allen AW16 Guide

SAFETY & OPERATIONS MANUAL
AW16 & AW21 Wheel Buggy
MANUAL PART #: 069583 | REVISION: -
LANGUAGE: ENGLISH | ORIGINAL INSTRUCTIONS

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.
SAFETY & OPERATOR MANUAL
This manual covers the products listed below:
Part No. Description
070080 Buggy, Recoil, 14 HP Kohler, 16ft3Polyethylene Bucket
070081 Buggy, Electric, 14 HP Kohler, 16ft3Polyethylene Bucket
070082 Buggy, Propane, 14 HP Kohler, 16ft3Polyethylene Bucket
070083 Buggy, Electric, 20.5 HP Kohler, 21ft3Polyethylene Bucket
PoWer Wheel 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 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:
10,384,704
With other Patents Pending.
Printed in U.S.A.
069583Page 2

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 ser-
vice 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 &
lter 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 main-
tenance on the product, modication to product, alterations or repairs made to the product without the written approval of
Allen. Allen specically 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 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 determines 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; EN-
VIRONMENTAL 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; COM-
MERCIAL 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 ofcer of Allen Engineering Corporation.
Limited Warranty & Limitation of
Liability
069583 Page 3
GENERAL
INFORMATION

Sect No. Title Page
Limited Warranty...................................................... 3
Information Contained In This Manual ...................................... 5
Dealer Information / Ordering Parts ........................................ 6
Model / Serial Number - Unit Identification .................................. 7
Technical specifications ................................................ 8
Machine Dimensional Specifications ....................................... 9
Engine Specifications ................................................. 10
1.0 Safety............................................................. 13
State / Federal Regulations ............................................. 14
Manual Tag Safety Detail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Spark Arrestor Notice / Safety Symbols.................................... 16
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
Tie Down Procedure .................................................. 57
Cleaning Procedure ................................................... 58
4.0 Accessories ........................................................ 59
Parts Manual........................................................ 60
Manual Revision Detail ................................................ 61
Table of Contents
069583Page 4
GENERAL
INFORMATION

069583 Page 5
GENERAL
INFORMATION
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 main-
tained 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 man-
ual for your engine.
Refer to enclosed owners engine manual for complete O&M instructions. See your battery manufacturer
for battery warranty.
SECTION 1
SAFETY
SECTION 2
OPERATIONS
SECTION 3
SERVICE
SECTION 4
ACCESSORIES
Information Contained in this Manual

The “PARTS & DECALS MANUAL” contain 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 & DECALS 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.
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 & Ordering Parts
069583Page 6
GENERAL
INFORMATION

Model & Serial Number /
Unit Identification
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 specically denes each signicant character or group of characters of the Model Number
and Serial Number codes.
Model Number
AW 16/21
Model
-16ft3
- 21ft3
Series
- Allen Wheel
Serial Number
The serial number found on the identication plate is a ten digit format. The model number identies your machine and will
ensure that you receive the correct replacement 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 information found on this plate below so it will be available should the identification 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
Model Number:
Serial Number:
Date Purchased:
Purchased From:
069583 Page 7
GENERAL
INFORMATION

Measurements in this manual are in standard units
Machine Features for AW16:
•Engine ............................................... Kohler CH440
•Payload .............................................. 2,500 lbs
•Dimensions (L x W x H) .................................. 97" x 47" x 50"
•Wheelbase ............................................ 40"
•Bucket Capacity ........................................ 16 ft3
•Weight ............................................... 1,300 lbs
•Lift Cylinder ........................................... 2” Diameter
•Dump/Return Speed (Empty) .............................. 5 Seconds
•Top Speed ............................................ 7 MPH
•Fuel Capacity .......................................... 1.7 GAL
Machine Features for AW21:
•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
069583Page 8
GENERAL
INFORMATION

Machine Dimensions
50.56 in
46.59 in
97 . 18 i n
069583 Page 9
GENERAL
INFORMATION

Kohler CH440 Engine Information (14 HP)
Engine Type: ..........................................................Air-Cooled, 4-stroke OHV
Bore x Stroke: .........................................................3.5" x 2.7"
Displacement: .........................................................429 cc
Gross Torque: .........................................................22.7 ft lbs
Compression Ratio: .....................................................8.0:1
Certified 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
069583Page 10
GENERAL
INFORMATION

Kohler CH640 Engine Information (20.5 HP)
Engine Type: ..........................................................Air-Cooled, 4-stroke OHV
Bore x Stroke: .........................................................3.1" x 2.6"
Displacement: .........................................................674 cc
Gross Torque: .........................................................35.7 ft lbs
Compression Ratio: .....................................................8.5:1
Certified 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

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

Section 1
SAFETY
SECTION 1
SAFETY
069583 Page 13

Federal / State Warning Regulations
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.
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.
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.
SECTION 1
SAFETY
069583Page 14

Manual Tag Safety Detail
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.
WARNING Indicative of a potentially hazardous situations that could result in
death or serious injury
DANGER indicates an imminently hazardous situation which, if not avoided, will
result in death or serious injury
SECTION 1
SAFETY
069583 Page 15

Spark Arrestor Notice / Safety Symbols
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.
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 notes.
SECTION 1
SAFETY
069583Page 16

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 instructions contained in both this manual and the engine
manual and familiarize yourself with the location 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 qualied 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 modications 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
trafc. 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 the Speed Control Cable- replacement is recommended every 24 months or
sooner for use in extreme conditions.
General Safety SECTION 1
SAFETY
069583 Page 17

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 sufcient to briskly snap back the speed
control lever when it is released. Broken, damaged, or deformed springs must be replaced immediately. Note: never
bend, otherwise modify, or attempt to repair this spring.
Due to the critical nature of the Speed Control Return Spring - replacement is recommended every 24
months or sooner for use in extreme conditions.
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
automatically 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 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 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 EMERGENCY stop switch, and steering assembly. Immedi-
ately 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.
General Safety
SECTION 1
SAFETY
069583Page 18

9) Before adding fuel:
• 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.
• 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 repair or adjustments before putting this equipment into operation. All guards must be
replaced; refer to the SERVICE 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
operation. Each operator must be able to identify any unsafe work site conditions and
report these conditions 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 reproduc-
tive harm.
ØThe monitoring of carbon monoxide on the job site by a qualified inspector following OSHA guidelines is man-
datory in order to determine the safety of job site ventilation. In Canada follow Provincial Ministry of Labor OHSA
guidelines.
ØDo not use this machine without safe job site ventilation.
ØDo not operate this machine on an elevator. Using this machine on an elevator will cause unsafe job site
ventilation.
General Safety SECTION 1
SAFETY
069583 Page 19

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 Kohler 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 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 operate this equipment in poorly lit areas. Provide artificial
lighting as required for safe operation.
ØDo not operate this machine under the influence of drugs and/or alcohol.
ØIdentify all unprotected openings on job site and do not operate this equipment near these openings.
ØIdentify all overhead structures, electrical wires, and door openings on the job site. Be sure this equipment and
operator will safely pass through and under.
ØIdentify the load requirements for the job site. 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 job site conditions so warrant, reduce load and speed.
ØOnly operate this machine in daylight or OSHA conforming artificial light.
General Safety
SECTION 1
SAFETY
069583Page 20