allen AR16 Application guide

Power Buggy
055838; 03/12
AR16 and AR21
OPERATIONS-PARTS
OPERATIONS-PARTS
MANUAL
MANUAL

055838; 03/12
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.

i
055838; 03/12
Power Buggy
OPERATIONS-PARTS MANUAL
Copyright © 2016 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 permission of Allen
Engineering Corporation (AEC). AEC assumes no responsibility or liability for any errors or inaccuracies that may
appear in this manual.
Allen Products are covered under one or more of the following patent numbers:
U.S. Design Patents: 344,736; 400,542; 400,544; 402,998; 402,999; 403,332; 404,041; 404,042; 410,931;
413,127; 416,564; 465,897; 466,909; 474,203.
U.S. Utility Patents: 5,108,220; 5,238,323; 5,328,295; 5,352,063; 5,405,216; 5,476,342; 5,480,257; 5,480,258;
5,533,831; 5,562,361; 5,567,075; 5,613,801; 5,658,089; 5,685,667; 5,803,658; 5,816,739; 5,816,740; 5,890,833;
5,934,823; 5,967,696; 5,988,938; 5,988,939; 6,019,433; 6,019,545; 6,048,130; 6,053,660; 6,089,786; 6,106,193;
6,857,815; 5,288,166; 6,582,153 B1, 7,108,449; 7,114,876; 7,316,523; 7,690,864 B2
Canadian Patents: 2,039,893.
First Issue: March 2012
Amended: February 2016
AEC Manual Part No.: 055838
Printed in U.S.A.
This manual covers the products listed below:
Part No.
058806
058807
058808
058801
058802
058809
058810
058803
058813
Description
BUGGY AR16 POLY BUCKET 13HPR NON FILL
BUGGY AR16 POLY BUCKET 13HPE NON FILL
BUGGY AR21 POLY BUCKET 20HPE NON FILL
BUGGY AR16 POLY BUCKET 13HPR FOAM
BUGGY AR16 POLY BUCKET 13HPE FOAM
BUGGY AR16 STEEL BUCKET 13HP RECOIL
BUGGY AR16 STEEL BUCKET 13HP ELEC
BUGGY AR21 POLY BUCKET 20HPE FOAM
BUGGY AR21 STEEL BUCKET 20HPE FOAM
064880 BUGGY AR16 POLY BUCKET PROPANE

ii 055838; 03/12
Limited Warranty
Allen Engineering Corporation (“Allen”) warrants its products to be free of defects in material or workmanship for:
TWO YEARS FROM END USER’S DATE OF PURCHASE
Warranty period begins on the date of purchase by the End User of the product. All warranty is based on the following
limited warranty terms and conditions, including the disclaimer of implied warranties and consequential damages.
1. Allen’s obligation and liability under this warranty is limited to repairing or replacing parts if, after Allen’s inspection,
there is determined to be a defect in material or workmanship. 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.
3. Replacement or repair parts, installed in the product, are warranted only for the remainder of warranty period of the
product as though they were the original parts.
4. Allen does not warranty engines or batteries. Engine warranty claims should be made directly to an authorized factory
service center for the particular engine manufacturer. Batteries are not warranted due to unknown treatment during
transport, etc, and any battery claims should be directed to the battery manufacturer.
5. Allen’s warranty does not cover the normal maintenance of products or its components (such as engine tuneups and
oil & filter changes). The warranty also does not cover normal wear and tear items (such as belts and consumables).
6. Allen’s warranty will be void if it is determined that the defect resulted from operator abuse, failure to perform normal
maintenance on the product, modification to product, alterations or repairs made to 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 Allen labor chart will determine the time allowed to complete a repair and will govern the shop labor hours that
will be allowed.
9. Allen will pay freight on warranty replacement parts at worldwide standard ground rates. No warranty replacement
parts will be shipped air freight at the expense of Allen. Allen only pays outbound freight charges when sending warranty
replacement parts to the customer via ground service. Allen does not pay any inbound freight. However, if Allen deter-
mines this to be a warranted item, only then will Allen reimburse the customer for inbound freight at standard ground
rates.
10. ALLEN ENGINEERING CORPORATION’S WARRANTY POLICY WILL NOT COVER THE FOLLOWING: TAXES;
SHOP SUPPLIES; ENVIRONMENTAL SURCHARGES; AIR FREIGHT; TRAVEL TIME; LOSS OF TIME; INCONVEN-
IENCE; LOSS OF RENTAL REVENUE; RENTAL COSTS OF EQUIPMENT USED TO REPLACE THE PRODUCT
BEING REPAIRED;
LOSS OF USE OF THE PRODUCT; COMMERCIAL LOSS; OR ANY OTHER CHARGES WHATSOEVER OR ANY LIA-
BILITIES FOR DIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGE OR DELAY.
11. ALLEN ENGINEERING CORPORATION MAKES NO OTHER WARRANTY, EXPRESSED OR IMPLIED. THIS LIM-
ITED WARRANTY IS IN LIEU OF THE WARRANTY OF MERCHANTABILITY AND FITNESS. THERE ARE NO OTHER
WARRANTIES THAT EXTEND BEYOND THE DESCRIPTION ON THIS DOCUMENT.
12. No Allen employee or representative is authorized to change this warranty in any way or grant any other warranty
unless such change is made in writing and signed by an officer of Allen Engineering Corporation.

1-1
055838; 03/12
SECTION 1
SAFETY
Section 1
SAFETY

1-2
SECTION 1
SAFETY
055838; 03/12
CALIFORNIA PROPOSITION 65
WARNING
Gasoline engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth defects and
other reproductive harm.
State Regulations

1-3
055838; 03/12
SECTION 1
SAFETY
Federal Regulations
SILICOSIS WARNING
Grinding/cutting/drilling of masonry, concrete, metal and other
materials with silica in their composition may give off dust or
mists containing crystalline silica. Silica is a basic component
of sand, quartz, brick clay, granite and numerous other miner-
als and rocks. Repeated and/or substantial inhalation of air-
borne crystalline silica can cause serious or fatal respiratory
diseases, including silicosis. In addition, California and some
other authorities have listed respirable crystalline silica as a
substance known to cause cancer. When cutting such materi-
als, always follow the respiratory precautions mentioned
above.
RESPIRATORY HAZARDS
Grinding/cutting/drilling of masonry, concrete, metal and other
materials can generate dust, mists and fumes containing
chemicals known to cause serious or fatal injury or illness,
such as respiratory disease, cancer, birth defects or other
reproductive harm. If you are unfamiliar with the risks associ-
ated with the particular process and/or material being cut or
the composition of the tool being used, review the material
safety data sheet and/or consult your employer, the material
manufacturer/supplier, governmental agencies such as OSHA
and NIOSH and other sources on hazardous materials.
California and some other authorities, for instance, have pub-
lished lists of substances known to cause cancer, reproduc-
tive toxicity, or other harmful effects.
Control dust, mist and fumes at the source where possible. In
this regard use good work practices and follow the recom-
mendations of the manufacturers or suppliers, OSHA/NIOSH,
and occupational and trade associations. Water should be
used for dust suppression when wet cutting is feasible. When
the hazards from inhalation of dust, mists and fumes cannot
be eliminated, the operator and any bystanders should
always wear a respirator approved by NIOSH/MSHA for the
materials being used.

1-4
SECTION 1
SAFETY
055838; 03/12
1.1
General Safety Precautions
1.1.1 Safety-Alert Signs
This manual contains Safety-Alert Signs, as defined below, which must be followed to
reduce the possibility of improper service 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. which is essential to
highlight that 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.
Potentially hazardous situations that could result in death
or serious injury are indicated by the word WARNING.
DANGER indicates an imminently hazardous situation which,
if not avoided, will result in death or serious injury.

1-5
055838; 03/12
SECTION 1
SAFETY
1.2
Spark Arrestor Notice
1.2.1 Laws Pertaining to Spark Arrestors
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. Consult the engine distributor
or local authorities and make sure that you comply with regulations regarding spark
arrestors.

1-6
SECTION 1
SAFETY
055838; 03/12
A) General Safety
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 instruc-
tions contained in both this manual and the engine manual and familiarize yourself with the loca-
tion and proper use of all controls. These safety and operating instructions for power buggies are
for your protection. Careless disregard of these instructions and other construction practices
could result in accidents and injury.
This machine is equipped with instructional and safety labels. Should any of
these labels become destroyed, faded, or otherwise illegible, replace them at
once. These labels can be purchased from an 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 customerser-
[email protected].
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 supplied machine in the operation, repair, and/or modifications 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/Extinguishers in Inspection Area.
1. Shut engine off. Remove Ignition Key if so equipped.
2. Disconnect spark plug wire(s) to prevent accidental starts.
3. Block wheels in both directions to prevent machine movement.
4. Perform a detailed inspection of the following systems:
a) Speed Control Cable. This cable connects the speed control lever to the
hydrostatic transmission. With all linkage fully assembled cable travel should be
smooth and easy. Approximately 15 lbs. of pressure should be required to depress the
speed control lever at the handlebar. Lever should snap back briskly when it is
released. 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 for severe
service.
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.
Broken, damaged, or deformed springs must be replaced immediately. Note: never
1.3
General Safety

1-7
055838; 03/12
SECTION 1
SAFETY
1.3, continued
General Safety
bend, otherwise modify, or attempt to repair this spring. ALWAYS REPLACE. Due to the
critical nature of this part, replacement is recommended every 24 months or sooner for
severe service.
In all cases, upon release of the speed control lever, the
speed control linkage should operate smoothly and freely
and stop machine travel within 6 - 8' in both forward and reverse. If the speed
control linkage does not operate smoothly and freely and/or does not automati-
cally stop machine travel upon release of the speed control lever, then remove
machine from service until repairs have been made.
c) The mechanical service and parking brake. The mechanical service brake is
designed to act as a reserve system to the primary dynamic hydrostatic braking pro
vided 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 main
tained and adjusted parking brake will hold a fully loaded buggy in position. Please
see "Machine Adjustments" in this manual for adjustment procedures.
d) Verify that all safety and instruction labels are intact and legible.
5. Inspect lug nuts for proper torque (see Safety and Operation Requirement Chart)
6. Inspect tires, wheels and tire pressure (see Safety and Operation Requirement Chart),
and tracks on machines so equipped.
7. Inspect the following controls for proper adjustment, cleanliness and operation: bed
dump valve and dumping mechanism, directional control valve, dash mounted EMER-
GENCY stop switch, and steering assembly. Immediately remove from service any
machine on which these controls are not adjusted and operating properly.
8. Inspect: engine oil level, hydraulic oil level. Add Fluids as required. Repair all leaks.
Follow all maintenance as outlined in the SERVICE section of this manual.

1-8
SECTION 1
SAFETY
055838; 03/12
1.3, continued
General Safety
9. Before adding fuel
• Extinguish smoking materials.
• Shut engine off.
• Shut off Fuel. On AR16 turn Fuel Valve at the carburetor to the OFF position.
Note: Fuel shut off on AR21 occurs when the ignition key is turned OFF.
• Let engine cool for a minimum of 5 minutes.
• Inspect Buggy for Fuel leaks. Repair any fuel leak(s) BEFORE refueling.
• Do not stand on Buggy Operator Platform while refueling.
• Add Fuel using only non-metal, UL approved portable fuel containers. If using
a funnel it must be plastic without a screen or filter.
• Do not overfill.
• Replace fuel cap after adding fuel.
• A hot engine can ignite spilled gasoline.
EXERCISE EXTREME CAUTION WHEN REFUELING.
10. Make any necessary repairs or adjustments before putting this equipment into
operation. All guards must be replaced. Refer to the SERVICE and section of this manual.
11. The above inspection procedures must also be performed by rental store personnel
prior 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 opera-
tion. Each operator must be able to identify any unsafe worksite conditions and report these con-
ditions to his supervisor for immediate correction.
ØThe Gasoline Engine on this machine produces carbon monoxide (CO) and hydrocarbon (HC)
emissions through its exhaust. Inhalation of this exhaust gas can cause serious injury or death.
ØEngine exhaust and some of its constituents are also known to cause cancer, birth defects,
and other reproductive harm.
ØThe monitoring of carbon monoxide on the jobsite by a qualified inspector following OSHA
guidelines is mandatory in order to determine the safety of jobsite ventilation. In Canada follow
Provincial Ministry of Labor OHSA guidelines.
ØDo not use this machine without safe jobsite ventilation.

1-9
055838; 03/12
SECTION 1
SAFETY
1.3, continued
General Safety
ØDo not operate this machine on an elevator. Using this machine on an elevator will cause
unsafe jobsite ventilation.
ØThe engine on this machine may be equipped with an exhaust purifier that may reduce, but
will not eliminate these dangerous emissions.
ØThe efficiency of this purifier decreases if the engine is not properly tuned, especially if the fuel
mixture is too rich. Do not modify the stock Honda fuel/air ratio. If this machine is to be operated
regularly at altitudes higher than 6,000 feet above sea level, see the engine manual for additional
information. Excessive exhaust temperatures above 1200F (649C) will damage the purifier.
ØThe exhaust purifier is extremely hot. Do not touch. Keep all flammable material at least 10
feet away. Avoid fuel spills. Allow engine to cool at least 20 minutes before refueling.
ØDo not operate this equipment on unsafe haul roads, load areas or dump areas. This
equipment is intended for use only on well lit, leveled and compacted surfaces. AVOID ALL
CONDITIONS OF SLOPE AND/OR GRADE, WHICH MAY CAUSE THIS EQUIPMENT TO TIP.
Never operate this equipment on any grade or slopes greater than 15% (8 degrees), less if site
conditions so warrant. Verify that all haul roads, load and dump areas will safely support this vehi-
cle with maximum payload. Operating this buggy on rough, uneven surfaces will cause the steer-
ing 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 oper-
ator to lose his footing and fall. Do not operate this equipment in poorly lit areas. Provide arti-
ficial lighting as required for safe operation.
ØDo not operate this machine under the influence of drugs and/or alcohol.
ØIdentify all unprotected openings on jobsite and do not operate this equipment near these open-
ings.
ØIdentify all overhead structures, electrical wires, and door openings on the jobsite. Be sure this
equipment and operator will safely pass through and under.
ØIdentify the load requirements for the jobsite. Do not exceed the load limits in weight or height
as shown on safety and operation requirements chart. Under all operating conditions, the
operator is solely responsible for a safe and secure load. If jobsite conditions so warrant,
reduce load and speed.
ØOnly operate this machine in daylight or OSHA conforming artificial light.

1-10
SECTION 1
SAFETY
055838; 03/12
1.3, continued
General Safety
NOTE: ON THE AR16 ONLY THE OUTSIDE WHEELS AND TIRES CAN BE REMOVED TO
REDUCE OVERALL WIDTH. WHEN OUTSIDE WHEELS AND TIRES HAVE BEEN REMOVED
OPERATE THE AR16 ONLY ON 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
AR16 WHEN OPERATING WITH OUTSIDE WHEELS AND TIRES REMOVED. DO NOT
REMOVE OUTSIDE WHEELS AND TIRES ON MODEL AR21.D. During operation of this D.
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1-11
055838; 03/12
SECTION 1
SAFETY
1.4
Operating Safety
D) During operation of this equipment:
ØUse caution when operating near other personnel and obstructions. Always look to the rear
before backing up and back up slowly. Be aware of other jobsite traffic.
DO NOT OPERATE THIS MACHINE WITH YOUR BACK FACING THE CON-
TROLS. ALWAYS ORIENT YOURSELF SO YOU ARE STANDING AND FAC-
ING IN THE DIRECTION OF THE CONTROLS.
ØIf the operator chooses to ride behind the buggy during operation, the operator’s platform must
be lifted, pulled back & lowered down to the horizontal position before using the buggy. The only
place for the operator to stand on the buggy while operating the machine is on the opera-
tor’s platform FACING THE CONTROLS. Keep operator’s platform clean.
ØBe sure dump body is securely down at all times when not actually dumping. Keep clear of
bucket when dumping and returning bucket to transport position.
DO NOT DUMP BED WHILE DRIVING EQUIPMENT. DUMP BUCKET ONLY
WHEN BUGGY IS ON A LEVEL SURFACE. FAILURE TO DUMP ON OTHER
THAN A 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 THE VERTICAL EDGES OF THE BUCKET OR PLATFORM.
ØThis vehicle is not intended for the transportation of any personnel other than the operator. NO
RIDERS!
ØDo not use excessive speed or operate recklessly. Careless operation causes accidents and
injury. SLOW DOWN when operating conditions so warrant i.e., approaching other personnel, wet
areas, and traveling up and down otherwise safe grade conditions. Always allow extra stopping
time when using a buggy on wet and/or loosely graded materials. The operator is solely respon-
sible for choosing a suitable machine travel speed for the existing jobsite conditions.
ALWAYS TRAVEL DOWN GRADES IN REVERSE WITH A LOADED
MACHINE. WHEN ON A GRADE NEVER TURN AND ALWAYS TRAVEL IN A
STRAIGHT LINE.

1-12
SECTION 1
SAFETY
055838; 03/12
1.4, continued
Operating Safety
ØIf 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.
c) Shut off engine by turning engine ignition switch off or depressing
EMERGENCY stop button on dash. Note: Some older Honda Engines required the
“Emergency Stop Switch” to be “Pushed Down and Held” to stopthe engine. Identify
which type of Honda Engine you have and the “Emergency Stop” switch operation
required to stop the engine.
ØWear appropriate clothing/safety equipment for the construction jobsite including but not limited
to safety glasses, clean gloves, safety toed work boots, hard hat, etc. Do not operate this equip-
ment with oily gloves or controls.
ØThis equipment is not intended to tow other items or equipment. NO TOWING.
ØKeep yourself and others away from pinch points on dumping mechanism.
ØRefer to LIFTING/LOADING/TIE-DOWN INSTRUCTIONS section of this manual. Note the two
(2) ways a buggy may be lifted and the appropriate lifting points for each method. Note the spe-
cific load ratings for chains, straps, forklifts. and cranes.
ØAvoid all operating conditions where any personnel, including the operator, could become
trapped or pinched between the buggy and another obstacle or where a lifted buggy may fall dur-
ing loading.
Refer to the Lifting/Loading/Tie Down Instructions in this manual. Note the proper method for
loading a buggy on a trailer and the limits for loading ramp angle and trailer towing vehicle capac-
ity. 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 ATMOS-
PHERES. REFER TO CODE OF FEDERAL REGUALTIONS OSHA 29 CFR PART 1910.178 TO
DETERMINE PERMISSIBLE AREAS WHERE THESE BUGGIES MAY BE OPERATED.
Ø Do not mount/dismount a moving buggy.
ØIf operator chooses to walk behind the buggy during operation, the operator’s platform must
be lifted, pulled back & locked in the UP position before using the buggy. Reduce travel speed to
a MAXIMUM of 3mph(comfortable walking speed) when using buggy in walk behind fashion.

1-13
055838; 03/12
SECTION 1
SAFETY
1.4, continued
Operating Safety
THIS BUGGY MUST BE CLEANED DAILY TO PREVENT CONCRETE AND DIRT BUILD-UP
FROM ADVERSELY AFFECTING SAFE MACHINE OPERATION. WASH BUGGY DOWN EACH
DAY WITH WATER.
ØAlways clean the Buggy in an area removed from pedestrian and other machine traffic. Avoid
areas where muddy surfaces can cause a Safety Hazard. Wear proper protective clothing, includ-
ing but not limited to safety glasses/face shield, rubber gloves and boots, etc. If using a pressure
washer, do not point the high pressure nozzle at any persons or part of the body.
ØInspect all machine Controls for proper function after cleaning. Refer to the Service Section for
proper lubrication if required.

1-14
SECTION 1
SAFETY
055838; 03/12
1.5
Propane Operating Safety
1. Never allow your LP-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. Do not use a wrench or pliers to close the service valve or fixed liquid level gauge. These
valves are designed to be closed leak-tight by hand or screw-driver as appropriate. If wrenches
are necessary to stop a leak, the valve needs repair or replacement.
3. When tightening the POL Nut (left hand thread) on the service valve, draw it up snug with a
proper wrench. This is a machined male brass fitting which seats securely against a female seat
in the POL valve - no pipe dope is necessary.
4. Acme/Type 1 valves have right handed threads which are secure when hand tight, and on the
Quick Disconnect/Type 2 Valves, the male connection is inserted into the female connection on
the cylinder valve. (No wrenches required for the Acme or the Quick Disconnect.)
5. When using container, slowly open service valve all the way. Listen to the regulator. A contin-
uous hiss or “clicking” sound may indicate a leak or an open valve on an appliance.
6. Check all tanks and the line connections periodically to be sure they are tight. When testing for
leaks, use an approved ammonia-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
pro-tects 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
caps for ACME valves. Secure the tank against falling or rolling.
9. Check for leaks after connecting. Apply approved leak detector solution to connection, turn off
all burners and pilots, and open service valve. Leaks will be detected by the growth of the bub-
bles. If bubbles grow, tighten or repair the connection as needed. Repeat leak test until problem
is corrected.
10. LP-gas is normally non-corrosive; you need not worry about the inside of your container.
However, the outside should be kept free from rust by a periodic coat of paint in a light reflective
color. It is very important to inspect and maintain the bottom and foot ring on the container.
11. Do not store LP-gas containers indoors or in en-closed areas. Do not expose LP-gas con-
tainer to heat. Always store with service valve closed and plugged or capped as required.
12. Do not attempt to repair any containers, container valves, regulator or appliances by yourself.
Use only trained certified LP-gas service personnel to perform repairs.

1-15
055838; 03/12
SECTION 1
SAFETY
1.5, continued
Propane Operating 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. Do not transport, install or
use a vertical cylinder in a horizontal or upside down position. Proper care must be taken to posi-
tion a horizontal container in the correct position for vapor withdrawal. Liquid LP-gas could enter
the system designed for vapor only, possibly creating a hazardous condition.
Always close the valve and install a POL plug on a POL valve or a dust cap on an ACME/Type 1
valve when transporting or storing disconnected containers (full or empty).
All LP-gas containers must be securely oriented in the proper position for intended use.
FILLING YOUR LP-GAS CONTAINER
Only qualified persons should fill your LP-Gas containers.
CAUTION: OVERFILLING IS HAZARDOUS!
Do not allow your LP-gas container to be overfilled. Stop filling when liquid appears at the fixed
level gauge. Bleed off excess propane in a safe area. Most LP-gas containers are equipped with
a fixed liquid level gauge which contacts 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 total capacity. If overfilled, excessive pressure could
develop within the container causing the relief valve to open and release flammable gas.
The fixed liquid level gauge is used only to determine safe fill levels and does not indicate lower
levels. LP-gas containers are available with visible gauges that monitor the amount of gas in the
container at all times, reading from full to empty. Do not use visible gauges for filling.
PURGING OF AIR FROM LP-GAS CONTAINERS
Air in LP-gas containers is a contaminant. Purging is done prior to initial filling to remove the air.
If the container is not properly purged, air in the container dilutes the LP-gas vapor. Failure to
purge may cause excessive tank pressure, slow filling and poor appliance operation. Appliances
then require constant adjustment and pilot lights won't stay lit. This condition would exist until all
air is depleted, leaving pure LP-gas vapor. Have your LP-gas container properly purged.

1-16
SECTION 1
SAFETY
055838; 03/12
NOTES