.
2. Pour concrete against the form
board as if the curb were to be
hand formed.
3. Form concrete as close as
possible to the shape of the
curb with rakes.
4. Make sure the top of the form
board is free of concrete.
Preparing the Curb Maker
1. Move the Curb Maker to the
pour site.
2. Remove pin from the handle
and fold out away from the drive
unit. Replace pin when handle
is in the desired operating
position.
3. Open access door and insert
the battery into the drive unit.
6

4. Grasp both handles and
squeeze the trigger gently to
determine the spin direction of
the drum. The drum should be
turning away from the operator.
5. If the drum is not spinning away
from the operator, fully depress
the directional button.
6. Verify the drum sweep is on the
top side of the drum neck.
Operating the Curb Maker
1. Place the Curb Maker on the
edge of the form with the guide
ring running along the inside
edge of the form.
2. Place belt around the operator’s
waist and adjust size as needed.
Place loops over the Curb
Maker’s handles.
3. Squeeze the trigger to begin
drum rotation.
4. Slowly walk backwards to begin
screeding. Ensure the drum
is spinning in the opposite
direction that it is being pulled.
5. Maintain a small amount of
concrete in front of the drum
and up against the drum sweep.
If more than two inches of
concrete builds up in front of
the drum it must be raked away
by a second person.
6. Use the adjusting boot to adjust
depth while screeding.
7

Cleanup and Maintenance
Cleanup
1. Move the Curb Maker away
from poured concrete.
2. Remove all concrete from the
Curb Maker with a garden hose
or pressurized water supply.
3. Dry concrete may be gently
removed using a scraper or
similar tool.
Maintenance
Charge all batteries before each
use.
Grease drum bearings before each
use.
Troubleshooting
Curb Maker Drum Does Not Spin
• Check the battery by pressing
the indicator button
• Check the pin that connects the
drum shaft to the drive chuck
• Check trigger and linkage for
bent parts or concrete build up.
• Remove battery and reinsert.
• Check directional button and
make sure it is pressed all the
way in.
Curb Maker Is Hard To Pull
• The Curb Maker comes with
an operator’s belt. The belt
reduces the diculty of pulling
the machine.
• Concrete may be too dry or a
dicult mix to screed. See the
ideal mix information.
8

Curb Maker Will Not Stay On
Forms
• Verify that all stakes and pins
are below the top of the form.
• Check the amount of concrete
in front of the machine. Make
sure there is no more than two
inches of excess.
Access Door Won’t Stay Closed
• Tighten door bolt.
Frequently Asked Questions
What are the drums made out of?
Curb Maker drums are made out of
steel. The average life of a drum is
40 to 60,000 linear feet.
Can I pour just one curb shape
with the Curb Maker?
The Curb Maker can be purchased
with any of our stocked drum styles
or a custom fabrication for specific
jobs.
What drives the Curb Maker?
The Curb Maker runs o of one
DeWalt FLEXVOLT battery. One
battery should power the Curb
Maker to pour 150-200 linear feet
of curb.
Can I use the Curb Maker for catch
or spill curb?
A standard curb drum can be used
to pour catch or spill curb with
the heights being adjusted by the
operator.
9

How do I change the direction of
the Curb Maker?
The direction of the drum is
changed with the directional
button on the drill. When switching
directions, you must also swap the
drum sweep to the other side. The
drum sweep should always be on
the top side of the drum.
How do I adjust the speed of the
Curb Maker?
The speed is adjusted the same as
most cordless power tools- by how
much you squeeze the trigger. If the
trigger is squeezed to the fullest
extent, the drum will go full speed.
If the trigger is barely squeezed, the
drum will move slowly.
Can I change the drum profile on a
Curb Maker?
The Curb Maker is designed to
easily adapt between dierent curb
profiles by changing the drums
attached to the main frame.
Can the Curb Maker power curb
and gutter drums?
No. The Curb Maker is designed for
curb only drums.
Can the Curb Maker be converted
to a roller screed?
No. The Curb Maker should only be
used with a curb-only drum.
10

11
2
3
4
1
5

12
Parts
No.
1 1 40563-001Handle Assy- Control
1 1 1001-055Pin-Detent, 3/8” x 1-1/2”
1 1 1001-351
1500-031
Pin-Clevis, 5/8” x 1-1/2”
2 1 40561-001
1500-051
Frame Assy-Idle, CrbMkr 4600
3 1 40506-001
40504-001
Sweep Assy-Long, CM4000
4 1 40562-001Drive Assy-CrbMkr 4600
5 1 40560-001Frame Assy-Main Drive, CrbMkr 4600
2 Batteries-12ah
1 Charger-120v
1 Operator Belt
*Assembly items broken down on following pages
Qty.
Qty.
Part No.
Part No.
Description
Description
Items Not Shown

13
67
8
9
10
12
11
23
22
24
25
14
13
15
16
17
18
19
20
21

14
Parts
No.
6
21
1
2
1021-121
881-167
Knob-Star, Soft (1/2”-13 x 1-1/4” Lg)
Nut-Nylock Hx, 1/4” -20, Zc
7
22
1
2
40517-001
1147-001
105-103
Handle Assy-Lift, Auxiliary
Grip-Handle, Rbbr, 1” ID x 1.63” OD x 4.75 OAL
8
23
1
1
40042-001
313-004
1383-001
151-019
1385-001
251-003
119-107
1143-001
40043-001
Boot Wdmt-Bionic, CrbMkr 4600
Handle Wdmt-Control, CrbMkr 4600
9
9
9
1
3
3
1147-001
Bearing-Flgd, 3-Bolt, 1” ID
Bolt-Crge, 5/16”-18 UNC x 1”, Zc Pltd
Nut-Lock, Srrtd Flg, 3/8”-16 Unc, Zc Pltd
10 1
313-004
Chuck-Drive
11 1
105-103
Sprt Wdmt-Brg, Idle, CrbMkr 4600
12
12
2
2
1356-001
Pin-Cnctng, CrbMkr 4600
Pin-Lynch, 1/4” x 1-1/4”, Zc Pltd
13
13
1
22
40037-001
Cover-Top
Screw-Self Tap, HWH, #10 x 3/4”, Zc Pltd
Screw-Self Tap, HWH, #10 x 3/4”, Zc Pltd
14 1
40038-001
Arm-Pivot
15 1
1001-704
Arm-Link, Speed Control
16
16
16
1
3
6
1386-001
1384-001
151-019
Bracket Wdmt-Positioning
Bolt-Crge, 5/16”-18 UNC x 1”, Zc Pltd
Nut-Lock, Srrtd Flg, 3/8”-16 Unc, Zc Pltd
17
17
17
4
8
8
1380-001
Bar-Rd (5/8” x 4-1/4”)
Bolt-HXH, 0.313” - 18 x 3/4”, Zc
Bolt-HXH, 0.250”-20 x 3/4”, Zc
Washer-Flat, 5/16”,USS, Zc
18
18
1
1
1331-001
Housing-Main
19
19
19
1
3
6
313-004
Bolt-HXH, 7/8-9 x 1.00
Access Door-Bttry
20
20
1
22
105-103
Bearing-Flgd, 3-Bolt, 1” ID
21 1
101-178
311-003
1393-001
Bolt-Crge, 5/16”-18 UNC x 1”, Zc Pltd
21 2
1382-001
Nut-Lock, Srrtd Flg, 3/8”-16 Unc, Zc Pltd
Bearing Spt-Drive
Qty. Part No.Description

15
67
8
9
10
12
11
23
22
24
25
14
13
15
16
17
18
19
20
21

16
Parts
No.
24 1 1391-001Lever-Vrble Spd
24 1 253-005Bolt-Crge, 1/4”-20 UNC x 1-1/4”, Zc Pltd
24 1 105-101Nut-Lock, Srrtd Flg, 1/4”, Zc Pltd
25
25
25
1
1
1
1392-001Slide
Bolt-Shldr, Allen, 5/16” ODx3/8”, 1/4”-20 Unc
Washer-Nylon, 5/16”, 0.34”ID x 0.88”OD x 0.06 Thk
25 1
155-064
Nut-Nylock Hx, 5/16”-18, Zc
101-522
119-108
Qty. Part No.Description

17
understands and agrees that the
sole and exclusive remedy against
Curb Roller Manufacturing shall be
for the replacement or repair of
defective goods as provided herein.
Machine is warranted for a period
of one (1) year after date of original
purchase to original purchaser.
Batteries are warranted for a
period of three (3) years after date
of original purchase to original
owner.
Curb Roller Manufacturing product
warranty shall not extend or apply
to:
1. Defects which in our
judgment are the result of
misuse, negligence, accident,
or failure to perform regular
maintenance or service, and
any parts that may wear and
need to be replaced.
2. Products and component
parts not manufactured by
Curb Roller Manufacturing
beyond the warranty period
provided by the original
manufacturer or supplier.
3. Products improperly installed,
maintained, or used not in
accordance with all applicable
NOTICE
Curb Maker Warranty
Curb Roller Mfg. warrants to the
original purchaser that this product
will be free from defects in material
and workmanship.
Curb Roller Mfg. agrees to repair
or replace, at manufacturer’s
discretion, any defective product
free of charge within one year from
the date of purchase.
Curb Roller Mfg. must authorize
all work and returns prior to any
work being performed or returns
made. If the customer does perform
work and makes a return without
authorization, the customer does so
with the understanding that Curb
Roller Mfg. or any of its agents shall
not be obligated for the cost of any
such unauthorized expenses or
actions.
Proof of purchase in the form of
your dated sales receipt showing
serial number and the model of
the product will be required before
our dealers can perform warranty
service on the product.
All allowances will be credited at
factory cost with no provisions
for overtime, travel time, mileage,
freight charges, or special services
(i.e. down time).
The purchaser of any goods
covered by this warranty