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allen AR16, Operations & Parts Manual

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allen AR16 Operations & Parts Manual Download Page 72

Factory Service Information

SECTION 4

PARTS

055838

Page 72

This section contains the illustrated drawings and parts list for help in identifying and/or ordering re-

placement parts for your machine. Follow the instructions in the front section of this manual “Ordering 

Parts” when ordering replacement parts to insure prompt and accurate delivery. 

All set screws have blue (LOC-TITE™) applied at 

the factory. If set screw is removed or loosened 

for any reason re-apply blue (LOC-TITE™).  

All grease fittings are capped with CAP PLUG 

GC-5(AEC PN 015692) to protect the fitting. If cap 

becomes missing or damaged replace it as soon as 

possible.  

Anti-Seize is applied at the factory to all drive line coupling, gear 

box main and counter shafts and pitch control threaded rod assem-

blies. If these parts are disassembled re-apply a light 

coat of a graphite based anti-seize. 

Summary of Contents for AR16

Page 1: ...OPERATIONS PARTS MANUAL AR16 AR21 Wheel Buggy MANUAL PART 055838 REVISION D ...

Page 2: ...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 055838 Page 2 ...

Page 3: ...R16 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 055838 Page 3 ...

Page 4: ...ions 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...

Page 5: ...y 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 As...

Page 6: ...ion 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 dat...

Page 7: ...owing 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 ...

Page 8: ..._______________________________ Address _________________________________________________________________ City ____________________________________ State ________ Zip _____________ Salesman _______________________________ Mobile Phone __________________ Additional Comments _____________________________________________________ ________________________________________________________________________...

Page 9: ...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 ...

Page 10: ...aracters 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 Numbe...

Page 11: ...ft 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 FI...

Page 12: ...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 Bucke...

Page 13: ... 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 ...

Page 14: ...aft 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 6...

Page 15: ... 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 k...

Page 16: ...INTENTIONALLY LEFT BLANK 055838 Page 16 ...

Page 17: ...Section 1 SAFETY 055838 Page 17 ...

Page 18: ...State Regulation Proposition 65 Warming SECTION 1 SAFETY 055838 Page 18 ...

Page 19: ...Federal Regulation Respiratory Hazard SECTION 1 SAFETY 055838 Page 19 ...

Page 20: ...nformation 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 WARN...

Page 21: ... 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 2 Spark Arrestor Notice SECTION 1 SAFETY 055838 Page 21 ...

Page 22: ...pair 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 Prote...

Page 23: ... act as a reserve system to the primary dynamic hydro static braking provided by the hydrostatic transmission Properly main tained 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...

Page 24: ...l 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 under stand its safe operation Each operator must be able to identify any unsafe work site conditions and report these conditions to his supervisor for imme diate correction Ø The Gasoline Engine on this machine produces carbon mo...

Page 25: ...rant 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 ...

Page 26: ...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 www facebook com AllenEngineering alleneng www youtube com AllenMachinery LIKE US FOLLOW US WATCH US VISIT US www alleneng com 1 3 General Safety contin...

Page 27: ...VEL 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 ...

Page 28: ...this manual Note the two 2 ways a buggy may be lifted and the appropriate lifting points for each method Note the specific load ratings for chains straps forklifts and cranes Ø Avoid 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 during loading Refer to the Lifting Loading T...

Page 29: ...here 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 Ø Inspect all machine Controls for proper function after cleaning Refer to the Service Section for proper lubrication if required 1 4 Ope...

Page 30: ...nia 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 caps ...

Page 31: ...cts 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 cap...

Page 32: ...Notes SECTION 1 SAFETY 055838 Page 32 ...

Page 33: ...Section 2 OPERATIONS 055838 Page 33 ...

Page 34: ...f improperly operated and serviced Follow operating instructions carefully If you have any questions about operating or servicing this equipment please contact your Allen Engineering Dealer or AEC Customer Service at 800 643 0095 or 870 236 7751 SECTION 2 OPERATIONS 055838 Page 34 ...

Page 35: ...alleled 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 compartment The stan dard high strength high density polyethylen...

Page 36: ...2 2 Start up Procedures SECTION 2 OPERATIONS 055838 Page 36 ...

Page 37: ...ting Procedures for AR16 13 HP Honda gasoline engine ØPosition yourself in operator s position standing on the ground between the handlebars or standing on the operator 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 contro...

Page 38: ...d or loss of power Avoid starting and stopping engine without warming engine Starting Procedures for AR21 20 HP Honda gasoline engine ØThis engine is equipped with a low oil level shut down Should the oil level fall below a safe minimum level the engine will not start Check oil level before starting engine ØPosition yourself in operator s position standing on the ground between the handlebars or s...

Page 39: ...il 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 Failure to permit engine to warm up will foul spark plugs and cause hard starting and or loss of power Avoid start i...

Page 40: ... 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 brak...

Page 41: ...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 Honda 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 PO...

Page 42: ... 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 vehicle...

Page 43: ... 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 enter ing the crankcase Steering the Buggy ØAllen Buggies models AR16 and AR21 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 in the F...

Page 44: ...customer service OUR QUALITY POLICY The Allen Engineering Team is fully committed to exceeding customer expectations for the quality of the products and services provided through the continuous improvement process of reducing waste defects and variability in everything we do OUR VISION Our Vision is to be a world class manufacturer of concrete placing and finishing equipment SECTION 2 OPERATIONS 0...

Page 45: ...Section 3 SERVICE 055838 Page 45 ...

Page 46: ...es 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 ser vice brake is engaged shorten 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...

Page 47: ...or buggy trav els more than 8 during brake inspection 1 Tighten brake bands 2 Clean concrete dirt oil accumulation away from brake bands 3 Hydrostatic pump is worn Engine fails to stall 4 Re place worn brake bands s Brass rivets are contacting brake drum and or brake lining worn less than 1 8 thick See Adjustment Repair Procedure Recommended for Brake Opera tional Problem items 1 and 3 above See A...

Page 48: ...hten 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 AllenEngi...

Page 49: ...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 3 2 Parking Brake Schematic SECTION 3 SERVICE 055838 Page 49 ...

Page 50: ... the 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 shi...

Page 51: ...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 bro ken 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 spring has not been replace...

Page 52: ...king 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 position of...

Page 53: ...YE 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 CUT ONE SID...

Page 54: ...nect hose item 5 from elbow in Port A 4 Connect pressure gauge with hose to elbow in Port A Note male thread on elbow is 7 8 14 37º JIC 5 Start engine run engine at full speed 6 Push dump lever forward dump bucket until dump cylinder fully extends and check pressure 7 Turn relief adjustment screw item 2 clockwise to increase pressure counterclockwise to decrease pressure 8 Replace hex cap disconne...

Page 55: ...ent 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 screw item ...

Page 56: ... to decrease maximum engine speed or counterclockwise to increase maximum engine speed 5 After adjusting to desired speed tighten jam nut on throttle lever limiting screw 6 Move throttle lever to the left idle speed and then to the right full speed Verify RPM and readjust if necessary 7 Refer to Honda engine manual for additional information CHOKE LEVER ON FUEL COCK OFF CHOKE LEVER OFF FUEL COCK O...

Page 57: ...mum engine speed or counterclockwise to increase maximum engine speed 5 After adjusting to desired speed tighten jam nut on throttle 6 Turn throttle lever to the full counter clockwise position idle speed and then to the full clockwise position full speed Verify RPM and readjust if necessary 7 Refer to Honda engine manual for additional information ADJUST MAXIMUM ENGINE SPEED TO 3000 100 0 RPM UND...

Page 58: ... 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 loosen 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 exce...

Page 59: ...r and valve spool move freely in all three 3 positions dump hold neutral return bucket Repair as required 2 Inspect the control cable 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 mis...

Page 60: ... the NF 28 cable end one quarter of an inch After each attachment is threaded onto the cable end 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 d...

Page 61: ...ghten 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 ele...

Page 62: ...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 no...

Page 63: ...oir by disconnecting hose item 28 from elbow fitting item 45 ØInspect 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 when...

Page 64: ...pin Do not reuse cotter pin Speed Control System Inspect speed control cable DAILY 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 Cable should be free of cuts kinks binds and sharp bends Rubber s...

Page 65: ...Y AND SOME OTHER OBSTACLE FOR LIFTING AND TYING DOWN ONLY USE OSHA COMPLIANT CHAINS OR STRAPS WITH A MINIMUM WORKING LOAD LIMIT OF 2 500 LB EACH LIFT OR LOAD THE BUGGY ONLY WHEN THE ENGINE IS OFF AND THE BUCKET IS EMPTY FOR 13 HP HONDA ENGINE ONLY WHEN TRANSPORTING THE BUGGY ON A TRAILER SHUT OFF THE FUEL AT THE CARBURETOR TO PREVENT FUEL LEAKING INTO THE CRANKCASE WHEN EMPTY THE BUGGY CAN WEIGH U...

Page 66: ...he slack out of the chains or straps and adjust them so the buggy is level when lifted CRANE HAVING MAXIMUM LIFT CAPACITY OF 2 000 LIFT REAR OF BUGGY USING 2 CUTOUTS AT REAR CORNER OF ENGINE COVER LIFT FRONT OF BUGGY BY R AISING BED TO 55 DEGREE ANGLE AND ATTACHING CH AIN OR STRAP TO LUG IN ST EEL BASE SUPPORTING BU CKET EMPTY BUCKET AND RAISE TO THE FULL UP POSITION 55 ANGLE AND ATTACHIN G CHAIN ...

Page 67: ...ber tired models excluding track models built after December 2003 have additional lifting pockets on the buggy frame to permit lifting the buggy from the REAR Follow the procedure 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 into t...

Page 68: ...losing traction and spinning 7 Slowly drive the buggy onto the trailer in the forward direction as shown below 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 13 HP Honda only and step away from the operator s platform MAXIMUM RAMP ...

Page 69: ...etor 13 HP Honda 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 rear cutouts at the rear of the buggy frame and through the corresponding rings mounted at the rear of the trailer or truck bed 9 All chains straps must pull away ...

Page 70: ...Notes SECTION 3 SERVICE 055838 Page 70 ...

Page 71: ...055838 Page 71 Section 4 PARTS ...

Page 72: ... accurate delivery All set screws have blue LOC TITE applied at the factory If set screw is removed or loosened for any reason re apply blue LOC TITE All grease fittings are capped with CAP PLUG GC 5 AEC PN 015692 to protect the fitting If cap becomes missing or damaged replace it as soon as possible Anti Seize is applied at the factory to all drive line coupling gear box main and counter shafts a...

Page 73: ...lacement parts by the appropriate part number not the key number This manual contains an illustrated parts list 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 Includ...

Page 74: ...4 1 General Arrangement Illustration SECTION 4 PARTS 055838 Page 74 ...

Page 75: ...l G 16595 see Page 101 for more detail 1 45043 04 Pushbutton E Stop for ELECTRIC START 1 NO 1 NC Contacts for machines built AFTER Serial G 16595 see Page 102 106 for more detail 1 EM0100 Pushbutton Emergency Stop for machines PRIOR to Serial G 16596 1 11 42117 02 Dump Lever 1 12 MS2100 Ball Knob 1 13 42117 17 Foot Operated Dump Pedal 1 14 42103 65 Handle for Directional Control Valve 1 15 42101 7...

Page 76: ...4 1 Decals Illustration SECTION 4 PARTS 055838 Page 76 ...

Page 77: ...ecal 1 12 42109 19 Manual Location in Holding Tube Decal 1 13 42109 24 Lifting Tie Down Safety Decal 1 14 42109 25 Operator Position Decal 1 15 42109 26 DANGER Travel Down Hill Instructions Decal 1 16 48200 05 EMERGENCY STOP Round Decal Place over Dash Decal 1 17 DE1100R Safety Operating Instructions Decal for Bucket only 1 18 DE2600 Check Stripe Decal X 20 Long 2 19 DE2700 Check Stripe Decal X 12...

Page 78: ...MBLY SEE PAGES 98 99 REF FRAME ENGINE MOUNTING PLATE NOTE LOCTITE AT ASSEMBLY 2 PLACES 3 32 TURNING CLEARANCE REQUIRED AFTER ASSEMBLY TORQUE TO 23 FT LBS REF FRAME CONSOLE NOTE PRESS CLAMPING COLLAR 8 SNUG AGAINST BEARING 9 CLEAN OIL FROM THREADS AND APPLY 1 ONE DROP OF SAFE T LOK T 70 TO THREADS ...

Page 79: ...ead Cap Screw 3 8 NC X 2 1 4 LG with Lock Nut 2 7 32100 08 Flanged Bearing 1 8 C00100 Clamping Collar 1 9 BE1400 Ball Bearing 1 10 BE1200 Bearing Cone 1 11 BE1300 Bearing Cup 1 12 MS3700 Grease Seal 1 13 32100 15 Spacer 1 14 32100 16 Flat Washer 1 15 42126 01 Handlebar 1 16 42102 07 Handlebar Grip Untrimmed 1 17 42102 08 Handlebar Grip Trimmed 1 18 32100 21 Stud Mounted Rubber Isolator 2 19 010090...

Page 80: ...4 4 Service Parking Brake Illustration SECTION 4 PARTS 055838 Page 80 Parts List Located on Page 82 ...

Page 81: ...4 4 Service Parking Brake Illustration continued SECTION 4 PARTS 055838 Page 81 Parts List Located on Following Page ...

Page 82: ...minimum No substitutes 1 19 42101 44 Brake Pedal 1 20 42101 46 Bolt Assembly 3 8 NC 16 x 1 1 2 Lg HHCS with USS Flat Washer Lock Nut and Hex Nut 1 21 42101 47 Bolt Assembly 5 8 NC 10 x 2 3 4 Lg HHCS with 3 4 NC Hex Nut 5 8 NC 10 Jam Nut 5 8 NC 10 Steel Lock Nut two 2 5 8 SAE Flat Washers 1 22 42101 48 Spring Brake Pedal Return 1 23 42101 49 Bolt Assembly 1 2 NC 13 x 1 1 2 Lg HHCS with Lock Nut and...

Page 83: ...SECTION 4 PARTS 055838 Page 83 PAGE LEFT BLANK INTENTIONALLY ...

Page 84: ...4 5 Hydraulic System Illustration SECTION 4 PARTS 055838 Page 84 Parts List Located on Page 86 87 ...

Page 85: ...4 5 Hydraulic System Illustration continued SECTION 4 PARTS 055838 Page 85 Parts List Located on Following Page ...

Page 86: ...mbly 18 Long with Spring Guard 1 18 HH2200 Hose Assembly 54 Long with Spring Guard 1 19 HH2300 Hose Assembly 72 Long with Spring Guard 1 20 HH2400 Hose Assembly 66 Long with Spring Guard 1 21 HH2500 Hose Assembly 18 Long 1 22 FG3800 Fitting Tee Male 2 23 FG3900 Fitting Elbow Male 90 2 24 FG3700 Fitting Elbow Male 90 3 25 061292 Fitting Elbow Male 90 1 26 FG4000 Fitting Elbow Straight Thread 90 2 2...

Page 87: ... 1 1 2 NC Hex Socket Flat Head Cap Screw x 2 Long 1 split Lock Washer 1 Nylock Lock Nut 8 43 42103 87 Pin Cotter 5 32 x 2 for Wheel Motor 2 44 42103 65 Handle Directional Valve 1 45 055034 Washer Flat 1 GR8 4 46 42103 63 REPLACEMENT Key Wheel Motor 5 16 square x 1 Long 1 per wheel 2 47 42103 64 REPLACEMENT Nut Castle Wheel Motor 1 20 Threads per Inch 1 per wheel 2 DUMP DIRECTIONAL VALVE ASSEMBLY D...

Page 88: ...t Thread O Ring 1 4 HH1700 Hose Assembly 20 Long 1 5 061060 Hose Assembly 18 Long 90 Straight 1 6 061055 Hose Assembly 17 Long 1 7 42103 07 Fan Transmission 1 8 42103 08 Coupling Pump Side Hydraulic Assembly 1 9 PM0150 Element Spider Jaw 1 10 42103 10 Washer Flat 1 11 42103 11 Fastner FSHCS 1 4 20 x 3 4 3 12 056700 Spacer Shaft 11 16 1 13 42103 13 Key Woodruff 606 3 16 x 3 4 Long 1 14 PM0100 Coupl...

Page 89: ...ng 1 4 HH1700 Hose Assembly 20 Long 1 5 061060 Hose Assembly 18 Long 90 Straight 1 6 061055 Hose Assembly 17 Long 1 7 42103 07 Fan Transmission 1 8 42123 05 Coupling Pump Side Hydraulic Assembly 1 9 42123 06 Element Spider Jaw 1 10 42123 03 Bolt Assembly 4 10 24 HSBHCS x 1 2 Long 4 Star Lock Washer 4 10 Flat Washer 1 11 42103 13 Key Woodruff 606 3 16 x 3 4 Long 1 12 42123 04 Coupling Half 1 Bore E...

Page 90: ...4 6 Bucket Base Assembly Illustration SECTION 4 PARTS 055838 Page 90 ...

Page 91: ...olyurethane Bucket Elevator Bolt Assembly 3 8 NC Elevator Bolt x 1 1 2 Long with 3 8 SAE Flat Washer and 3 8 NC Nylock Locknut 6 42105 10 Steel Bucket Carriage Bolt Assembly 3 8 NC Carriage Bolt x 1 Long with 1 2 USS Flat Washer 3 8 USS Flat Washer and 3 8 NC Steel Crimp Locknut 6 3 42110 02 AR16 Bucket Base Plate 1 063321 AR21 Bucket Base Plate 1 4 42110 11 Pivot Pin 1 5 42110 16 Clamping Collar ...

Page 92: ...4 7 Travel Speed Control Assembly Illustration SECTION 4 PARTS 055838 Page 92 ...

Page 93: ...ed Control Lever 1 16 42107 30 Metal Cord Grip 1 17 010093 Fastener Lock Washer 1 2 1 ITEM PART DESCRIPTION QTY 18 42107 27 Extension Spring Repair Kit Consists of Extension Spring 1 4 NC Eye Bolt 1 4 USS Flat Washer 1 4 NC Nylock Lock Nut See Assembly Note For Important Assembly Information 1 Assembly Note for Extension Spring Repair Kit 1 Adjust the Eye Bolt so the length of the Extension Spring...

Page 94: ...4 8 Wheel Assemblies Illustration SECTION 4 PARTS 055838 Page 94 ...

Page 95: ... WHEEL ASSEMBLY ITEM PART DESCRIPTION QTY 7 42113 03 High Speed Hub Complete with Bearings Grease Seal and Grease Cap 2 8 42113 04 Castle Nut 2 9 42113 05 Cotter Pin Ws x 1 Y 2 10 42113 12 Roller Bearing Cone 4 11 42113 13 Roller Bearing Cup 4 12 42113 14 Grease Cap 2 13 42113 15 Wheel Bolts 8 14 42113 16 Grease Seal 2 15 32100 01 Steering Column 1 16 42113 21 Foam Filled Steering Tire and Wheel A...

Page 96: ...SECTION 4 PARTS 055838 Page 96 4 9 Console Mounted Dump Lever Illustration ...

Page 97: ...h 5 USS Flat Washers 1 Hex Nut and 1 Nylock Lock Nut 1 4 42117 09 Yoke 2 5 42107 11 Clevis Pin 2 6 42117 11 Cotter Pin 3 32 x 3 4 Long 2 7 42117 12 Hex Nut 3 8 NF 24 2 8 42117 13 Dump Rod 1 9 42117 17 Dump Pedal 1 10 42117 23 Bolt Assembly 5 8 NC x 2 1 4 HHCS with 2 SAE Flat Washers 1 Hex Nut and 1 NyLock Lock Nut 1 4 9 Console Mounted Dump Lever Parts List ...

Page 98: ...SECTION 4 PARTS 055838 Page 98 4 10 Handlebar Mounted Dump Lever Illustration ...

Page 99: ... Clevis with Pin 2 10 42126 24 Hex Nut 10 32 UNF Plated 2 11 42126 25 Dump Cable Cover 1 12 42126 26 Valve Link Bracket Kit 1 13 42126 27 Bolt Assembly 1 4 NC HHCS x 1 3 4 Long with 2 SAE Flat Washers Steel Lock Nut 1 14 42126 28 Bolt Assembly 1 4 NC x 1 X Long Shoulder Bolt with 10 24 Nylock Lock Nut 1 15 42126 29 Bolt Assembly 3 8 NC HHCS x 1 1 4 Long with SAE Flat Washer Steel Crimp Lock Nut 5 ...

Page 100: ... Start with Recoil Backup 1 2 32103 02 Bolt Assembly 3 8 NC HHCS x 1 3 4 Long with 1 SAE Flat washer 1 USS Flat Washer and 1 Lock Nut 4 3 45048 05 Throttle Stop Bolt Retaining Nut M5 x 0 8 Hex Nut Plated 1 4 32103 15 Heat Shield 1 5 45048 06 Key 1 4 SQ x 1 3 4 Long 1 4 11 13HP Honda Engine with Recoil Electric Start AR16 Illustration Parts List ...

Page 101: ...838 Page 101 ITEM PART DESCRIPTION QTY 6 45049 25 Pushbutton E stop 1N O Contact 1 7 42109 01R Emergency Stop Legend Plate 1 4 12 Electric Schematic for AR16 with 13HP Honda Engine Recoil Start Illustration and Parts List ...

Page 102: ...SECTION 4 PARTS 055838 Page 102 4 13 Electric Schematic for AR16 with 13HP Honda Engine Electric Start Illustration ...

Page 103: ...1 BF0200 Black Ground Cable x 10 Long 1 2 BF0100 Black Positive Cable x 36 Long 1 3 45043 04 Pushbutton E Stop 1N O 1N C Contact 1 4 42409 01R Emergency Stop Legend Plate 1 4 13 Electric Schematic for AR16 with 13HP Honda Engine with Electric Start Parts List ...

Page 104: ...SECTION 4 PARTS 055838 Page 104 4 14 Electric Schematic for AR21 with 20HP Honda Engine with Electric Start Illustration ...

Page 105: ... 9 42124 08 Bolt 8mm 1 25 Pitch Thread HHCS x 16mm Long 1 10 42124 09 Pipe Coupling 1 11 42124 10 Bolt Assembly 7 16 NC HHCS x 2 Long with 1 USS Flat Washer and 1 Split Lock Washer 1 12 42124 11 5 16 USS Flat Washer 1 13 42124 12 5 16 USS Lock Washer 1 14 42124 17 Heat Shield 1 15 42124 18 Bolt Assembly 1 4 NC HHCS x 1 1 4 Long with Lock Nut 2 16 42124 19 Pipe Coupling 2 17 40112 68 1 2 Loom Clamp...

Page 106: ...SECTION 4 PARTS 055838 Page 106 4 14 Electric Schematic for AR21 with 20HP Honda Engine with Electric Start Illustration continued ...

Page 107: ...200 Black Ground Cable x 10 Long 1 2 BF0100 Black Positive Cable x 36 Long 1 3 45043 04 Pushbutton E Stop 1N O 1N C Contact 1 4 42409 01R Emergency Stop Legend Plate 1 4 14 Electric Schematic for AR21 with 20HP Honda Engine with Electric Start Parts List continued ...

Page 108: ...SECTION 4 PARTS 055838 Page 108 13 14 6 7 8 11 9 12 5 2 4 15 Propane Assembly Illustration Only Available on AR16 Model ...

Page 109: ...TN HHCS 5 16 18 X 1 GRD8 4 7 010090 FSTN LW 5 16 GRD8 4 8 010082 FSTN FW 5 16 GR8 4 9 012990 FSTN Cable 3 8 16 X 1 1 4 4 10 010464 FSTN Nut Nylock 3 8 16 4 11 064879 KIT Tank Mounting Bracket 1 12 064849 Bracket Propane Tank Mount 1 13 068069 Hose Assembly Hose Fitting and Cylinder Connector 1 14 32105 02 Guard Fan for Engine 1 15 066748 Regulator Propane T60 390 CERT NOT SHOWN 1 4 16 Propane Asse...

Page 110: ...LTER HYDRAULIC POWER UNIT 1 AR21 BUGGY ITEM PART DESCRIPTION QTY 1 066442 KIT AR21 BUGGY FILTER 1 1 1 064832 FILTER AIR AR21 BUGGY 1 1 2 064831 FILTER OIL 1 1 3 064833 FILTER FUEL 1 1 4 038937 FILTER HYDRAULIC POWER UNIT 1 AR16P Propane ITEM PART DESCRIPTION QTY 1 066443 KIT AR16P BUGGY FILTER 1 1 1 066440 FILTER AIR AR16 BUGGY 17210 ZE3 1 1 2 038937 FILTER HYDRAULIC POWER UNIT 1 4 16 Filter Kits ...

Page 111: ...SECTION 4 PARTS 055838 Page 111 Notes ...

Page 112: ...age 112 MANUAL REVISION DETAIL REVISION REVISION DATE REVISION REFERENCE REVISION BY 03 2012 Initial Release AW A 02 2016 AW B 03 2018 MW C 05 2018 MN 18 016 MN 18 046 MW D 06 2018 MN 18 059 MW Revision Detail ...

Page 113: ...ny errors or inaccuracies that may appear in this man ual 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 61...

Page 114: ...CONNECT WITH US ON P O BOX 819 PARAGOULD AR 72451 USA 800 643 0095 USA ONLY 870 236 7751 FAX 800 643 0097 USA ONLY 870 236 3934 WWW ALLENENG COM ...

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