PBU Propane Floor Burnisher - Performance Systems Janitorial
Contents
1. cce s as sa s as s s as s s hmm e 14 Maintenance and Adjustments _ __ rns 14 Replace burnishing disc pad gripper assembly _ r r es e s 14 Replace Burnishing Disc Assembly Drive Belt a a ea e e s s s 15 Replace Drive Belt Tensioner 244442226684 xou e be ee a dox FORO Heb OES 16 Relocating Belt Tensioner Mounting Position Some 27 Inch Models 16 Replace Drive CUI PPP 18 Electrical System uude eee ew dL e uo a s RC l s e 19 Functional Description omo ok OR EUROS 4o o x x ES X US EG 19 COMP GGG SSS 3 oa EI hee eee ee eee ed eee ee eee ee y I e S ee 19 Carb Gard Normal Operation eeeREEE OR ote ob ow h X ow xxm 9d s 19 Component Locations RS SURE SON OE ee Re X 4 9 8 3 03 8 AO PR RE 20 Troubleshooting eo v xo 3o hee ken R w R33 3 OS E O BOX EOR X 3 20 Oxygen Sensor TeSt xo xov x REX OR M XXe sz EW Oe RR ses s s Wow x X GEE EE 20 Wiring DIaSKalTiS x amp ex don ROO Ou X Xu UP XE XC OP TR SCC NO cde a a ea Ro AR Oe RE en dee 22 Engine Systemi s gt v v v v o x K w X X cw KOS Ok X 3 3 5 4 9 S w x s X3 Q w w W SE ud d 24 Functional Description ee 24 IION SYSTE ss dw RU Xe eee POS Qa Ae ee Q S Q UN REOR OE SN 24 Ignition System Operation Theory 9X GE X X EE RR S 24 Maintenance and Adjustments _ _ rns 25 Air Cleaner Element Cleaning an2. ISO 11201 Productivity 25 000 ft hr 2 322 m hr 25 000 ft hr 3 066 m hr Rate Agency EPA plus UL Approved Propane Components Approvals CARB Yes Yes Yes Yes Yes Certified California source Board Weight 212 Ibs 214 Ibs 240 Ibs 246 lbs 238 Ibs 96 kg 97 kg 109 kg 111 kg 108 kg Length SL 51 5 59 59 59 131 8 cm 131 8 cm 149 9 cm 149 9 cm 149 9 cm Width 23 3 59 cm 23 3 59 cm 29 3 74 4 cm 29 3 74 4 29 3 74 4 cm cm Height 43 109 2 cm 43 109 2 cm 43 109 2 cm 43 109 2 43 109 2 cm cm 2 Years Parts amp Labor Air Re 10 Service Manual PBU Propane Floor Burnisher General Information 11 Model 21KBCATCLDC 27KBCATCLDC 27KBCATCLST MPS 1721 MPS 1727 Part Number 56381408 56381409 56381410 56381412 56381413 21 53 CM 27 68 cm 21 53 CM 21 53 CM 27 68 cm Engine 603CC KAWASAKI Catalytic Muffler Carb Gard Clutch Centrifugal Centrifugal Centrifugal Centrifugal Centrifugal Pad Speed 2100 RPM 1500 RPM 1400 RPM 1400 RPM 1400 RPM Eng 3600 RPM Pad Speed 1750 RPM 1250 RPM 1170 RPM 1170 RPM 1170 RPM Eng 3000 cs Propane Tank Tank 20 Ib 9 1 ee 80 ME Fill Auto Fuel Shutoff Low Oil Shutdown Sound 87 dB LpA 3dB KpA Pressure ISO 11201 Agency EPA plus UL Approved Propane Components Approvals CARB Yes Yes Yes Yes Yes Certified California Air Resource Boar
3. Keep the plugs as far away as possible from the plug holes Service Manual PBU Propane Floor Burnisher Engine System 38 Open the throttle fully Crank the engine by turning the engine switch key several times until the compression gauge stops rising Read the highest compression value Cylinder Compression MIN 448 kPa 64 psi Engine Oil Temperature 50 60 C 122 140 F Cranking Speed 500 rpm 5 Seconds Repeat the measurement on the other cylinder Ifthe compression is higher than the specified value the piston rings cylinder and valves are probably in good condition If the compression 1s too high check the following 1 Carbon build up on the piston crown and cylinder head clean off any carbon on the piston crown and cylinder head 2 Cylinder head gasket use only the proper gasket The use of a gasket of incorrect thickness will change the compression 3 Valve guides and piston rings rapid carbon accumulation in the combustion chamber may be caused by worn valve guides and or worn piston oil rings This may be indicated by white exhaust smoke Ifthe cylinder compression is lower than the MIN check the following 1 Gas leakage around the cylinder head replace the damaged gasket with a new one and check the cylinder head warp 2 Condition of the valve seating 3 Valve clearance 4 Piston cylinder wear piston seizure 5 Piston ring piston ring groove Service Manual PBU Propane Fl
4. passage eCheck carburetor setting Service Manual PBU Propane Floor Burnisher Engine power loss Is engine overheated YES NO Is the ignition spark normal Is lubricating condition normal Is unusual smoke emitted out of muffler Is compression sufficient Engine runs erratically Problem in the engine rotation Problem in the fuel system lack of fuel Engine System 40 Engine oil level too low Adjust level or add Engine oil level too high Adjust level Excessive engine load Decrease load Carburetor not properly adjusted Carbon deposit in combustion chamber e Damaged cooling fan Wrong spark plug e Faulty ignition coil e Incorrect air gap Engine oil level too low or high Excessively contaminated engine oil e Defective oil filter e Faulty relief valve e Faulty oil pump e Clogging oil system e Plugged air cleaner element Carbon deposit in exhaust hole and muffler Carburetor not properly adjusted e Engine oil level too high Worn piston piston rings Worn cylinder bore See Engine hard to start e Spark plug fouled pitted or Replace or adjust gapped incorrectly e Plugged air fuel passes in Clean carburetor Carburetor not properly adjusted Adjust Carburetor flange leaking at Retighten or replace gasket Worn carburetor body and Replace throttle shaft Service Manual PBU Propane Floor Burnisher En
5. thickness gauge C between the rocker arm and valve stem end and turn the adjusting bolt until the thickness gauge begins to bind between the rocker arm and valve stem end Sweep the thickness gauge during this adjustment Valve Clearance when cold Intake Exhaust Figure 32 Thickness Gauge Between Rocker Arm and 0 10 0 15 mm 0 004 0 006 in Valve Stem End Service Manual PBU Propane Floor Burnisher Engine System 31 Holding the adjusting bolt with a spanner A tighten the adjusting locknut B to the specified torque Torque Valve Clearance Adjusting Locknuts 11 N m 1 1 kgf m 87 in 1b Do not overtighten the valve clearance adjusting locknuts After the valve clearance adjustment measure the valve clearance again Readjust the valve clearance if necessary K Figure 33 Tighten Locknut Valve Seat Inspection N Note The valve stem and guide must be rine in good condition or this check will Remove the valve Inspect the valve seats for damage If the seats are warped or distorted beyond reconditioning replace the cylinder head with a new one Pitted or worn valve seats can be refaced Lap the valves to the seats after refacing Coat the valve seat with machinist s dye Push the valve into the guide Rotate the valve against the seat with a lapping tool Figure 34 Check for Correct Width Pull the valve out and check the seating pattern on the valve head It must be the corr
6. 1600 1700 RPM CO lt 0 02 goal 007 HC lt 50ppm NOx lt 60ppm b Muffler without Catalyst at 1600 1700 RPM CO lt 0 2 HC lt 500ppm NOx lt 80ppm 5 Push the throttle to high speed and run for 15 seconds Move throttle back to idle and recheck idle speed and mixture If not correct repeat steps 3 5 If okay go on to step 6 6 Place a small amount of 242 Loctite at the edge of the opening over the regulator adjustment screw Using a wide punch and hammer to compress the cap found taped to the side of the regulator into the opening Engine System 53 Regulator Idle Mixture Adjustment Screw Service Manual PBU Propane Floor Burnisher Replace Engine The engine 1s secured to the unit frame by three bolts ft WA re EE a 5 2 t Engine Mounting E Bolts Be Figure 71 Engine Mounting Bolts Engine System When replacing the engine apply 242 Loctite to the three engine mounting bolts and torque to 31 ft lb 54 Service Manual PBU Propane Floor Burnisher Engine System 55 Specifications Engine Specifications Item Specification Forced air cooled vertical shaft OHV 4 stroke gasoline engine 90 V Twin 73 mm x 72 mm 2 87 in x 2 84 in 603 om 36 8 cu in Counterclockwise facing the PTO shaft Automatic compression release 1600 1700 RPM High Idle Speed Before Serial 3600 RPM Number 3000083761 High Idle Speed After Serial 3000 3100 RPM Number 3000083
7. Check pad driver for loose parts BEEN Check belt for wear or slippage EN Check engine pulley for tightness mE Check wheel bolts Was Check engine mount bolts Wa Check handle bolts EEEN mE Check for leakage of engine oil at the various seals Change dust control filter Check and adjust engine valve clearance Clean and lap valve seating surface Clean dust and dirt from cylinder and cylinder head fins Cean and re gap spark pos T Clean combustion chambers Return machine to authorized service center for overall checkup Service Manual PBU Propane Floor Burnisher Burnishing System Maintenance and Adjustments Burnishing System Replace burnishing disc pad gripper assembly 1 2 3 Use an open end wrench to grip the bolt that secures the burnishing disc assembly bearing Brace wrench against adjacent bolt to prevent the bearing from rotating Rotate the pad gripper assembly counter clockwise to remove To replace thread pad gripper assembly onto shaft and rotate clockwise until secure WEE PROCURE ub 4 amp 7 303 BENIN TACUIT ca glr c b t apn sigh ye t MA E Figure 7 Remove Pad Gripper Assembly Figure 8 Replace Pad Gripper Assembly 14 Service Manual PBU Propane Floor Burnisher Burnishing System 15 Replace Burnishing Disc Assembly Drive Belt An idler assembly is used to keep the burnishing disc drive belt tight The idler assembly mu
8. Liquid Propane Gas powered engines including this engine produce Carbon Monoxide CO It is a LETHAL POISON that is a colorless odorless tasteless and non irritating gas It is produced by incomplete combustion of carbonaceous material such as propane LPG Failure to provide for proper venting of CO produced during the operation of combustion powered engines may result in SERIOUS INJURY OR DEATH to the operator and those in the contaminated area The effects of CO can be experienced at different exposure levels depending on the health of the individual Conditions that affect the tolerance of the individual are smoking age temperature humidity and other conditions Warning Read and understand The Operators Manual completely before using this machine This document explains how CO produced can be managed to reduce the risk of carbon monoxide poisoning All distributors owners and operators should be aware of the potential effects of CO and the methods used to prevent over exposure We are dedicated to our customers their safety and providing information services and products that meet those needs 5 Service Manual PBU Propane Floor Burnisher General Information 1 Warning A Warning The Products sold with this Manual contain or may contain chemicals that are known to certain governments such as the State of California as identified in its Proposition 65 Regulatory Warning Law to cause cancer birth def
9. a new air cleaner element according to the maintenance schedule Engine System Figure 47 Install Element Figure 49 Install Cover MN NE 36 Service Manual PBU Propane Floor Burnisher Engine System 37 Troubleshooting Engine turns over but does not start 1 Check ignition system a Check spark at both spark plug wire ends for a minimum of 10 KV b Check spark plugs 2 Check fuel delivery a Check primary regulator pressure b Check fuel lock off solenoid 3 Check Mechanical Engine a Check compression b Check for plugged exhaust c Check for plugged intake d Check oil pressure Engine shuts down Oil pressure drop Fuellock off solenoid failure Oxygen sensor see Carb Gard Compression Measurement Before measuring compression do the following Besure the battery is fully charged Thoroughly warm up the engine so that engine oil between the piston and cylinder wall will help sealing the compression as it does during normal running Stop the engine Disconnect the spark plug caps of each cylinder and remove the spark plugs Attach the compression gauge assembly firmly into one plug hole Figure 50 Compression Measurement Special Tools Compression Gauge 20 kgf cm A 57001 221 Compression Gauge Adapter M14 x 1 25 B 57001 1159 Ground the spark plugs to the engine Warning To avoid fire do not ground the spark plugs in proximity to the plug holes
10. and nut Service Manual PBU Propane Floor Burnisher Using a large wrench on the large nut of the tensioner arm and a back up wrench on the mounting bolt rotate the arm against spring pressure until the indicator marks on the tensioner arm align near the third index mark on the stationary tensioner body as shown in the photo Tighten the mounting bolt to hold the tensioner in place Crank the engine over a few times to set the belt and then recheck the belt tension If it is incorrect loosen the mounting screw and reposition the tensioner as necessary Replace Drive Clutch 1 To replace the drive clutch first remove the drive belt See Replace Burnishing Disc Assembly Drive Belt above for the procedure to remove the drive belt Using an impact wrench remove the bolt that secures the clutch Remove clutch Apply Loctite 243 to the bolt the secures the clutch Position the replacement clutch Insert the bolt and torque to 40 ft lb An alternate method can be used to remove the clutch This method requires a vicegrip or channel locking pliers 1 Use the vicegrip or pliers to grip the washer at the end of the clutch Use a wrench or socket to remove the bolt that secures the clutch Remove clutch Apply Loctite 243 to the bolt the secures the clutch Position the replacement clutch Insert the bolt and secure the washer with the vicegrip or pliers Tighten the bolt If a torque wrench is available
11. but engine can not crank Does pinion mesh with ring NO Worn pinion or ring gear Replace gear Incorrect starter alignment Correct YES Replace Repair or replace e Faulty pinion clutch e Faulty engine Starter does not stop in engine switch OFF Can stop starter Andi engine e Forte ME engine switch Repair or replace switch Andi 7 e Forte ME solenoid switch Replace e Faulty pinion or ring gear Repair or replace Incorrect starter alignment Correct e Faulty pinion return Repair or replace mechanism Service Manual PBU Propane Floor Burnisher Engine System 44 Removal and Installation Ignition Coil Removal Remove the fan housing see Flywheel and Stator 4 Coil Removal Cut off the band A Remove Spark Plug Cap B Bolts C Stop Switch Lead Connector D Ignition Coil 1 E Ignition Coil 2 F Ignition Coil Installation Install the ignition coil on the crankcase so that the stop switch lead connector A face the upward and tighten bolt B first then tighten bolt C While tightening bolts adjust the air gaps to specified gap value as shown D between left leg of 1gnition coil and left pole plate of magnet E between center of ignition coil and right pole plate of magnet Figure 52 Coil Installation Service Manual PBU Propane Floor Burnisher Ignition Coil Air Ga
12. engine oil see Engine Oil Change Using a suitable tool A remove the oil filter B When unscrewing the oil filter place a suitable container beneath the oil drip tray to receive oil from the oil filter and oil passages 1n the engine Engine System Ambient Temperature gt 20C 10t Iri 10 Ex 30 s 400 ere SAET10W 30 SAE10W 40 on sai Figure 39 Oil Types and Temperatures Figure 40 O Ring Figure 41 Unscrew Oil Filter 33 Service Manual PBU Propane Floor Burnisher Engine System 34 Replace the oil filter A with a new one Apply light film of engine oil to the seal B Install the oil filter Torque Oil Filter 11 8 N m 1 2 kef m 104 in lb Turn the filter until the seal contacts mounting surface C of the engine Then turn the filter BY HAND S 3 4 turn Run the engine at slow idle speed 3 minutes While running the engine check for oil leaks around Figure 42 Install Oil Filter it Stop the engine and check the oil level see Engine Oil Level Inspection Electrical System Spark Plug Cleaning and Inspection Carefully pull the plug cap from the spark plug and remove the spark plug If the plug is oily or has carbon built up on it clean the plug using a high flash point solvent and a wire brush or other suitable tools NNN 2222292299 NN 7 If the spark plug electrodes are corroded or damaged S or if the insulator is cra
13. inch Allen wrench Phillips screwdriver Hammer Exhaust gas analyzer Punch large 1 Setthe butterfly valve adjustment screw on the carburetor mixer Using a Phillips screwdriver turn the butterfly valve adjustment screw clockwise until resistance 1s felt Then turn the screw counterclockwise 1 1 4 turns Figure 56 Butterfly Valve Adjustment Screw 2 Use a 3 32 Inch Allen tool to adjust the top of regulator adjustment screw to a depth of 1 4 inch below the top of housing Use a caliper or tools on hand to measure depth 1 4 In Regulator Screw M Figure 57 Regulator Adjustment Screw 3 The throttle cable must move freely and not restrict throttle movement over the full range of low to high speed If necessary loosen the cable housing clamp screw and reposition the cable housing to allow unrestricted throttle movement Cable Housing Clamp Screw Figure 58 Throttle Cable Housing Clamp Screws Service Manual PBU Propane Floor Burnisher Engine System 48 4 Connect a tachometer to a spark plug lead 5 Start and warm up the engine Run at full throttle for a minimum of five minutes Figure 59 Connect Pulse Tachometer 6 Return to idle While referring to the tachometer use a 3 32 1nch Allen wrench to turn the regulator adjustment screw to achieve the highest engine RPM at 1dle Regulator 3 Adjustment 7 After achieving the highest engine RPM F Nu SC turn t
14. torque the bolt to 40 ft lb Figure 12 Replace Clutch Burnishing System 18 Service Manual PBU Propane Floor Burnisher Electrical System 19 Electrical System Functional Description Carb Gard Carb Gard is a warning device to alert the operator that the engine needs to be serviced The Carb Gard system includes an oxygen O2 sensor The oxygen sensor is mounted in the exhaust manifold to monitor how much unburned oxygen is in the exhaust as the exhaust exits the engine The O2 sensor produces electrical voltage when it gets hot It will generate approximately 1 0 volts when the fuel mixture is rich and there is little unburned oxygen in the exhaust When the mixture is lean the sensor output voltage will drop down to 0 2 volts or less When the air fuel mixture is balanced the oxygen sensor will generate around 5 volts Carbon monoxide CO may be produced if the engine operates with a fuel mixture that is too rich Carbon monoxide can be highly toxic If the Carb Gard system senses too high of a voltage from the oxygen sensor resulting from a fuel mixture that is too rich the engine will be shut down to prevent a possible build up of carbon monoxide in the work area See Carb Gard Normal Operation description below Carb Gard Normal Operation 1 Upon starting the engine the GREEN Alert LED will begin flashing It will continue flashing for 3 minutes This allows the engine and the oxygen sensor mounted in the exh
15. 760 Transistorized flywheel magneto Per Canada and U S A requirements Electric starter 12 V 15 amps with regulator NGK BPR4ES Float type fixed main jet internally vented single barrel Diaphragm type pulse pump Dual stage element dry type Flyweight all speed governor Pressure feed by positive displacement pump 30HD or 10W30 API rating SJ or higher Cartridge type full flow filter Oil Capacity when engine is 2 0 L 2 1 US qt completely dry Cooling System Forced air cooling by fan Dimensions L x W x H 486 mm x 429 mm x 362 mm 19 1 in x 16 9 in x 14 3 in Dry Weight without muffler 36 7 kg 80 9 Ib Specifications are subject to change without notice Item Service Limit 448 kPa 64 psi Engine Oil Temperature 50 60 C 122 144 F Cranking Speed 500 rpm 5 Seconds 0 05 mm 0 002 in Valve Head Thickness 0 35 mm 0 0138 in Intake Exhaust Service Manual PBU Propane Floor Burnisher Engine System 56 ltem Service Limit TIR 0 05 mm 0 002 in Intake Exhaust Valve Stem Diameter 5 95 mm 0 234 in VaveGudeisdeDimeer 6 08 mm 0 239 in Vave Spring Freleng aw RoWerAmPushRodRumut OOOO O Rocker Shaft Outside Diameter OC O OOOO 10 91 mm 0 430 in Roera umawa CyindePistom OOOO 72 79 mm 2 866 in Piston Ring Groove Clearance Top 0 12 mm 0 0047 in Second 0 12 mm 0 0047 in Piston Ring Thickness To 1 1 mm 0 043 in Second 1 1 mm 0 043 in Piston Rin
16. LOW H31HVIS YALYVLS dGION31OS Service Manual PBU Propane Floor Burnisher Engine System Functional Description Ignition System Engine System The engine ignition is controlled by a solid state ignition assembly and requires no periodic maintenance except for the spark plugs The system consists of the following Inductive Ignition Assemblies Permanent Magnet Flywheel Spark Plugs Stop Switch Co Core Lamination C Collector D1 Diode E Emitter L1 Primary Coil R1 Control Resistor L2 Secondary Coil TS1 Trigger Sensor Q1 Transistor SP Spark Plug B Base SW Stop Switch Ignition System Operation Theory N North Pole S South Pole Figure 16 Ignition System KHO BOBSBN Permanent magnets are mounted around the edge area of a flywheel As the flywheel magnetic pole rotates clockwise and passes the ignition module on a laminated core group voltage 1s produced at the primary winding L1 allowing a small bias current to flow from the control resister R1 to the transistor Q1 base and thereby exciting the transistor base Thus the transistor forms turns ON the primary circuit This circuit current flows from the plus side of the primary winding to ground through the transistor Collector C to Emitter E 24 Service Manual PBU Propane Floor Burnisher Engine System 25 When the base current is flowing the trigger sensor TS1 detects optimum time peak current to shut off the t
17. OQd HOLIMS dau yid H qaq ac qaq NHO o 7 ya gt lt 1109 NOLLIND 9fildoluvds O d z lt ON1d MHVdS 109 NOLLINSI lu R HOLIMS 3unSS3ti 110 dau HOLOW H31HVI1S YALYVLS GION310S qaq YOLVLS dO1VNd31l1TV LHM LHM qad Y gt lsILOAY YOLVINDAY ADVLIOA PAZ AYALLVE 23 Electrical System Service Manual PBU Propane Floor Burnisher Wd 0061 oJeq sdoip pseds eu Bue ueym Bujusse uejs M 31 SIP z AL6 0 jo Bujpea LS191V98XL2 0LFL8 9S 20191V9842 60rL8 96 OGTOLVIGMLZ 80r18 96 SI POW L ainbig Josuas ueB xo ue je Bujusey ue1s Q3 8948S ajyou BuluuuimiBoiqd S9 8 91 I1HVIS HOSN3S ZO g 7 NOY Z N3959 450 ALINNILNOO NOILISOd HOLIMS duvo SHVO S x18 IHM NHO TIA Ta HOLVIS HOLVNH3LTV dINV St MO18O1S Asn D g agu Bt qatu HOLIMS 3NION3 S MHO TJA _ s 2 i n Z I o JP 1 Beg Oa Nua di gt lt J09 NOILINS Md eves J t S BB H3l3WHnoH T 4 Z o ualJiLO3H HOLVINDAY 3DVLTOA 2 OM1d MHVdS 109 NOILINDI a TBA Nua Taf dlON310S a Nua L H LIMS 3unssautd TIO _ pA Z AH311V8 IN Fam i HO
18. PBU Propane Floor Burnisher 21KB 21KBCAT 21KBCATCL 27KB 27KBCL 27KBCAT MPS 1721 MPS 1727 24KBCATCLFC 27KBCATCLDC Service Manual Nilfisk Advance PBU Machines 56381402 56381404 56381405 56381406 56381407 56381408 Dust control unit 56381409 Dust control unit 56381454 Nilfisk Advance Propane Stripper Machine 56381410 Diamatic Machines 56381412 56381413 Nilfisk Advance 03 11 Revised 07 12 Form No 56043153 Service Manual PBU Floor Burnisher Contents General Information 0 s sz sz se sz se sz sz sz s sz sz s s eee as sas s m s s sa 4 Service Manual Purpose and Application llle 4 Document Revision History 2 a a e a a e a a es a a e aos 4 Other Reference Manuals ee s 4 CONVENTIONS s 3x 4x a a a as as ss asas s s s as s as is nas asb s as 5 4 Transporting the Machine ee 5 Cautions and Warnings ee 5 General Machine Description ee 7 Nameplate u 7 uw umo bos w w w OS Eom k w w SA eee teen quu a 434x243 4335 8 Operator Controls web we a ee ee O3 X x X XC RC RU SUR we 8 Know Your Machine Major components ees 9 Specifications ss bute eek c a w w 6 Nox S WX xd w a x anak h w es wg Q Q eH 10 Maintenance Schedule celeron s 13 Burnishing System
19. achine which is often referred to as the Model Number and Serial Number Model PBU 27KBCATCLDC Part No 56381409 Serial No 3000050657 Fuel Propane GVW 3081b 140kg Type LP Floor cleaning machine Code K10 re NE Qu Figure 1 Nameplate Location Figure 2 Nameplate Location Operator Controls 4 Ignition Carb Gard Key Indicators f Figure 4 Controls Non Carb Gard Figure 5 Controls Carb Gard Service Manual PBU Propane Floor Burnisher General Information 9 Know Your Machine Major components Air Cleaner Element Y Oil Filland Dip Stick Carb Gard Controller Oil Pressure Switch Carb Gard Control Panel Figure 3 Major Components Service Manual PBU Propane Floor Burnisher General Information Specifications See other system chapters for specifications not listed here Model 21KBCAT 21KB 27KB 27KBCL 27KBCAT 21KBCATCLST Part 56381402 56381404 56381405 56381406 56381407 Number 27 68 cm Muffler Carb Gard Pad Speed Pad Speed Pad Speed Pad Speed Pad Speed Pad Speed Eng 2100 RPM 2100 RPM 1500 RPM 1500 RPM 1500 RPM 3600 RPM Pad Speed Pad Speed Pad Speed Pad Speed Pad Speed Pad Speed Eng 1750 RPM 1750 RPM 1250 RPM 1250 RPM 1250 RPM 3000 RPM Propane 20 Ib 9 1 kg Capacity 80 Safety Fill Tank Auto Fuel Yes Yes Yes Yes Yes Shutoff Low Oil Yes Yes Yes Yes Yes Shutdown Yes Sound 87 dB LpA 3dB KpA Pressure
20. aust manifold enough time to warm up During this time it 1s okay to operate the burnisher 2 After 3 minutes the Alert LED will stop flashing a If the engine is idling then the YELLOW Idle LED will begin flashing This allows the engine to idle for up to 2 minutes b After 2 minutes the engine will shut down and the idle LED will remain solid to notify the operator why the machine shut down Note If this occurs simply turn the key switch to OFF This will reset the Carb Gard Restart the engine normally to continue operation c If at any time before the 2 minute countdown the engine is revved up to full throttle the LED will stop flashing and the Carb Gard will begin monitoring the oxygen sensor d If the engine is allowed to slow back down to the idle position the idle LED will again start flashing for another 2 minutes wl Note Every time the engine 1s revved up and allowed to slow down the 2 minute countdown T restarts itself 3 Once the engine 1s revved up the Carb Gard begins monitoring the oxygen sensor a If at any time during full throttle the Carb Gard senses a higher than normal oxygen sensor output voltage it will activate the RED Service LED and 1t will begin flashing b If the RED service LED flashes continuously for 1 minute then the engine will shut down and the RED service LED will remain solid to notify the operator why the engine shut down normal range the service LED will s
21. cked replace the plug with a NE new one Use the standard spark plug or its equivalent Insulator A 17 Center Electrode B E A Z Plug Gap C LT Side Electrode D f Spark Plug Gap Inspection Figure 43 Spark Plug Measure the gap with a wire type thickness gauge If the gap is not correct carefully bend the side electrode with a suitable tool to obtain the correct gap Spark Plug Gap Standard 0 7 0 8 mm 0 028 0 031 in Service Manual PBU Propane Floor Burnisher Air Cleaner Element Removal Turn the fasteners A clockwise Remove the air cleaner cover B Loosen the clamp A Remove the intake hose B together with the element assembly C Loosen the clamp A Remove Intake Hose B Foam Element C Engine System d E Figure 44 Remove Air Cleaner Cover B vm r Figure 46 Remove Intake Hose and Foam Element 35 Service Manual PBU Propane Floor Burnisher Element Installation Install the form element A to the paper element b Install the intake hose A and tighten the clamp b Check that the element C 1s horizontally installed Install the intake hose A and tighten the clamp B Install the air cleaner cover A Turn the fasteners B counterclockwise Element Cleaning and Inspection Cleaning of paper air cleaner elements 1s not recommended Each air cleaner element should be replaced with
22. d Weight 292 lbs 302 Ibs 242 lbs 248 Ibs 292 lbs 132 5 132 5 kg 137 kg 110 kg 112 5 kg kg Length 66 69 51 5 DLS 99g 167 4 cm 175 3 cm 131 8 cm 131 8 cm 149 9 cm Width 293 29 5 23 3 23 3 29 3 59 cm 74 9 cm 59 cm 59 cm 74 4 cm Height 43 43 43 43 43 109 2 cm 109 2 cm 109 2 cm 109 2 cm 109 2 cm Warranty 2 Years Parts amp Labor Service Manual PBU Propane Floor Burnisher General Information 12 Model 21KBCATCL 21 53 CM Muffler Pad Speed 2100 RPM Eng 3600 RPM Pad Speed 1750 RPM Eng 3000 RPM 20 Ib 9 1 kg Capacity 80 Safety Fill Shutoff Shutdown Sound 87 dB LpA 3dB KpA Pressure ISO 11201 Agency EPA plus UL Approved Propane Components Approvals Yes CARB Certified California Air Resource Board 51 5 131 8 cm 23 3 59 cm 43 109 2 cm Service Manual PBU Propane Floor Burnisher General Information 13 Maintenance Schedule Interval Daily 8 Hour Every Every Every Every Every ITEM Break In 25 50 100 200 300 Hours Hours Hours Hours Hours Check or clean air intake screen Check for fuel and oil leakage Check for loose or lost nuts and screws EM MON Tighten nuts and screws as Check battery electrolyte level DEM Check and add engine oil L Change engine oil EN Change oil filter EN Clean air cleaner foam element ZEN Replace air cleaner paper element EE
23. d Inspection cee ee ee ee ns 25 Engine Top End Cylinder Head Inspection 25 Engine Top End Cylinder Head Cleaning 844 e244 BS 26 Engine Top End Cylinder Head Assembly Removal ee ee ens 26 Engine Top End Cylinder Head Assembly Installation ls 28 Engine Top End Valve Clearance Inspection nn 29 Valve Clearance Adjustment een n 30 Valve Seat Inspection s 2 ce xo 4 ee Rd Rue r EX EGR Hw om RB DOR Oe 0 ox o x3 31 EuDHEBHON System x v v 2 w 0 eee eee ww ara ee eA RES Suas 32 Engine Oil Level Inspection iu so oo mene daw we a e UE BRA OE e xx a 32 Engine Oil Change 244245 ue ded dope REOR UR Rae EERE BEG SE 32 Oil Filter Replacement J cwm ea He SG 9x ox ee eee Pee NOCHE SERS HE 33 Form Number 56043153 Page ii Service Manual PBU Floor Burnisher Electrical System u we s 5 Rae p w So O eee SU Ed K W S S Re R4 EI SW a 34 Spark Plug Cleaning and Inspection aa 34 AI CIE lcu eS s4 42 959m5b rM SEWER Ge 49 9 35 Element Removal s 4 kx o9 2x dodo RES BOB Ros GS FOROR NEA es d Wo a x 35 Element Installation xo do de a ue REO UR RAKE Ee ER OS eS 36 Element Cleaning and Inspection wx x bee E ROO BOE GE EX ok Oxo 36 Troubleshooting X d mp dd RUE 3 ee 9 HO 4 XX eRe TERS SS 37 Compression Measurement uw wv aw ear 9 deck OX EUR e a ee ee eO Y x x o9 37 Engine Tro
24. der Head Inspection Lay a straightedge A across the mating surface of the head at several different points and measure warp by inserting a thickness gauge B between the straightedge and head If warp exceeds the service limit repair the head by lapping the mating surface with emery paper secured to a surface plate first No 200 than No 400 If the mating surface is badly damaged replace the cylinder head Cylinder Head Warp Service Limit 0 05 mm 0 002 in Check the cylinder head for cracks or other damage Figure 18 Cylinder Head Inspection Service Manual PBU Propane Floor Burnisher Engine System Cracks not visible to the eye may be detected by coating the suspected area with mixture of 25 kerosene and 75 light engine oil Wipe the area dry and immediately apply a coating of zinc oxide dissolved in wood alcohol If a cracks is present the coating will become discolored at the defective area Ifa cracks is present in the cylinder head replace it Inspect the mating surface for burrs and nicks Engine Top End Cylinder Head Cleaning Scrape the carbon deposits from the cylinder head and the exhaust port with a suitable tool A N Note To avoid gouging use scrapers reine that are made of a material that will not cause damage Clean the head in a bath of high flash point solvent and dry it with compressed air Figure 19 Cylinder Head Cleaning sparks or flam
25. e anywhere near the working area this includes any appliance with a pilot light Do not use gasoline or a low flash point solvent to clean the cylinder head A fire or explosion could result Warning Clean the cylinder head in a well ventilated area and take care that there are no Engine Top End Cylinder Head Assembly Removal Remove Fan Housing Bolt A Lift Hook B Figure 20 Cylinder Head Assembly Removal 26 Service Manual PBU Propane Floor Burnisher Remove Intake Manifold Engine Shroud Spark Plugs Unscrew the rocker cover bolts in the order shown 1 to 5 Remove the cover A and the gasket When removing the 1 2 cylinder head set each piston at the top dead center T D C A of the compression stroke Remove Rocker Arm Push Rod Rocker Arm Bracket Loosen the cylinder head bolts 1 4 turn in the sequence as shown in the figure A Caution Ifthe above procedure is not followed the cylinder head may be warped during removal Repeat the sequence until all bolts are removed and lift off the cylinder head assembly e Note Mark the push rods and rocker TP arms so they can be installed in their original position during assembly Engine System Figure 23 Cylinder Head Assembly Removal 27 Service Manual PBU Propane Floor Burnisher Engine System 28 Engine Top End Cylinder Head Assembly Installation Clean th
26. e cable housing Do not over tighten The throttle lever must be able to freely advance or retract the throttle cable Move throttle lever to idle position Advance the throttle lever fully Verify high speed engine RPM is 3500 to 3600 Move throttle lever to idle position Verify low speed engine RPM is 1600 to 1700 Engine System 50 Service Manual PBU Propane Floor Burnisher oO Throttle Lever in Idle Position ete Figure 66 Throttle Lever in Idle Position Models without Clutch Figure 67 Throttle Lever in Idle Position Models with Clutch Service Manual PBU Propane Floor Burnisher 14 The idle speed throttle set screw must not push on the plate beneath it Loosen the jam nut that secures the idle speed throttle set screw Adjust the idle speed throttle set screw so that it does not make contact with the plate Tighten the jam nut to secure the idle speed throttle set screw at this position 15 Measure the exhaust Carbon Monoxide content An exhaust analyzer is required for this test measurement Acceptable test measurement results PBU with Muffler version RPM Range 1600 1700 Target CO 0 1496 Max CO 0 296 Target HC 168 ppm Max HC 500 ppm NOx Less than 80 ppm Max CO 0 02 Max HC 50 ppm If the test results are unacceptable repeat the procedure above beginning at Step 2 16 Place a small amount of 242 Loctite at the edge of the opening over th
27. e mating surfaces of the cylinder heads and cylinders Replace the gaskets with new ones Install the dowel pins A Set each piston at the T D C A of the compression stroke Put new gaskets and the cylinder head assemblies on each cylinder X Note Asthe head gaskets are coated a with sealing agents be careful not to damage the surfaces Tighten the cylinder head bolts following the tightening sequence as shown in the figure 1 CYLINDER 42 CYLINDER Torque Cylinder Head Bolts 27 4 N m 2 8 kgf m 20 ft 1b A Caution A torque wrench must be used to assure proper torque Improper tightening of the head bolts may result in warping of the cylinder head Figure 26 Cylinder Head Bolt Tightening Sequence Service Manual PBU Propane Floor Burnisher Engine System 29 Install Rocker Arm Bracket Push Rod Rocker Arm Install the new gaskets and rocker covers Tighten the rocker cover bolts following the tightening sequence as shown in the figure Torque Rocker Cover Bolts 5 9 N m 0 60 kgf m 52 in lb Install Spark Plugs Engine Shroud Lift Hook A Tighten Torque Lift Hook Bolt B 5 9 N m 0 60 kgf m 52 in 1b Install the removed parts Figure 28 Lift Hook Engine Top End Valve Clearance Inspection e Note Valve clearance must be checked when the engine is cold at room temperature x ne Remove the rocker covers Place the piston at t
28. e regulator adjustment screw Using a wide punch and hammer to compress the cap found taped to the side of the regulator into the Opening Catalyst Muffler version RPM Range 1600 1700 Target CO 0 007796 Engine System 51 Idle Speed Throttle Set e Screw m Figure 68 Idle Speed Set Screw Figure 69 Exhaust Analyzer NOx Less than 60 ppm Figure 70 Cap Compressed Into Opening Service Manual PBU Propane Floor Burnisher Engine System 52 LP Regulator Replacement After Serial Number 3000083760 After replacing the regulator the idle mixture regulator screw must be adjusted and capped off Correct adjustment requires the use of an exhaust analyzer Tools required Pulse tachometer 3 32 and 3 16 inch Allen wrench Phillips screwdriver Hammer Exhaust gas analyzer Punch large Set the idle mixture regulator screw to the base setting of 1 4 6 4 mm from the top of the regulator housing to the top of the screw head as shown Regulator Screw Connect a tachometer Start the engine and warm it up 3100 rpm maximum for 4 minutes Push throttle back to idle speed The idle speed should be 1 600 1 700 RPM If not correct adjust the idle stop screw on the carburetor Service Manual PBU Propane Floor Burnisher 4 Using an exhaust analyzer to measure the engine exhaust adjust the idle mixture screw in the regulator to obtain a Muffler with Catalyst at
29. ect width A and even all the way around not be valid Good A Too Wide B Too Narrow C Uneven D If the valve seating pattern is not correct repair the seat Valve Seating Surface Width STD Exhaust 0 8 1 4 mm 0 031 0 055 in Intake 0 8 1 4 mm 0 031 0 055 in Figure 35 Seating Pattern Service Manual PBU Propane Floor Burnisher Engine System 32 Lubrication System Engine Oil Level Inspection o Place the engine on a level surface Remove the oil filler cap A and wipe its dipstick B with a clean cloth Insert the dipstick into tube C without screwing it in then check the oil level o The oil level should be the operating range grid area D on the dipstick If the oil level is ADD range E add enough engine oil to bring oil level to the operating range f Figure 36 Dipstick Caution Do not add more oil above the operating range Excess oil will cause a smoking condition Use the same type and make of oil that is already in the engine N Note Ifthe engine oil type and make are vine unknown use any brand of the specified oil to top up the level in preference to running the engine with the oil level low Then at your earliest convenience change the oil completely Figure 37 Oil Level on Dipstick Ifthe oil level is FULL range F drain the excess oil by loosening the quick drain fitting Engine Oil Change Change the oil af
30. ects or other reproductive harm In certain locations including the State of California purchasers of these Products that place them in service at an employment job site or a publicly accessible space are required by regulation to make certain notices warnings or disclosures regarding the chemicals that are or may be contained in the Products at or about such work sites It is the purchaser s responsibility to know the content of and to comply with any laws and regulations relating to the use of these Products in such environments The Manufacturer disclaims any responsibility to advise purchasers of any specific requirements that may be applicable to the use of the Products in such environments Deployment of a monitor detector is essential for the safe operation of any equipment that has the potential to produce CO CO sensors detectors became available on the mass market around 1978 At present several brands sell in the fifty dollar range The main differences between the technologies involved are battery or electric and Semiconductor or Biomimetic types Detectors for carbon monoxide CO are manufactured and marketed for use in either the home or occupational industrial settings The detectors for home use are devices that will sound an alarm before CO concentrations in the home become hazardous There is an Underwriters Laboratories Inc performance standard UL 2034 for residential CO detectors Detectors currently available on the marke
31. ended with reference to the operator s position that 1s to say 1n operating position with the hands on the handlebar 4 Service Manual PBU Propane Floor Burnisher General Information Transporting the Machine Caution Before transporting the machine on an open truck or trailer make sure that The machine is tied down securely e All access doors and covers are secured tape and strap as needed Cautions and Warnings lt gt Danger lt is the owner operator s responsibility to ensure that an air exchange blower either of positive or negative pressure is used in any location where a propane floor care machine is being operated to support a sufficient fresh air supply to the operator during use of such a machine OSHA and other County State or Federal Agencies publish guidelines for safe machine usage regarding exhaust emissions and CO exposure in the workplace Failure on the part of the owner operator to ensure that a propane floor care machine is operated safely in accordance with OSHA or local state indoor air quality guidelines in a given location may lead to injury sickness or even loss of life To be completely aware of what local authorities may require contact the Fire Marshal of your community This Owner s Manual Safety Procedures Guide has been prepared for the promotion of educational purposes only and does not claim or assume any responsibility for the operator s actions or safety Danger All LPG
32. g End Gap To 0 mm 0 028 in Second 0 9 mm 0 035 in 1 05 mm 0 041 in Piston Pin Outside Diameter 15 96 mm 0 628 in Piston Pin Hole Inside Diameter 16 08 mm 0 633 in Connecting Rod Small End Inside 16 05 mm 0 632 in Diameter O O Cylinder Inside Diameter Standard Cylinder 73 10 mm 2 878 in 0 50 mm Oversize Cylinder 73 60 mm 2 898 in Cylinder Inside Diameter Out 0 05 mm 0 002 in Round Valve Clearance C1 Intake Exhaust 10 0 15 mm 0 0039 0 059 in Valve Seating Surface Angle Intake Exhaust Valve Seating Surface Width Intake 0 8 1 4 mm 0 031 0 055 in Exhaust 0 8 1 4 mm 0 031 0 055 in Service Manual PBU Propane Floor Burnisher Engine System 57 ltem Service Limit Valves Guide Inside Diameters lll I I I I Intake Exhaust 6 000 6 012 mm 0 2362 0 2367 in Cylinder Inside Diameter p Standard Cylinder 72 98 73 00 mm 2 873 2 874 in 0 50 mm Oversize Cylinder 73 48 73 50 mm 2 893 2894 in Ignition Coil Specifications Measure the ignition coll winding resistance as shown in the table Ignition Coil Winding Resistance A 5 10 20kQ 18 28kQ B KM GBOS9 P Figure 72 Ignition Coil Inspection Special Tools Exhaust Gas Analyzer
33. gine System 41 e Incorrect governor linkage Correct adjustment e Faulty governor spring Replace Governor assy malfunctioning Check Problem in the governor system Engine malfunctions at high speed Is revolution fluctuation of relatively large period produced YES e Entry of dust and air into fuel Clean filter or fuel pipe when a load is applied Engine malfunctions at low speed Remove spark plug and check e Faulty plug insulation Replace spark by cranking engine while Fouled electrodes Clean having the plug touched against e Faulty ignition coil Replace engine block Incorrect air gap Correct WARNING Keep the plug as far away as possible from the plug hole To avoid an electric shock do not hold the plug itself Make sure to hold the plug cap Is unusual smoke emitted out of muffler Directly and gradually open YES e Plugged in carburetor interior Disassemble and throttle valve by hand Does the clean revolution drop or does engine NO stall at a certain position Is air sucked through carburetor YES Loose flange nuts Retighten flange NO e Damaged gasket Replace Are valve clearances of normal NO e Compression leakage Adjust valve clearance values e Wrong valve timing Correct alignment of YES timing gear marks Is alignment of timing gear NO e Largely deviated valve timing Correct alignment of marks correct timing gear marks YES Overrich fuel in pilot system Turn
34. he regulator adjustment screw counterclockwise two full turns 8 Using a Phillips screwdriver and the tachometer turn the butterfly valve adjustment screw to achieve an engine idle RPM of approximately 1600 to 1700 9 Repeat steps 6 7 and 8 above to verify Us Us I regulator adjustments ean E j f EU E Butterfly Valve i Adjustment Screw Ef i l i kM 1 t 1 w Figure 61 Butterfly Adjustment Screw Service Manual PBU Propane Floor Burnisher 10 Advance the throttle a Models without a clutch advance the throttle lever fully lever locks into detent to achieve the highest possible engine RPM b Models with a clutch pull the throttle lever up against handle to achieve the highest possible engine RPM 11 Loosen the Jam nut that secures the high speed throttle set screw f Using the tachometer adjust the high speed throttle set screw so that the engine runs at 4 3500 to 3600 RPM when the throttle lever is I fully advanced Tighten the Jam nut to secure w pa the high speed throttle set screw at this High Speed position Throttle Set Screw CAUTION use of gloves is recommended Figure 64 High Speed Throttle Screw Engine System 49 Advance Throttle Pull Throttle Lever Up 12 15 Check the tightness of the throttle cable clamp If necessary tighten the throttle cable housing clamp screws to firmly secure the throttl
35. he top dead center TDC of the compression stroke by turning the crankshaft clockwise facing the flywheel No 1 Cylinder The left projection A on the flywheel is faced with the right leg B on the 1 ignition coil C as shown in the figure Check the intake and exhaust valves are closed completely if not turn the flywheel one turn 860 clockwise and face the left projection with the right leg again Figure 29 Check Closing of Valves Service Manual PBU Propane Floor Burnisher Engine System 30 No 2 Cylinder The left projection A on the flywheel is faced with the right leg B on the 1 ignition coil C as shown in the figure Check the intake and exhaust valves are closed completely if not turn the flywheel one turn 860 clockwise and face the left projection with the right leg again Then check the valve clearance Using a thickness gauge A measure the valve clearance between the rocker arm B and the valve stem end If the valve clearance is incorrect adjust it e Valve Clearance when cold Intake Exhaust 0 10 0 15 mm 0 004 0 006 in Valve Clearance Adjustment Since valve repairs change the valve clearance adjust the valve clearance to the specification Turn the crankshaft 1n proper direction until the piston is at the TDC of the compression stroke as described above Loosen the locknut A and adjusting bolt B nsert a 0 05 mm 0 0020 in
36. in Clean engine e Excessive engine load Adjust e Engine overheating See Engine power loss e Faulty ignition coil Replace Service Manual PBU Propane Floor Burnisher Engine System 43 Starter Motor Troubleshooting Guide 1 Disconnect spark plug caps from the spark plugs 2 Turn engine switch to START position and check condition Warning Engine may be cranked in this test Do not touch any rotating parts of engine and equipment during test Caution If starter does not stop by engine switch OFF disconnect negative cable from battery as soon as possible Starter does not rotate NO Faulty battery Charge or replace e Faulty leads or connection Repair or replace e Melted fuse Replace e Faulty engine switch Repair or replace YES e Faulty solenoid switch Replace Is click sound from solenoid switch Weak battery Charge or replace Faulty leads or connection Repair or replace Solenoid to motor Faulty solenoid switch Replace Main terminal in solenoid e Faulty starter motor Repair or replace Starter rotates but slow Is battery normal and well NO e Weak battery Charge or replace charged YES e Faulty leads or connection Repair or replace Solenoid to motor e Faulty solenoid switch Replace Main terminal in solenoid e Faulty starter motor Repair or replace e Faulty engine Repair or replace Starter rotates
37. in pilot screw by a minor extent Service Manual PBU Propane Floor Burnisher Engine System 42 Fuel consumption is excessive Oil consumption is excessive Is compression sufficient YES NO Engine backfires Engine knocks ES gt Is compression sufficient Y NO e High idling RPM Adjust Choke partially closed Open choke Worn piston piston rings Replace Stuck piston Clean or replace Worn cylinder bore Bore or replace oose of cylinder head bolt Retighten e Faulty valve seat contact Lap e Plunge up of valve Adjust valve clearance Wrong valve timing Adjust Broken valve spring Replace e Stuck valve Clean or replace e Plugged oil ring groove Clean e High oil level Adjust Worn valve stem and valve guide Replace e Oil leakage along governor shaft Replace Oil leakage from oil seal Replace e Oil leakage from mounting surface Replace gasket e Oil leakage from drain bolt Retighten or replace gasket e Clogged breather valve Clean Drain back hole in breather Clean chamber plugged Incorrect oil viscosity Correct Worn piston rings Replace e Stuck piston rings Clean or replace Worn cylinder bore Bore or replace Broken piston ring Replace oose carburetor or intake manifold eloose cylinder head bolt or leaking head gasket e Burned or sticking inlet valve e Faulty ignition coil e Carburetor not properly adjusted Excessive carbon deposit
38. mounting bolt to hold the tensioner in place Crank the engine over a few times to seat the belt and then recheck the belt tension If it is incorrect loosen the mounting screw and reposition the tensioner as necessary Relocating Belt Tensioner Mounting Position Some 27 Inch Models These instructions only apply to the following models 56381405 56381406 56381407 56381413 1 Remove the drive belt 2 Loosen all 3 engine mounting bolts and back out approximately 1 2 inch 13mm This will allow you to lift the engine slightly and will aid in installing the tensioner mounting bolt in the new location later 3 Remove the tensioner Engine Mounting Bolts Service Manual PBU Propane Floor Burnisher Burnishing System 17 4 Working from the bottom of the deck locate the position of the new mounting bolt hole by scribing two arcs from fixed positions and finding their intersecting point a Using a tape measure scribe the first arc 3 11 16 inches from the center of the original tensioner mounting bolt b Using a tape measure scribe the second arc 7 inches from the center of the forward engine mounting bolt head 5 Drill a 3 8 hole where the arcs intersect Drill 3 8 inch hole 6 Install tensioner mounting bolt through the new hole just made and install the tensioner finger tight Old Location EN 8 Tighten the engine mounting bolts Location 7 Plug the old mounting bolt hole using a bolt
39. ne to run poorly or not at all In addition overfilling allows liquid propane to enter the fuel control system possibly ruining the lockoff regulator assembly This voids the warranty on affected parts of the machine To avoid problems read and understand fully the section Filling and Storing Propane Tanks General Machine Description The PBU Propane Floor Burnisher is manufactured for two applications a buffer burnisher and a floor stripper Both designs are portable Buffers operate at high speed to produce high gloss floor surfaces The unit 1s powered by a 4 stroke air cooled v twin liquid propane fueled engine During operation the unit buffing wheel contacts the floor to provide buffing action Operator walking speed behind the unit determines results The operator should avoid loose tile electric outlets door thresholds and any object which may come in contact with the pad other than the floor itself When equipped the Carb Gard system is a warning device that alerts the operator to the need for engine service Carb Gard monitors an oxygen sensor for an indication of relative air fuel mixture If the mixture exceeds an allowable limit for more than one minute Carb Gard will shut down the engine 7 Service Manual PBU Propane Floor Burnisher General Information 8 Nameplate The nameplate contains important identification information which will be needed when ordering parts Model Name Part No Part number of the m
40. nical service operations This manual covers the Nilfisk Advance models 56381402 56381404 56381405 56381406 56381407 56381408 56381409 56381410 propane stripper 56381412 21 Diamatic machine and 56381413 27 Diamatic machine The cover page of this manual lists each machine part number that the manual applies to Compare the model number of the machine you are working on to the model numbers listed on the cover page to be sure you are using the correct manual Document Revision History November 2011 Engine Fuel System and RPM changes o General Information Brush Speed specifications Engine System Added section for adjusting regulator after serial number 3000083760 Updated Specification table High Idle Speed values Burnishing System Added information for replacing the drive belt tensioner Other Reference Manuals The following documents contain parts information and instructions for machine operation Parts List Form 56091022 applies to the following models 56381402 21KBCAT 56381404 21KB 56381405 27KB 56381406 27KBCL 56381407 27KBCAT Parts List Form 56091023 applies to the following models 56381408 21K BCATCLDC 56381409 27KBCATCLDC Parts List Form 56091024 applies to the following model 556381410 21KBCATCLST Parts List Form 56091025 applies to the following models 56381412 MPS 1721 56381413 MPS 1727 Conventions Forward backward front rear left or right are int
41. oor Burnisher Engine System 39 Engine Troubleshooting Guide This chart describes typical troubleshooting procedures from engine manual Engine hard to start Remove spark plug and Are sparks produced check spark by cranking when spark plug is YES 3 Faulty spark plug SEPALO engine while having the replaced plug touched against NO engine block WARNING Are sparks produced YES gt eFaulty ignition coil Replace Keep the plug as far away when ignition coil is as possible from the plug replaced NO elncorrect air gap Correct eFaulty flywheel Replace hole eNo fuel in the tank Add eEntry of dust or air into Clean fuel hose or filter To avoid an electric shock do not hold the plug itself Make sure to hold the plug cap Make starting attempts a number of times and then remove spark plug and observe electrodes Are they wet Is compression sufficient eExcessive use of choke Remove the plug and turn the crankshaft without loading ePlugged air cleaner Clean or replace eWorn piston piston rings Replace eStuck piston rings Clean or replace eWorn cylinder bore Bore or replace eLoose of cylinder head FRetighten bolt eFaulty contact of valve Lap seat ePlunge up by valve Adjust valve clearance eWarped cylinder head Replace eBroken valve spring Replace eStuck valve Clean or replace eBurned head gasket Replace Check carburetor eCheck for plugged fuel line eCheck for plugged air
42. p Standard 0 2 0 4 mm 0 008 0 016 in Torque Ignition Coil Bolts 5 9 N m 0 60 kgf m 52 in lb e Note Use the above procedure to T insure proper coil air gap Fit the 1gnition coil leads A to the each engine shroud groove B Install the spark plug cap C Attach the solenoid valve connector lead A and stop switch lead B to the 1gnition coil lead C with the band D Engine System Figure 53 Air Gap Figure 55 Attach Leads 45 Service Manual PBU Propane Floor Burnisher Engine System 46 Spark Plug Removal Carefully pull the plug caps from the spark plugs Remove the spark plugs using a suitable plug wrench Spark Plug Installation Insert the spark plug vertically into the plug hole with the plug installed in the plug wrench Tighten the plugs Torque Spark Plugs 22 N m 2 2 kgf m 16 ft lb Fit the plug caps securely Pull up the spark plug caps lightly to make sure of the installation of the spark plug caps Spark Plug Cleaning and Inspection Refer to the Maintenance schedule Spark Plug Gap Inspection Refer to the Maintenance schedule Service Manual PBU Propane Floor Burnisher Engine System 47 LP Regulator Replacement Before Serial Number 3000083761 After replacing the regulator the idle mixture regulator screw must be adjusted and capped off Correct adjustment requires the use of an exhaust analyzer Tools required Pulse tachometer 3 32 and 3 16
43. pational Safety and Health at 1 800 35 NIOSH 1 800 356 4674 6 Service Manual PBU Propane Floor Burnisher General Information are dependent on engine tune up and air filter replacement CO concentration production skyrockets when the air to fuel ratio becomes fuel rich Follow the recommended Maintenance Schedule for the engine found in the Engine Operator Owner Manual as well as the Maintenance And Adjustments schedule found in the Propane Floor Equipment Operator s Manual that were supplied with the equipment 1 Warning The proper maintenance of equipment is vital to safe operation LPG engines CO SAFETY EQUIPMENT AVAILABLE BY MANUFACTURER Carb Gard automated emissions monitoring will shut down the engine when high emissions are detected Three way type catalytic converter to scrub CO Hydro Carbons HC and Nitrides of Oxygen NOx from the engine exhaust providing the lowest possible emissions NOTE Dead Stop CO Detector provided in Literature Pack Replacement part number 98758A CO SAFETY EQUIPMENT AVAILABLE ON THE MARKET Positive or negative pressure high volume ventilation blower capable of exchanging complete room air volume to maintain CO levels below OSHA exposure limits Digital combustion analyzers for tail pipe emissions monitoring OSHA Approved CO Monitor Caution Overfilling the propane tank is the number one cause of problems with a propane machine This can cause the engi
44. ransistor base current With the transistor rapidly shutting off the current at the primary coil counter electromotive force is generated and voltage in hundreds volts is induced through the primary winding L1 thereby producing extremely high voltage at the secondary winding L2 When this secondary voltage steps up to k volts ionization meaning ignition occurs across the electrodes at the spark plug SP The trigger sensor located internally in the ignition system is set to give constant ignition timing according to engine speed and temperature The diode D1 located at the ignition shut off circuit prevents misconnection of battery voltage protecting the internal components of the ignition system When the stop switch SW is set at the closed position primary voltage is routed to ground not allowing igniting operation Maintenance and Adjustments Air Cleaner Element Cleaning and Inspection Cleaning of paper air cleaner elements 1s not recommended Each air cleaner element should be replaced with a new air cleaner element at the maintenance time as shown in the maintenance chart chart above e Note Operating in dusty condition may require more frequent maintenance than shown in the M Remove the foam and paper elements e Clean the foam element A in a bath of detergent and water and let the element air dry thoroughly Figure 17 Air Cleaner Element Engine Top End Cylin
45. st be rotated slightly to free the belt for removal EA Assembl j ay iid E Yi Idler _ Assembly 1 To remove tension on the drive belt use a wrench to grip the idler assembly Pull down on the wrench to rotate the idler assembly slightly and free the belt 2 Position the replacement belt on the drive or clutch and burnishing disc pulleys Again use the wrench to pull the idler assembly down slightly Position the belt in the idler assembly pulley and allow the idler assembly to return to its normal position Check the belt to make certain that it is fully seated in all three pulleys Figure 11 Pull Down on Idler Assembly Service Manual PBU Propane Floor Burnisher Burnishing System 16 Replace Drive Belt Tensioner Note On some 27 inch models 56381405 56381406 56381407 56381413 the tensioner location should be updated when replacing the tensioner if it has not already been moved See Relocating Belt Tensioner Mounting Position below for further information 1 Remove the drive belt 2 Remove the tensioner 3 Install the tensioner with the mounting bolt finger tight and install the drive belt 4 Using a large wrench on the large nut of the tensioner arm and aback up wrench on the mounting bolt rotate the arm against spring pressure until the indicator marks on the tensioner arm align near the third index mark on the stationary tensioner body as shown in the photo Tighten the
46. t are battery powered wall mount Operator worn portable personal protective plug in or hard wired Some models incorporate a visual display of the parts per million ppm concentration of CO present in the home For more information on CO detectors for home use call the Consumer Product Safety Commission Hotline at 1 800 638 2772 CO detectors for use in residential settings are not designed for use in typical workplace settings Monitoring requirements in an occupational setting are different from monitoring requirements in the home In the workplace it is frequently necessary to monitor a worker s exposure to carbon monoxide over an entire work shift and determine the time weighted average TWA concentration of the exposure It may also be necessary to have carbon monoxide monitors with alarm capabilities in the workplace The direct reading instruments are frequently equipped with audio and or visual alarms and may be used for area and or personal exposure monitoring Some have microprocessors and memory for storing CO concentration readings taken during the day It is significant to note that some of the devices mentioned for workplace CO monitoring are not capable of monitoring TWAs and not all are equipped with alarms The appropriate personal protective monitor must be chosen on an application by application basis For more information on the availability of workplace CO monitors or their application call the National Institute for Occu
47. ter first 8 hours of operation Thereafter change oil every 50 hours Start and warm up the engine to drain the oil easily Stop the engine CILE Place the unit on a level surface Tube Usea suitable container to contain drained engine oil Release the drain tube from the clamp Position the drain tube into the container Twist the quick open oil drain fitting approximately 1 4 turn to allow the oil to drain from the engine into the container When all oil has drained twist the oil drain fitting Figure 38 Oil Drain Components closed and secure the drain hose Warning Be careful of hot oil when draining It may be hot enough to burn you severely Service Manual PBU Propane Floor Burnisher Remove the oil filler cap and pour in the specified type and the amount of oil Engine Oil Grade SJ or higher class Viscosity SAE40 SAE30 SAE10W 30 SAE10W 40 or SAE5W 20 Capacity When the oil filter is not removed 1 5 L 1 6 US qt When the oil filter is removed 1 7 L 1 8 US qt Check the O ring A on the oil filler cap for damage Replace the oil filler cap assembly if O ring 1s damaged When checking the oil level do not turn oil filler cap on threads Wn Note Some increase in oil consumption may NA a be expected when a multi grade engine oil 10W 30 10W 40 5W 20 is used Check the oil level more frequently than recommended interval Oil Filter Replacement Drain the
48. to chassis A 4 P ground ys E e at 9M j WZ Connect Positive ps 4 Remove air cleaner housing p 5 Start and warm up engine Set the multimeter to VDC dT BE 4 Dl J Wi 6 While at high idle with warm engine note pF rH aki L the VDC meter reading MHES 7 Remove the air intake filter Figure 14 Sensor Test Service Manual PBU Propane Floor Burnisher 10 Use a sturdy clean flat object to partially block the air intake NOT YOUR HAND Note the multimeter reading while the air intake 1s restricted at high idle With a tuned engine and properly adjusted LP regulator an oxygen sensor should produce 9 VDC or more when the engine is forced to run rich and below 2 VDC when the engine is forced to run lean If the oxygen sensor does not produce these VDC values when tested it should be replaced Figure 15 Partially Blocked Air Intake Electrical System 21 22 Electrical System Service Manual PBU Propane Floor Burnisher LZLL SdW LFL8 9S LZ4L SdW ZLVLBE9S LYOSMAZZ LOVLEE9S TDEMZZ 90rL8 96 8M42 S0rL889S HMLZ rOrL8 9S LYOSMLIZ ZOFL8 9S SJIepoW 94 aanbig iring Diagrams i m 9 dWv St MOT8OTS ASNA HOLIMS 3NION3 dal3mWHnoH Taf GION310S Ndg ddd S848 qs ND LYVLS NNd c JJO I ALINNILNOO NOILIS
49. top flashing If the voltage rises to higher than normal the service LED will start flashing again ONLY after the service LED continuously flashes for 1 minute will it shut down the engine e Note Carb Gard continuously monitors O2 sensor electrical voltage If the voltage drops into the un Service Manual PBU Propane Floor Burnisher Electrical System 20 Component Locations a Carb Gard a A gt Controller Z y Carb Gard or Oxygen Sensor P r Carb Gard I3 System Panel Figure 13 Carb Gard System Components Troubleshooting Check the following if unexplained engine shutdown occurs Oil pressure switch function assumes engine can be restarted Fuellock off solenoid function Primary regulator pressure If too high the regulator may require replacement Ifthe primary regulator pressure is within specifications the regulator orifice may be faulty and the regulator may require replacement If the above items have been eliminated as causes of engine shut down test the Carb Gard oxygen sensor for possible malfunction If the oxygen sensor test described below determines that the sensor is functioning properly replace the Carb Gard system Oxygen Sensor Test Requires digital multi meter Connect Ground Air Intake Filter 1 Connect jumper between oxygen sensor lead and harness plug 2 Connect positive multimeter lead to the jumper wire 3 Connect negative multimeter lead
50. ubleshooting Guide 1 lens 39 Starter Motor Troubleshooting Guide es 43 Removal and Installation ens 44 Ignition Coil Removal d a ar e e e ee s e e xx e s s 44 Ignition Coil Installation o vow ur xm o P o DE L 44 Spark Plug Removal s sx o 08x ede 9m RO Yo oy wo ORO we do E ho o4 9 4E 46 Spark Plug Installation 2s eee ee XE UR OE ROC QE OR duin OR dO EO s d 46 Spark Plug Cleaning and Inspection es 46 Spark Plug Gap Inspection s uacua ue uo8 e REGE OX P L 46 LP Regulator Replacement Before Serial Number 3000083761 47 LP Regulator Replacement After Serial Number 3000083760 52 Replace P QI a y y 2 2 lt xe SEES Re X gud iged owe 3 93953 4 54 Specifications 2 CUCPRPPPTT rrr 55 Engine Specifications sus lt lt o 3 GRECE X ORE P S GR Se Re eee Q CUR 55 Ignition Coil Specifications sso so ow bb ew eee EO OR X X e e EES 57 Special TOOlS s x sxXx ez k RXRExuRWGEE wx 9453 S W w a k x k Q amp ages s 57 Form Number 56043153 Page iii Service Manual PBU Propane Floor Burnisher General Information General Information Service Manual Purpose and Application This Service Manual is a resource for professional service technicians It provides information for understanding how the machine operates where components are located basic troubleshooting maintenance and mecha
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