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allen AW16 Safety & Operation Manual

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AW16 & AW21 W
B
heel
uggy
SAFETY & OPERATIONS MANUAL
MANUAL PART #: 069583 | REVISION: -
LANGUAGE: ENGLISH | ORIGINAL INSTRUCTIONS

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  • Page 1 AW16 & AW21 W heel uggy SAFETY & OPERATIONS MANUAL MANUAL PART #: 069583 | REVISION: - LANGUAGE: ENGLISH | ORIGINAL INSTRUCTIONS...
  • Page 2 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 manual.
  • Page 3 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 Table of Contents GENERAL INFORMATION Page 4 069583...

  • Page 5: Information Contained In This Manual

    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, Inc warranty.
  • Page 6 GENERAL INFORMATION Your Dealer has Allen Engineering Corporation trained mechanics and original Allen replacement parts. Always 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 7: Model And Serial Number

    The serial number found on the identification plate is a ten digit format. The model number identifies your machine and will ensure that you receive the correct replacement parts. Serial Number Example AW16 01 19 01 Sequence Number Year Month...

  • Page 8: Technical Specifications

    Measurements in this manual are in standard units Machine Features for AW16: • Engine ..........Kohler CH440 •...

  • Page 9: Machine Dimensions

    Machine Dimensions GENERAL INFORMATION 97.18 in 50.56 in 46.59 in Page 9 069583...

  • Page 10: Engine Specifications

    Engine Specifications GENERAL INFORMATION Kohler CH440 Engine Information (14 HP) Engine Type: ............Air-Cooled, 4-stroke OHV Bore x Stroke: .
  • Page 11 Engine Specifications GENERAL INFORMATION Kohler CH640 Engine Information (20.5 HP) Engine Type: ............Air-Cooled, 4-stroke OHV Bore x Stroke: .
  • Page 12 Engine Specifications GENERAL INFORMATION Reserved for Propane Engine - Pending Approval Page 12 069583...
  • Page 13 SECTION 1 SAFETY Section 1 SAFETY Page 13 069583...
  • Page 14 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 15 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 16 Spark Arrestor Notice / Safety Symbols SECTION 1 SAFETY 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 17: General Safety

    AEC dealer in your trade area. Should you need the name of a dealer in your area, call Allen Engineering at 800-643-0095 or email customerservice@alleneng.com. All repairs to this machine must be made by a qualified service mechanic using only Allen Engineering replacement parts or their approved equal. Any deviation from the original AEC...
  • Page 18 General Safety SECTION 1 SAFETY b) Speed control return spring. This spring is mounted on the transmission shift bar and allows the speed control lever to return automatically when released. Spring tension should be sufficient to briskly snap back the speed control lever when it is released.
  • Page 19 • Extinguish smoking materials. • Shut engine off. • Shut off Fuel. On AW16 turn Fuel Valve at the carburetor to the OFF position. Note: Fuel shut off on AW21 occurs when the ignition key is turned OFF. • Let engine cool for a minimum of 5 minutes.
  • Page 20 General Safety SECTION 1 SAFETY Ø The engine on this machine may be equipped with an exhaust purifier that may reduce, but will not eliminate these dangerous emissions. Ø The efficiency of this purifier decreases if the engine is not properly tuned, especially if the fuel mixture is too rich.
  • Page 21 SECTION 1 SAFETY NOTE: ON THE AW16 ONLY THE OUTSIDE WHEELS AND TIRES CAN BE REMOVED TO REDUCE OVERALL WIDTH. WHEN OUTSIDE WHEELS AND TIRES HAVE BEEN REMOVED OPERATE THE AW16 ONLY ON LEVEL, HARD SURFACES I.E., CONCRETE, ASPHALT, OR COMPACTED STONE. OPERATING BUGGY ON ANY OTHER CONDITIONS MAY CAUSE BUGGY TO TIP.

  • Page 22: Operating Safety

    Operating Safety SECTION 1 SAFETY D) During operation of this equipment: Ø Use caution when operating near other personnel and obstructions. Always look to the rear before backing up and back up slowly. Be aware of other job site traffic. DO NOT OPERATE THIS MACHINE WITH YOUR BACK FACING THE CONTROLS.
  • Page 23 Operating Safety SECTION 1 SAFETY Ø If operator must leave operator’s station (standing between handlebars either on operator’s platform or standing on the ground with the platform in the “UP” position) the operator must: a) Stop equipment. Do not block access to fire isles, stairways, fire equipment. b) Set and lock parking brake.
  • Page 24 Operating Safety - Propane SECTION 1 SAFETY 1. Never allow your (LP) Liquid Propane-gas container to be filled above the maximum safe level as indicated by a scale or the fixed liquid level gauge (outage). Do not use the visible gauge for filling. 2.
  • Page 25 Operating Safety - Propane SECTION 1 SAFETY CAUTION: USE LP-GAS CONTAINERS IN PROPER POSITION Most LP-gas appliances for cooking, heating, lighting, water heating and refrigeration are designed to operate on LP-gas vapor only. Therefore, all LP-gas containers designed for vapor service must be transported, installed and used in the proper position.
  • Page 26 SECTION 2 OPERATIONS Section 2 OPERATIONS Page 26 069583...

  • Page 27: Introduction Section

    The sixteen cubic foot AW16 and the twenty-one cubic foot AW21 have earned their rank as the standard by which all power buggies are judged. Their massive two-inch thick solid steel tank-tough frames provide unparalleled strength and durability along with a lower center of gravity and ideal weight distribution.

  • Page 28: Start-Up Procedures

    Start-up Procedures SECTION 2 OPERATIONS Page 28 069583...
  • Page 29 2) Receive training on the Safety, Machine Operation, Machine Adjustments, Maintenance and Machine Lifting and Tie Down Procedures. Starting Procedures for AW16 (14 HP Kohler gasoline engine) ØPosition yourself in operator’s position standing on the ground between the handlebars or standing on the oper- ator’s platform.
  • Page 30 Start-up Procedures SECTION 2 OPERATIONS ØTo start electric start Kohler CH440 14 HP, turn engine start switch to START position and return switch to ON position when engine starts. ØAfter engine starts, move choke lever to OPEN position. Let engine warm up at full throttle and run smoothly for approx- imately 5 minutes, before applying load.
  • Page 31 Parking Brake Operation SECTION 2 OPERATIONS Setting and Releasing the Parking Brake To set parking brake: 1. Stand on the operator’s platform. 2. Place right foot on brake pedal (1) and stand on the pedal so it depresses to the lowest point. 3.
  • Page 32 Battery Jump Start Procedure SECTION 2 OPERATIONS WHEN JUMP STARTING THESE KOHLER ELECTRIC START ENGINES FOLLOW INSTRUCTIONS BELOW. FAILURE TO FOLLOW THESE INSTRUCTIONS CAN CAUSE BURNS AND/OR EYE INJURIES FROM ELECTRIC SPARKS, IMPROPER CONNECTIONS, ETC., TO PERSONNEL OR DAMAGE TO ENGINE. ØWear OSHA compliant safety glasses when jump starting.
  • Page 33 Operating Instructions SECTION 2 OPERATIONS Driving Equipment ØThe Directional Control Lever (located on the top right side of the dash) controls the direction of travel - forward, reverse and neutral (free-wheeling). Select the direction of travel desired. The Speed Control Lever (located on the right side of the handle bar) controls the vehicle speed, power, and dynamic hydraulic braking.
  • Page 34 ØTurn fuel valve on engine to the OFF position. Failure to do so will ultimately result in gas entering the crankcase. Steering the Buggy ØAllen Buggies, models AW16 and AW21 are steered using the Handlebars in front of the operator’s platform.
  • Page 35 Section 3 SERVICE Page 35 069583...

  • Page 36: Brake Service

    Brake Service SECTION 3 SERVICE Service Brake See page 49 for brake schematic. Inspect the Service Brake DAILY. A daily Service Brake inspection performed with an empty buggy traveling at full speed must demonstrate that when full foot pressure (125 LB.) is applied to the brake pedal both brakes engage equally, the pedal is level with the top of the operator’s platform, the buggy stops in 6-8’...
  • Page 37 Brake Service, continued SECTION 3 SERVICE Brake Operational Problem Adjustment/Repair Required Adjustment/Repair Procedure 1) Clean concrete/dirt accumulation Clean all dirt from pedal area. Adjust away from brake pedal (44). clearance of brake pedal (44) with pivot 1) Brake pedal (44) travels below bolt assembly (47) by tightening 5/8”...

  • Page 38: Parking Brake

    Parking Brake SECTION 3 SERVICE Parking Brake See page 3-5 for brake schematic. Adjust parking brake so that when engaged, parking brake will hold a loaded buggy on 15% slope (8.5 degrees). If parking brake does not operate as indicated, adjust as follows: ØAdjust service brake per the troubleshooting guide above.
  • Page 39 Parking Brake Schematic SECTION 3 SERVICE ADJUST CLEARANCE OF BRAKE PEDAL 44 WITH PIVOT BOLT ASSEMBLY 47 BY TIGHTENING 5/8”NC -10 JAM NUT AGAINST FLAT WASHERS AND 3/4” HEX NUT. THEN BACK OFF JAM NUT 1/4 TURN WHILE HOLDING PIVOT BOLT, TIGHTEN 5/8” NC STEEL LOCKNUT TO 120 FT/LBS.

  • Page 40: Speed Control

    Speed Control SECTION 3 SERVICE When making adjustments to the Speed Control system, block the buggy’s wheels in both directions to prevent injury. 1. Adjust Speed Control Lever, Cable and Spring (Refer to drawing on page ??) A. Position the buggy on a hard, level surface. Turn the engine off. Remove spark plug wire(s) to disable engine. Engage the parking brake.
  • Page 41 Speed Control SECTION 3 SERVICE ix. Place a 5/8”NF-18 jam nut on the threaded end of both bulkhead fittings protruding through the mounting holes. x. Attach a clevis (item 10) to the end of the cable used to attach to the transmission shift bar. Note: In all cases the cable attachments must be threaded onto the ¼”NF-28 cable end one-quarter of an inch(¼”).
  • Page 42 Speed Control SECTION 3 SERVICE 2) Adjust Neutral The speed control assembly when properly adjusted will not permit the buggy to creep in either direction when the speed control lever is released (in neutral), the service/parking brake is released and the directional control lever is in either the forward or reverse position.
  • Page 43 Speed Control SECTION 3 SERVICE SIDE RUBBER BUSHING THRU AND INSTALL CABLE 9. REF: HANDLEBAR #42126-01 INSTALL CORD GRIP .840” DIAMETER HOLE IN THE TOP OF CONSOLE #42100-38 TO THE LEFT OF REAR STEERING ASSEMBLY. LEVER ENGAGED SHIFT CABLE HYD RESVOIR END PLATE NYLON LOCKNUT (TORQUE TO 80 IN LBS)

  • Page 44: Pressure Setting

    Relief pressure setting should be 1500 +/-50 PSI. To adjust pressure: 2. Remove hex cap (item 1) covering pressure relief valve (beside valve spool). 3. With a 5/16” allen wrench, turn pressure adjusting screw (item 2) three turns counter c l o c k - wise.
  • Page 45 Relief pressure setting should be 2000 +/-50 PSI. To adjust pressure: 1. Remove hex cap (item 1) covering pressure relief valve. 2. With a 5/16” allen wrench, turn pressure adjustment screw (item 2) three turns counter clockwise. 3. Remove hex cap (item 3).
  • Page 46 Dump Lever Adjustment SECTION 3 SERVICE Dump Control Lever 1) Console mounted dump control lever Three (3) adjustments are possible: Position of foot pedal, drag on valve lever pivot, and drag on dump pedal pivot. 1. Position of foot pedal: To readjust foot pedal position remove cotter pin (6) and clevis pin (5) at pedal.
  • Page 47 Dump Lever Adjustment SECTION 3 SERVICE 2) Handle Mounted Bucket Dump Control Lever Two (2) adjustments/inspections are possible (These adjustments are made with the engine off and the parking brake engaged). A) Adjust/inspect the position of handle mounted bucket dump control lever (items 18 and 21 on the following page): To readjust the position of the handle dump lever remove bolt/nut (28) and pivot handle (18) out of the way to access to clevis and pin with cotter pin (23).
  • Page 48 Dump Lever Adjustment SECTION 3 SERVICE J. Place a 5/8”NF-18 jam nut on the threaded end of the bulkhead fitting protruding through each mounting hole. K. Attach a clevis to each end of the cable. Note: In all cases the cable attachments must be threaded onto the ¼”NF-28 cable end one-quarter of an inch(¼”). After each attachment is threaded onto the cable end its position must be secured by tightening the jam nut (item 24) against the clevis.
  • Page 49 Flex Coupler Adjustments SECTION 3 SERVICE Flexible Coupling for Engine/Transmission A flexible coupling is mounted between the engine and transmission. The half with the 1” bore mounts to the engine, the half with the ¾” bore mounts to the transmission. A flexible coupling element is between the two coupling halves. 1.

  • Page 50: Maintenance

    Maintenance SECTION 3 SERVICE Place buggy on level ground, shut off engine, apply parking brake, and block all wheels before servicing. Should bucket or platform need to be kept in the raised position, securely block bucket in raised position. Service Buggy only in well lit area, free from vehicle and pedestrian traffic.

  • Page 51: Maintenance Section

    Maintenance SECTION 3 SERVICE Hydraulic Drive/Bucket Dump: • Check hydraulic oil level daily. Check oil level with bucket in the “down” position, and with oil temperature cold. Fill reservoir to bottom of bolt head on filler cap or “F” mark on dipstick with SAE 10W-40 weight SE motor oil. Reservoir capacity is 18.7 quarts.
  • Page 52 Maintenance SECTION 3 SERVICE Wheels & Tires • For machines that do not have SuperFlex filled tires, inspect DAILY for correct tire pressure (check cold). • Inflate front tires to 50 PSI • Inflate rear tires to 50 PSI INFLATE TIRES WITH CARE. AVOID POSITIONING YOUR BODY WHERE IT CAN BE INJURED BY AN EXPLODING TIRE.
  • Page 53 Lifting Procedures SECTION 3 SERVICE 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 54: Lifting Procedures

    Lifting Procedures SECTION 3 SERVICE Lifting a Buggy with a Crane 1. Make sure the bucket is completely empty. 2. Raise the bucket to a 55 degree angle with the frame as show below. 3. Attach three (3) chains or straps to the lifting cutouts in the frame as shown below. 4.
  • Page 55 Lifting Procedures SECTION 3 SERVICE Lifting a Buggy with a Forklift 1. Make sure the bucket is completely empty. 2. Lower the bucket completely against the buggy frame. 3. Lower the operator’s platform to the stand-on position. 4. Use a forklift rated to lift a minimum 2,000 LB. payload. The forks on the lift must not exceed five (5) inches in width and one and one-half (1-1/2) inches in thickness.
  • Page 56 Loading Procedures SECTION 3 SERVICE Loading a Buggy onto a Trailer 1. Make sure the bucket is completely empty. 2. Lower the bucket completely against the buggy frame. 3. Lower the operator’s platform to the down / stand-on position. 4. Use a trailer rated to haul a minimum 2,000 LB. payload at posted highway speeds. The trailer must be equipped with Federal DOT approved lighting and braking systems and tie-down loops at the front and rear to secure the buggy as shown on the following page.
  • Page 57 Tie Down Procedures SECTION 3 SERVICE Tying Down a Buggy onto a Trailer or Truck Bed FAILURE TO FOLLOW ALL OF THE FOLLOWING STEPS WHEN TYING DOWN A BUGGY MAY RESULT IN SERIOUS INJURY OR DEATH. 1. Make sure the bucket is completely empty. 2.

  • Page 58: 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 59 Popular Accessories SECTION 4 ACCESSORIES Page 59 069583...

  • Page 60: Parts Manual

    Click the link, or go to the following website https://alleneng.com/images/manuals/069583P%20-%20AW16%20and%20AW21%20-%20Parts%20 and%20Decals%20Manual.pdf 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.

  • Page 61: Revision Detail

    Revision Detail MANUAL REVISION DETAIL REVISION # REVISION DATE REVISION REFERENCE # REVISION BY 09/2019 Initial Release Page 61 069583...
  • Page 62 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 CONNECT WITH US ON...

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