allen AW16-K 2019, Safety & Operation Manual

Page 1: ...SAFETY OPERATIONS MANUAL Manual Part 069583 Revision A Language English Original Instructions W H E E L B U G G I E S AW16 K AW21 K AW16 P ...

Page 2: ...l Buggy Copyright 2019 Allen Engineering Corporation All rights reserved All information specifications and illustrations in this manual are subject to change without notice and are based on the latest information at the time of publication 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 permi...

Page 3: ...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 the date of the warranty claim An Al len labor chart ...

Page 4: ...6 General Safety 17 Operating Safety 22 Propane Operating Safety 25 2 0 Operations 26 Introduction 27 Start Up Procedures 28 Parking Brake 31 Battery Jump Start Procedures 32 Operating Instructions 33 3 0 Service 35 Brake Service 36 Parking Brake 38 Speed Control 40 Pressure Settings 44 Dump Lever Adjustments 46 Flex Coupler Adjustments 49 Maintenance 50 Lifting Procedure 53 Loading Procedure 56 T...

Page 5: ...divided into the following sections 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 Your engine manufacturer...

Page 6: ...thout receiving written authorization from AEC All authorized returns must be shipped pre paid 5 When placing an order please contact the AEC dealer nearest you ALL INFORMATION SPECIFICATIONS AND ILLUSTRATIONS IN THIS MANUAL ARE SUBJECT TO CHANGE WITHOUT NOTICE AND ARE BASED ON THE LATEST INFORMATION AT THE TIME OF PUBLICATION Your Dealer has Allen Engineering Corporation trained mechanics and ori...

Page 7: ...eplacement parts Serial Number Example AW16 01 19 01 Series Sequence Number Month Year Unit Identification Plate Location An identification plate listing the model number and the serial number is attached to each unit and is located on the rear lower left side of mainframe Refer below for serial number and model number location This plate should not be removed at any time Please record the informa...

Page 8: ...ylinder 2 Diameter Dump Return Speed Empty 5 Seconds Top Speed 7 MPH Fuel Capacity 1 7 GAL Machine Features for AW21 K Engine Kohler CH640 Payload 3 200 lbs Dimensions L x W x H inch cm 97 x 47 x 50 Wheelbase 40 Bucket Capacity 21 ft3 Weight 1 405 lbs Lift Cylinder 2 5 Diameter Dump Return Speed Empty 8 Seconds Top Speed 5 9 MPH Fuel Capacity 2 1 GAL Technical Specifications 069583 Page 8 GENERAL ...

Page 9: ...Machine Dimensions 50 56 in 46 59 in 97 18 in 069583 Page 9 GENERAL INFORMATION ...

Page 10: ...RPM 3600 Dry Weight 72 8 lbs Oil Capacity 1 37 US qt Starting System Recoil Electric Fuel Type Unleaded 87 Octane or Higher Fuel Capacity 1 85 Gal Air Cleaner Dual Element Dimensions L x W x H 16 2 x 17 8 x 17 4 Lubrication Splash Back Pressure Limit 2 40 Governor Type Mechanical Carburetor side draft with manual shutoff Engine Specifications 069583 Page 10 GENERAL INFORMATION ...

Page 11: ...ed RPM 3600 Dry Weight 90 0 lbs Oil Capacity 2 0 US qt Starting System Electric Fuel Type Unleaded 87 Octane or Higher Air Cleaner Dual Element Dimensions L x W x H 14 0 x 17 7 x 19 0 Lubrication Full Pressure w Full Flow Filter Back Pressure Limit 2 50 Governor Type Mechanical Carburetor downdraft with solenoid shutoff Engine Specifications 069583 Page 11 GENERAL INFORMATION ...

Page 12: ...Reserved for Propane Engine Pending Approval Engine Specifications 069583 Page 12 GENERAL INFORMATION ...

Page 13: ...Section 1 SAFETY SECTION 1 SAFETY 069583 Page 13 ...

Page 14: ...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 15: ...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 16: ...haust It is often required when operating equipment on forested land to prevent the risk of fires Consult the engine distributor or local authorities and make sure that you comply with regulations regarding spark arrestors Potential hazards associated with the operation of this equipment will be referenced with haz ard symbols which may appear throughout this manual in conjunction with safety note...

Page 17: ...ications of the machine without the express written consent of AEC voids all machine warranties and any liability for injuries and or damage to person or property B Before putting this equipment into operation inspect the equipment DAILY Inspect this equipment on a hard and level surface with proper lighting and ventilation away from pedestrian and vehicle traffic Place Fire Protection equipment E...

Page 18: ...tem to the primary dynamic hydrostatic braking provided by the hydrostatic transmission Properly maintained and adjusted mechanical service brakes will stop a fully loaded machine traveling at full speed in the event of failure of the speed control system or loss of hydraulic pressure A properly maintained and adjusted parking brake will hold a fully loaded buggy in position Please see Machine Adj...

Page 19: ...or to each rental of this equipment C Familiarize yourself with the work site and job conditions This equipment must only be operated by trained personnel who fully understand its safe operation Each operator must be able to identify any unsafe work site conditions and report these conditions to his supervisor for immediate correction Ø The Gasoline Engine on this machine produces carbon monoxide ...

Page 20: ...erify that all haul roads load and dump areas will safely support this vehicle with maximum payload Operating this buggy on rough uneven surfaces will cause the steering wheels to jerk and make it difficult for the operator to steer All haul roads must have a suitable surface for good footing for the operator Wet muddy and or loose surfaces may cause an operator to lose his footing and fall Do not...

Page 21: ...LEVEL HARD SURFACES I E CONCRETE ASPHALT OR COMPACTED STONE OPERATING BUGGY ON ANY OTHER CONDITIONS MAY CAUSE BUGGY TO TIP REDUCE MAXIMUM NET PAYLOAD BY ONE THIRD 900 LBS ON THE AW16 K WHEN OPERATING WITH OUTSIDE WHEELS AND TIRES REMOVED DO NOT REMOVE OUTSIDE WHEELS AND TIRES ON MODEL AW21 K D During operation of this D General Safety SECTION 1 SAFETY 069583 Page 21 ...

Page 22: ...LEVEL SURFACE MAY CAUSE BUGGY TO TIP THIS MACHINE IS DESIGNED TO DUMP LOOSE FREE FLOWING MATERIALS LIKE WET CONCRETE SLAG DRY SOIL ETC DO NOT DUMP MATERIALS THAT ARE NOT FREE FLOWING I E LARGE CHUNKS OF DRIED CONCRETE CONSTRUCTION DEBRIS ETC THESE TYPES OF MATERIALS MAY CAUSE A SUDDEN LOAD SHIFT TIP THE MACHINE FORWARD AND THROW THE OPERATOR DO NOT LOAD A BUGGY WITH MATERIAL THAT EXTENDS BEYOND TH...

Page 23: ...s manual Note the proper method for loading a buggy on a trailer and the limits for loading ramp angle and trailer towing vehicle capacity Refer to this same section for specific ratings for chains straps and binders used to tie down a buggy DO NOT OPERATE THIS BUGGY IN AREAS WITH FLAMMABLE OR EXPLOSIVE ATMOSPHERES REFER TO CODE OF FEDERAL REGULATIONS OSHA 29 CFR PART 1910 178 TO DETERMINE PERMISS...

Page 24: ...mmonia free leak detector solution not matches 7 Make certain your container is properly fastened in place 8 Turn container with open part of container guard towards trailer travel trailer installation This protects valves and regulator against flying rocks and mud Transport container in the proper position in which it is used with the valves closed and POL plugs inserted for POL valves or dust ca...

Page 25: ... con tacts the liquid level at 80 of container capacity allowing 20 for expansion LP gas containers not equipped with a fixed liquid level gauge can only be filled by weight LP gas containers must not be filled over 80 of total capacity Propane expands approximately 1 5 for each 10 F temperature rise Pumps do not stop filling automatically Pumps by pass when containers are dangerously filled to to...

Page 26: ...Section 2 OPERATIONS SECTION 2 OPERATIONS 069583 Page 26 ...

Page 27: ...aral leled strength and durability along with a lower center of gravity and ideal weight distribution These buggies give excellent traction in real world job site conditions Drive components are protected by a removable steel shroud This shroud is louvered to keep concrete out while providing proper ventilation and cooling to the engine compart ment The standard high strength high density polyethy...

Page 28: ...Start up Procedures SECTION 2 OPERATIONS 069583 Page 28 ...

Page 29: ... ground between the handlebars or standing on the oper ator s platform ØSet parking brake refer to page 40 for instructions on setting the parking brake ØPlace directional control lever on dash in NEUTRAL position ØMove choke lever to closed position When engine is cold ØSet throttle control to one third open position To increase engine speed move throttle from right to left as you face the recoil...

Page 30: ...tart the engine using the recoil starter switch engine ignition switch to ON position and pull recoil starter until engine starts After the engine starts return starter rope handle slowly against the flywheel cover of the engine ØAfter engine starts move choke lever slowly to the OPEN position Let engine warm up at full throttle and run smoothly for approximately 5 minutes before applying load Fai...

Page 31: ...ke pedal 1 Remove right hand from parking lock knob The parking brake is now set To release 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 When the pedal is depressed fully the parking brake detent rod will disengage and the parking lock knob 2 will return to its up position 3 Remove right foot from br...

Page 32: ... negative battery terminals ØUse only jumper cables in good condition with tight connections secure insulation and a 100 AMP 5 gauge minimum rating ØMake cable connections as follows a Attach one 1 end of POSITIVE jumper cable to the POSITIVE post of Kohler electric starter motor solenoid Refer to engine manual for location of these items b Attach the other end of the POSITIVE jumper cable to the ...

Page 33: ...ed to control buggy speed Letting the Speed Control Lever return to the neutral position will slow the buggy by means of dynamic hydraulic braking and increase power at the drive wheels acting as a downshift ØTo slow and or stop vehicle Release Speed Control Lever Service brake pedal located at right of stand on platform may be pushed down to acti vate service brake and assist in slowing the vehic...

Page 34: ...to the OFF position or push or activate Engine Stop Switch on dash 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 K and AW21 K are steered using the Handlebars in front of the operator s platform Turning the Handlebars Clockwise will cause the Buggy to turn to the Left when traveling...

Page 35: ...Section 3 SERVICE 069583 Page 35 ...

Page 36: ... engage at the same time by running buggy applying brake and having an observer verify both brakes lock up together 2 If after making adjustment in 1 above the pedal is still below operator s platform when the service brake is engaged short en the distance of the 2 clevis item 34 Reattach clevis pins with NEW 1 8 x 3 4 long cotter pins 2 One brake engages before other brake Tighten brake band on b...

Page 37: ... or buggy travels more than 8 during brake inspection 1 Tighten brake bands 2 Clean concrete dirt oil accumula tion away from brake bands 3 Hydrostatic pump is worn Engine fails to stall 4 Replace worn brake bands s Brass rivets are contacting brake drum and or brake lining worn less than 1 8 thick See Adjustment Repair Procedure Rec ommended for Brake Operational Prob lem items 1 and 3 above See ...

Page 38: ...ighten clevis 34 1 turn clockwise ØReplace clevis pin 35 and test parking brake ØIf required continue to tighten clevis by turning clockwise until proper parking brake adjustment is made ØReplace cotter pin 31 with a NEW 1 8 X 3 4 Long Plated Cotter Pin ØTighten hex nut 37 ØApply approved lube to all brake pivot points See Maintenance Section BLOCK WHEELS TO PREVENT INJURY www facebook com AllenEn...

Page 39: ...S B B DETAIL B B 37 47 44 47 44 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 Parking Brake Schematic SECTION 3 SERVICE 069583 Page 39 ...

Page 40: ...e neutral stop bolt The bar must rotate freely in both directions If the transmission shift bar does not rotate freely return the hydrostatic transmission to an Eaton authorized repair facility or to AEC for service H Inspect the shift cable item 9 Move the shift lever item 25 with the cable attached through the full range of travel The lever must move freely with no binding or catching The shift ...

Page 41: ...he speed control lever is 3 below the bottom edge of the handlebar grip when the transmission shift bar is against the neutral stop bolt I Inspect the return spring item 26 The return spring must have no physical damage i e broken loops sprung coils etc Verify the spring overall length and outside diameter see page 24 Replace the spring if damaged and or if not the correct size If the return sprin...

Page 42: ...the parking brake engaged E Shift the directional control lever on the dash to the Forward position F Turn the neutral stop bolt item 17 clockwise until the buggy just begins to creep in the Reverse direction The engine will begin to slow lug down slightly when creep begins to occur G Then slowly turn the neutral stop bolt counter clockwise until the creep just stops Tighten hex nut to secure posi...

Page 43: ... IN LBS 20 EYE BOLT POSITION THE EYE OF THE BOLT TO LINE UP WITH SPRING LOOP ENDS AS SHOWN 14 LOCKNUT TORQUE TO 22 FT LBS 15 16 9 SHIFT CABLE 5 8 NF 18 BULKHEAD NUT 1 4 NF 28 CLEVIS JAM NUT 2 PLACES 10 CLEVIS TRANSMISSION SHIFT BAR 13 12 11 CLEVIS PIN PLATED COTTER PIN INSTALL CORD GRIP IN 840 DIAMETER HOLE IN THE TOP OF CONSOLE 42100 38 TO THE LEFT OF REAR STEERING ASSEMBLY REF HANDLEBAR 42126 01...

Page 44: ...isconnect hose item 5 from elbow in Port A 5 Connect pressure gauge with hose to elbow in Port A Note male thread on elbow is 7 8 14 37º JIC 6 Start engine run engine at full speed 7 Push dump lever forward dump bucket until dump cylinder fully extends and check pressure 8 Turn relief adjustment screw item 2 clockwise to increase pressure counterclockwise to decrease pressure 9 Replace hex cap dis...

Page 45: ...adjustment procedures 6 Start engine increase throttle to full speed on 13HP engines move throttle fully to the left on 20HP engines turn throttle lever clockwise and shift directional control valve to the Forward direction 7 Squeeze speed control lever item 5 until maximum pressure is registered on the gauge without stalling engine 8 Adjust relief pressure to 2000 PSI Turn pressure adjusting scre...

Page 46: ...e to raise pedal Replace clevis pin 5 and cotter pin 6 Tighten hex jam nut 7 2 Drag on valve lever 1 Pivot This lever should return easily to neutral position To change drag loos en hex locknut on bolt assembly 3 Tighten hex nut to increase drag Loosen hex nut to decrease drag Tighten locknut to 25 ft lbs Spray with lube after adjustment 3 Drag on dump pedal pivot 9 t same as adjustment 2 above ex...

Page 47: ... item 22 Move the handle mounted bucket dump control lever item 18 with the cable item 22 attached through the full travel range The lever must move freely with no binding or catching The control cable must have no physical damage i e cuts in outer cable covering missing and or torn end boots two 2 places etc Replace the control cable if it is damaged and or does not work freely Replace the contro...

Page 48: ...its position must be secured by tightening the jam nut item 24 against the clevis L Then attach the cable end clevises to the handle mounted dump control lever items 14 and 18 and the dump valve connecting link bar item 13 using the Clevis Pins Secure the clevis pins in the clevises with NEW 3 32 093 diameter x 3 4 long plated cotter pins Do not reuse cotter pins M Tighten the two 2 5 8 NF 18 jam ...

Page 49: ...Tighten transmission mounting bolts C Using a straight edge make the horizontal adjustment to the coupling assembly by moving the engine left or right on the engine mounting plate Tighten engine bolts D When alignment is correct and the engine and transmission mount bolts are secured recheck alignment with a straight edge E When alignment is correct both coupling halves and the flexible coupling e...

Page 50: ...e covers 2 linkage 3 Operator s platform 4 Hydraulic reservoir cover keep all louvers clean 5 Parking brake and linkage 6 Dump lever controls including foot control linkage and console mounted lever or handlebar mounted lever on machines so equipped 7 Bucket 8 Handlebar and speed control lever 9 Directional control lever 10 Hydraulic lift cylinder 11 Crawler tracks on machines so equipped NOTE Do ...

Page 51: ...reservoir by disconnecting hose item 28 from elbow fitting item 45 Inspect all hydraulic hoses fittings daily Repair or replace as required Chassis Lubrication Lubricate all machine points per the following schedule Brake Inspect both service brake and parking brake lock DAILY Parking brake must hold a loaded buggy on 15 grade 8 5 degrees Service brake must lock both drive wheels of a loaded buggy...

Page 52: ...cable travel should be smooth and easy Approximately 15 lbs of pressure should be required to depress the speed control lever at the handlebar Cable should be free of cuts kinks binds and sharp bends Rubber seals to prevent entry of contamination should be intact at both cable ends Due to the critical nature of this part replacement is recommended every 24 months or sooner in extreme conditions In...

Page 53: ...etail 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 Removal from service Synthetic web slings shall be immediately removed from service if any of the following conditions are present OSHA 1926 251 e 8 SECTION 3 SERVICE 069583 Page 53 ...

Page 54: ...e the slack out of the chains or straps and adjust them so the buggy is level when lifted CRANE HAVING MAXIMUM LIFT CA PACITY OF 2 000 LIFT REAR OF BUGGY USING 2 CUTOUTS AT REAR CORNER OF ENGINE COVER LIFT FRONT OF BUGGY BY RAISING B ED TO 55 DEGREE ANGLE AND ATTA CHING CHAIN OR STRAP TO LUG IN S TEEL BASE SUPPORTING BUCKET EMPTY BUCKET AND RAISE TO THE FULL UP POSITION 55 ANGLE AND ATTACHING CHAI...

Page 55: ... rubber tired models excluding track models built after December 2003 have addi tional lifting pockets on the buggy frame to permit lifting the buggy from the REAR Follow the pro cedure outlined above with the following changes 1 Raise the operator s platform to the upright walk behind position 2 Insert the forks into the two 2 lifting pockets at the rear of the buggy Continue to insert the forks ...

Page 56: ... losing traction and spinning 7 Slowly drive the buggy onto the trailer in the forward direction as shown below 8 Position the buggy on the trailer so that the recommended tongue load for the trailer and towing vehicle is achieved Engage and lock the buggy parking brake shut off the engine turn off fuel supply at the carburetor 14 HP Kohler only and step away from the operator s platform MAXIMUM R...

Page 57: ...arburetor 14 HP Kohler engine only 7 Attach two 2 chains or straps through the ring in the front of the buggy frame and through the two 2 rings mounted at the front of the trailer or truck bed 8 Attach one 1 chain or strap through each of the d rings at the rear of the buggy frame and through the corre sponding rings mounted at the rear of the trailer or truck bed 9 All chains straps must pull awa...

Page 58: ...lude electronic displays lights switches wiring etc The electronic components may be damaged if water is sprayed on them 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 c...

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

Page 60: ...ith a compatible device cellular phone tablet etc Computer 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 P...

Page 61: ...Revision Detail 069583 Page 61 MANUAL REVISION DETAIL REVISION REVISION DATE REVISION REFERENCE REVISION BY 09 2019 Initial Release MW A 01 22 Updated Covers MK ...

Page 62: ...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 ...