allen AR16 Application guide

OPERATIONS & PARTS MANUAL
AR16 & AR21 Wheel Buggy
MANUAL PART #: 055838 | REVISION: D

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.
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OPERATIONS-PARTS MANUAL
This manual covers the products listed below:
Part No. Description
058806 BUGGY AR16 POLY BUCKET 13HPR NON FILL
058807 BUGGY AR16 POLY BUCKET 13HPE NON FILL
058808 BUGGY AR21 POLY BUCKET 20HPE NON FILL
058801 BUGGY AR16 POLY BUCKET 13HPR FOAM
058802 BUGGY AR16 POLY BUCKET 13HPE FOAM
058809 BUGGY AR16 STEEL BUCKET 13HP RECOIL
058810 BUGGY AR16 STEEL BUCKET 13HP ELEC
058803 BUGGY AR21 POLY BUCKET 20HPE FOAM
058813 BUGGY AR21 STEEL BUCKET 20HPE FOAM
Power Buggy
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Table of Contents
Sect No. Title Page
... Limited Warranty ............................................6
... Information Contained In This Manual ............................7
... Dealer Information ...........................................8
... Ordering Parts ..............................................9
... Model Number - Serial Number Codes ..........................10
... Unit Identification ...........................................11
... Technical specifications ......................................12
... Machine Dimensional Specifications ............................13
... Engine Specifications ........................................14
1.0 Safety....................................................17
... State Regulations ...........................................18
... Federal Regulations .........................................19
1.1 General Safety Precautions ...................................20
1.2 Spark Arrestor Notice........................................21
1.3 General Safety .............................................22
1.4 Operating Safety ...........................................27
1.5 Propane Operating Safety ....................................30
2.0 Operations................................................33
2.1 Introduction................................................35
2.2 Start Up Procedures.........................................36
2.3 Parking Brake..............................................40
2.4 Battery Jump Start Procedures ................................41
2.5 Operating Instructions .......................................42
3.0 Service...................................................45
3.1 Brake Service ..............................................46
3.2 Parking Brake..............................................48
3.3 Speed Control .............................................50
3.4 Pressure Settings ...........................................54
3.5 Setting Engine RPM.........................................56
3.6 Dump Lever Adjustments.....................................58
3.7 Flex Coupler Adjustments ....................................61
3.8 Maintenance...............................................62
3.9 Lifting Procedure ...........................................66
3.10 Loading Procedure ..........................................68
3.11 Tie Down Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
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Table of Contents, continued
4.0 Parts.....................................................71
... Factory Service Information ...................................72
... Replacement Part Procedure..................................73
4.1 General Arrangement........................................74
4.2 Decals....................................................76
4.3 Steering Column Assembly ...................................78
4.4 Service and Parking Brake....................................80
4.5 Hydraulic System ...........................................84
4.6 Bucket and Base Assembly ...................................90
4.7 Travel Speed Control Assembly................................92
4.8 Wheel Assemblies ..........................................94
4.9 Console Mounted Dump Lever Assembly ........................96
4.10 Handlebar Mounted Dump Lever Assembly ......................98
4.11 13 HP Honda Engine with Recoil and Electric Start - AR16 .........100
4.12 Electric Schematic - AR16 w/ 13HP Honda Engine(Recoil Start) .....101
4.13 Electric Schematic - AR16 w/ 13HP Honda Engine(Electric Start) ....102
4.14 Electric Schematic - AR21 w/ 20 HP Honda Engine(Electric Start)....104
4.15 Propane Assembly .........................................108
4.16 Filter Kits ................................................110
... Manual Revision Detail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
... Copyright Information .......................................113
055838 Page 5

Table of Contents, continued
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 fac-
tory 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 nor-
mal 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;
INCONVENIENCE; 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
LIABILITIES FOR DIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGE OR DELAY.
11. ALLEN ENGINEERING CORPORATION MAKES NO OTHER WARRANTY, EXPRESSED OR IMPLIED. THIS
LIMITED 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.
055838Page 6

This manual provides information and procedures to safely operate and maintain the Allen
Machine.
For your own safety and protection from personal injury, carefully read, understand, and observe
the safety instructions described in this manual. Keep this manual or a copy of it with the machine
at all times.
Always operate this machine in accordance with the instructions described in this manual. A well
maintained piece of equipment will provide many years of trouble free operation.
This manual is 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 should be contacted if you wish to purchase a parts manual or a repair
manual for your engine.
Refer to enclosed owners engine manual for complete O&M instructions. See your battery man-
ufacturer for battery warranty.
SECTION 1
SAFETY
SECTION 2
OPERATIONS
SECTION 3
SERVICE
SECTION 4
PARTS
Information Contained
In This Manual
055838 Page 7

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.
Dealer Name: ______________________________________________________________
Phone #: (____) - ____ - ______________________________________________________
Address: _________________________________________________________________
City: ____________________________________ State:________ Zip:_____________
Salesman: _______________________________ Mobile Phone __________________
Additional Comments: _____________________________________________________
_________________________________________________________________________
_________________________________________________________________________
_________________________________________________________________________
Dealer Information
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Section 4.0 (page 71) contains illustrated parts lists for help in ordering replacement parts for
your machine. Follow the instructions below when ordering parts to insure prompt and accurate
delivery:
1. All orders for service parts - include the serial number for the machine. Shipment
will be delayed if this information is not available.
2. Include correct description and part number from the “PARTS” section of this
manual.
3. Specify exact shipping instructions, including the preferred routing and complete
destination address.
4. DO NOT return parts to AEC without 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.
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Ordering Parts
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Manufacturer’s Codes:
When ordering parts or requesting service information, you will always be asked to specify the
model and serial numbers of the machine. The legends below specifically defines each significant
character or group of characters of the Model Number and Serial Number codes.
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.
B16 12 11 006
Production Sequence
Model Number
AR/AT 16/20
MODEL
16 - 16HP
20 - 20HP
Year Mfd
Month Mfd
Series/Model
SERIES
AR - Rubber Tire
AT - Track
Model Number - Serial Number Codes
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Model Number: ________________________
Serial Number: ________________________
Date Purchased: ______________________
Purchased From: ______________________
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 to Figure 1 for serial number and
model number location. This plate should not be removed at any time.
Please record the information found on this plate below so it will be available should the identifi-
cation plate become lost or damaged. When ordering parts or requesting service information, you
will always be asked to specify the model and serial numbers of the machine.
FILL IN FOR FUTURE REFERENCE
Figure 1
Serial Number Location
SERIAL NUMBER
MODEL SERIES
Unit Identification
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Measurements in this manual are in U.S. units and their customary metric units (i.e., metric units
contained within brackets [8 mm]).
Machine Features for AR16:
•Engine ........................................Honda GX390
•Payload .......................................2,500 lbs [1,134 kilos]
•Dimensions (L x W x H) inch [cm] ...................97x47x50
...........................................[246x119x127]
•Wheelbase .....................................40 in [102cm]
•Bucket Capacity .................................16 FT3 [0.45 M3]
•Weight ........................................Polly Bucket: 1,300 lbs [590 kilos]
...........................................Steel Bucket: 1,450 lbs [658 kilos]
•Lift Cylinder ....................................2” Diamter [51mm]
•Dump/Return Speed (Empty). . . . . . . . . . . . . . . . . . . . . . .5 Seconds
•Top Speed .....................................7 MPH [11.2 kph]
•Fuel Capacity ...................................1.7 GAL [6 Liters]
Machine Features for AR21:
•Engine ........................................Honda GX630
•Payload .......................................3,200 lbs [1,451 kilos]
•Dimensions (L x W x H) inch [cm] ...................97x47x50
...........................................[246x119x127]
•Wheelbase .....................................40 in [102cm]
•Bucket Capacity .................................21 FT3 [0.59 M3]
•Weight ........................................Polly Bucket: 1,405 lbs [637 kilos]
...........................................Steel Bucket: 1,566 lbs [710 kilos]
Technical Specifications
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•Lift Cylinder ....................................2.5” Diameter [63.5mm]
•Dump/Return Speed (Empty). . . . . . . . . . . . . . . . . . . . . . .8 Seconds
•Top Speed .....................................5.9 MPH [9.5 kph]
•Fuel Capacity ...................................2.1 GAL [8 Liters]
Machine Dimensional Specifications
50” [127cm]
50” [127cm]
97” [246cm]
Technical Specifications, continued
055838 Page 13

Honda GX390 Engine Information (13 HP)
Engine Type ............................................... Air-cooled 4-stroke OHV
Bore x Stroke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 X 64 mm
Displacement............................................... 389 cm3
Net Power Output* .......................................... 11.7 HP (8.7 kW) @ 3,600 rpm
Net Torque ................................................ 19.5 lb-ft (26.4 Nm) @ 2,500 rpm
PTO Shaft Rotation .......................................... Counterclockwise (from PTO shaft side)
Compression Ratio .......................................... 8.2:1
Lamp/Charge coil options ..................................... 25W, 50W / 1A, 3A, 10A, 18A
Carburetor ................................................. Butterfly Float Type
Ignition System ............................................. Digital CDI with variable timing
Starting System ............................................. Recoil/electric
Lubrication System .......................................... Splash
Governor System ........................................... Centrifugal Mass Type
Air cleaner ................................................. Dual element
Oil Capacity ................................................ 1.16 US qt (1.1 L)
Fuel Tank Capacity .......................................... 6.4 U.S. qts (6.1 liters)
Fuel ................................................... Unleaded 86 octane or higher
Dry Weight................................................. 69 lb (31.5 kg))
Engine Specifications
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Honda GX630 Engine Information
(20 HP)
Engine Type ............................................... Air-cooled 4-stroke OHV
Bore x Stroke. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 X 72 mm
Displacement............................................... 688 cm3
Net Power Output* .......................................... 20.8 hp (15.5 kW) @ 3,600 rpm
Net Torque ................................................ 35.6 lbs ft (48.3 Nm) @ 2,500 rpm
PTO Shaft Rotation .......................................... Counterclockwise (from PTO shaft side)
Compression Ratio .......................................... 9.3:1
Lamp/Charge coil options ..................................... 2.7A, 17A, 26A
Carburetor ................................................. Horizontal type, two barrel butterfly
valve, internal vent
Ignition System ............................................. Digital CDI with variable ignition timing
Starting System ............................................. Electric
Lubrication System .......................................... Forced lubrication
Governor System ........................................... Mechanical
Air cleaner ................................................. Dual element
Oil Capacity ................................................ 2.1 US qt (2.0l)
Fuel ................................................... Unleaded 86 octane or higher
Dry Weight................................................. 96.8 lb (44 kg)
Engine Specifications, continued
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INTENTIONALLY LEFT BLANK
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Section 1
SAFETY
055838 Page 17

State Regulation Proposition
65 Warming
SECTION 1
SAFETY
055838Page 18

Federal Regulation
Respiratory Hazard
SECTION 1
SAFETY
055838 Page 19

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.
1.1 - General Safety Precautions
SECTION 1
SAFETY
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