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PBU Propane Floor Burnisher
21 KACAT
Base Model
21 KACAT CLDC
Dust Control Model
Service Manual
Model Numbers:
56384165
PBU 21KACAT
56384166
PBU 27KACAT
New & Reconditioned Equipment - www.southeasternequipment.net
27 KACAT
Base Model
27 KACAT CLDC
Dust Control Model
56384167
PBU 21KACATCLDC
56384168
PBU 27KACATCLDC
04/15 Form No. 56043169
English
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Table of Contents
Troubleshooting
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Summary of Contents for Nilfisk-Advance PBU 21KACAT
- Page 1 Base Model Base Model 21 KACAT CLDC 27 KACAT CLDC Dust Control Model Dust Control Model Service Manual Model Numbers: 56384165 PBU 21KACAT 56384167 PBU 21KACATCLDC 56384166 PBU 27KACAT 56384168 PBU 27KACATCLDC English 04/15 Form No. 56043169 New & Reconditioned Equipment - www.southeasternequipment.net...
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Page 2: Table Of Contents
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Contents Contents General Information General Machine Description Service Manual Purpose and Application Other Reference Manuals and Information Sources Document Revision History Safety Information Symbols General Safety Messages Nameplate Component Locations Specifications... - Page 3 New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Contents Top End, Heads Compression Test Cooling Fan Cover Valve Cover Valve Clearance Cylinder Head Removal Cylinder Head Cleaning and Inspection Valve Removal Valve and Seat Inspection Cylinder Head Replacement Engine Specifications Special Tools...
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Page 4: General Information
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher General Information General Information General Machine Description The PBU machine is a propane-powered floor burnisher, with replaceable pads for burnishing floor surfaces. The machine is manually propelled, and the buffing pad rotates at high speed to produce high gloss floor surfaces The PBU is powered by a 4-stroke, air-cooled, v-twin, propane-engine When equipped with the Carb Gard system, an oxygen sensor monitors exhaust oxygen content 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... -
Page 5: General Safety Messages
A properly filled cylinder should not exceed 80% of the rated capacity. Caution: − Do not make unauthorized modifications or alterations to this machine. Nilfisk-Advance assumes no liabilities for injury or damage resulting from an unauthorized modification or alteration to the machine. Any unauthorized modification or alteration to this machine voids all warranties. -
Page 6: Nameplate
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher General Information Nameplate The machine nameplate is located on the interior face of the handle upright, and contains the machine model and serial number Component Locations The following images show the locations of some of the primary components of the machine •... -
Page 7: Specifications
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher General Information Specifications (See other system chapters for specifications not listed here.) Model 21KACAT 27KACAT 21KACAT CLDC 27KACAT CLDC Part Number 56384165 56384166 56384167 56384168 Pad Size 21”... -
Page 8: Maintenance Schedule
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher General Information Maintenance Schedule Interval Daily 8 Hour Every Every Every Every Every ITEM (Break In) Hours Hours Hours Hours Hours Check or clean air intake screen •... -
Page 9: Burnishing System
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Burnishing System Burnishing System Functional Description The burnishing system consists of a replaceable burnishing pad and pad holder, which is driven by a belt from the engine’s output shaft Belt tension is controlled by a spring loaded idler pulley Some units are equipped with a clutch on the engine output shaft to disconnect the drive pulley when not in use The clutch is electrically actuated, and controlled by a switch on the operator’s handle Units equipped with dust control have an aluminum shroud which covers most of the burnisher drive components... -
Page 10: Troubleshooting
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Burnishing System Troubleshooting Problem Cause Correction • Burnishing pad turns When the drive belt slips • Inspect the drive belt for glazing (smooth glassy slow the pad will rotate slower surface on the tapered faces). -
Page 11: Removal And Installation
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Burnishing System Removal and Installation Burnishing Pad Holder The burnishing pad holder may need to be replaced if it becomes damaged and no longer holds the burnishing pad securely It may also need to be removed as a prerequisite to other maintenance procedures Close the propane service valve and remove the propane... -
Page 12: Drive Belt
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Burnishing System Drive Belt The drive belt needs to be replaced if it becomes worn, frayed, or glazed Glazing is caused by the belt slipping against the pulleys, which causes the belt to slip even more A glazed belt has a shiny texture of the sloped edges that contact the pulleys Pulley Dust Control Model... -
Page 13: Burnishing Clutch
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Burnishing System Burnishing Clutch The burnishing clutch is an optional accessory on models with dust control It is a 12 volt magnetically actuated clutch that disengages the burnishing drive when not in use Close the propane valve, tip the machine into the pad change position, and remove the Burnishing Pad Holder... -
Page 14: Engine System
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Engine System Component Locations • Starter Solenoid • Fuel Cutoff Valve • Muffler • Starter • Oil Dipstick • Air Filter • Voltage Regulator •... -
Page 15: Maintenance And Adjustments
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Maintenance and Adjustments This section includes maintenance and adjustment procedures associated with routine maintenance Additional procedures are located within the mechanical sections of this chapter Maintenance Specifications The table below contains a quick reference for common maintenance parameters Also refer to the complete list of... -
Page 16: Intake Air Filter
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Intake Air Filter The engine air intake has a 2-stage air filter: A washable pre-filter and a disposable main filter. The main filter prevents fine dust from entering the engine, and the pre-filter increases the life of the main filter by keeping coarse debris from clogging the filter. -
Page 17: Oil And Filter Change
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Oil and Filter Change The oil should be changed every 50 engine-hours, and the oil and filter should be changed every 100 engine- hours (every other oil change) Oil Change Parameters Oil Grade SJ or higher... -
Page 18: Spark Plug Change
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Spark Plug Change Spark plugs provide a view into the health of the engine When changing spark plugs it is a good idea to make note of the condition of the plugs to see if the engine is operating properly Normal spark plugs will generally have a light tan or gray color around the electrode If the spark plugs have a different appearance, additional engine troubleshooting should be completed There are many different signs of an unhealthy... -
Page 19: Troubleshooting
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Troubleshooting The following troubleshooting decision tree is courtesy of Kawasaki and contains information relating to both gasoline and propane engines New & Reconditioned Equipment - www.southeasternequipment.net... - Page 20 New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System New & Reconditioned Equipment - www.southeasternequipment.net...
- Page 21 New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System New & Reconditioned Equipment - www.southeasternequipment.net...
- Page 22 New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System New & Reconditioned Equipment - www.southeasternequipment.net...
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Page 24: Fuel System
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Fuel System The PBU fuel system functionally consists of the propane tank, pressure regulator, carburetor, mechanical governor, and operator throttle position selector The fuel (propane) is stored in the tank as a liquid, but is dispensed into the fuel system as a gas The fuel pressure in the tank is much too high to be used by the engine The pressure regulator reduces the pressure of the gas before it is delivered to the carburetor The pressure regulator does more than just reduce the pressure, however It also meters the amount of fuel... -
Page 25: Throttle High Idle Position
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Throttle High Idle Position This adjustment sets the upper limit of the Throttle Position Link Arm, which indirectly controls the high idle speed of the engine via the governor This adjustment may be completed on its own, or as a followup adjustment to adjusting the fuel mixture described on page 26 Start the engine and bring it up to operating temperature... -
Page 26: Fuel Regulator/Fuel Mixture
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Fuel Regulator/Fuel Mixture This adjustment sets the fuel flow for high and low idle, which determines the fuel to air mixture entering the engine This procedure requires the removal of the anti-tampering caps from the pressure regulator Make sure you have a new set of caps available before beginning the procedure The procedure below uses the oxygen sensor for evaluating the engine performance An exhaust gas analyzer may be used instead Use the parameters below if the exhaust gas analyzer is used... -
Page 27: Low Idle Mixture
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Low Idle Mixture Starting with a warm engine running at high idle, bring the throttle selector to the Slow position Check the voltage of the oxygen sensor It should be between 35 and 50 mV (0 035 - 0 050 V) If the oxygen sensor voltage is out of range, turn the Low Idle Mixture screw with increments of... -
Page 28: Intake Manifold
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Intake Manifold Removing the intake manifold is frequently a prerequisite procedure for removing the cylinder heads This procedure is based on the minimal amount of disassembly necessary to remove the manifold You may optionally choose to remove the carburetor from the manifold Shut off the propane service valve... -
Page 29: Exhaust System
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Exhaust System Muffler/Exhaust Manifold Caution: To avoid risk of serious burn, do not work on the exhaust until the engine has cooled. Remove the 2 bolts and washers (B) that secure the support bracket (C) to the #2 cylinder head Optionally, remove the bolt, washers, and nut... -
Page 30: Ignition/Electrical System
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Ignition/Electrical System Starter The starter consists of a 12-volt motor which drives a pinion Bendix Pinion gear to engage the flywheel of the engine to turn the engine. The Gear pinion gear is mounted to a bendix drive, which is a spiral gear When the motor first turns, inertia keeps the pinion gear from... -
Page 31: Voltage Regulator
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Voltage Regulator Voltage The voltage regulator takes the AC Regulator voltage from the engine’s generator and converts it to DC power and reduces the 13 to 15 VDC voltage to approximately 14 1 volts (DC) The most common sign of a failed voltage... -
Page 32: Ignition Coil
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Ignition Coil Troubleshooting The ignition coil is self-contained with no serviceable components So troubleshooting should be limited to pass/fail and component replacement Contrary to intuition, the ignition keyswitch does not provide power to the ignition coil Instead, the keyswitch grounds the coil circuit when the engine is not supposed to be... - Page 33 New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Replacement Remove the Intake Air Filter described on page 16 Filter Dipstick Remove the 5 screws that secure the fan cover to the engine, and remove the cover Note the position of the wire clamp and oil dipstick for the replacement Unplug the ignition wire (A) from the coil...
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Page 34: Carbgard System
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System CarbGard System CarbGard is an emissions monitoring device that monitors the exhaust emissions and will shut the engine down if the oxygen level is too low or too high The oxygen sensor must reach operating temperature before it will start to send signals to the CarbGard module A unit may shut down at a cold start up after one minute because the oxygen sensor did not reach required temperature to start to send a signal The oxygen sensor creates a small voltage based on the... -
Page 35: Top End, Heads
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Top End, Heads Compression Test A compression test is used to determine the health of the engine The engine pistons make 14mm compression as part of their normal combustion Fitting cycle You will need a compression tester (pressure... - Page 36 New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Interpreting the Results • Because compression results will vary from engine to engine, there is no specific “normal” compression value However, the minimum acceptable compression for this engine is: Min Comp: 483 kPa (70 psi) (hot engine) •...
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Page 37: Cooling Fan Cover
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Cooling Fan Cover Removing the cooling fan cover is a prerequisite to completing many of the engine top-end procedures Remove the Intake Air Filter described on page 16 Remove the 5 screws that secure the fan... -
Page 38: Valve Clearance
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Valve Clearance Make sure the engine is cool and at ambient air temperature before Right Post making any adjustments of Coil Optionally, remove the Cooling Fan Left Lobe Cover... -
Page 39: Cylinder Head Removal
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Cylinder Head Removal Remove the Intake Air Filter described on page 16 Remove the 5 screws (A) that secure the fan cover to the engine, and remove the cover Note the position of the wire clamp (B) and oil dipstick for the replacement Remove the... - Page 40 New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System 10 Remove the Valve Cover described on page 11 Before removing the rocker arms, set that cylinder to top-dead-center to remove pressure from the push rods Wiggle the rocker arms to make sure there is no pressure on them (Do this for each cylinder in-turn ) 12 Remove the rocker arm nuts (H) bolts (J), and...
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Page 41: Cylinder Head Cleaning And Inspection
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Cylinder Head Cleaning and Inspection Inspect for head warp by laying a straightedge across the head at several different points, and measure warp by Straight inserting a feeler gauge between the Edge... -
Page 42: Valve Removal
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Valve Removal The prerequisite for this procedure is that the heads are removed from the engine as described on page 39, which includes the rocker arm removal at step 11 on page 40 Using a suitable valve spring compressor,... - Page 43 New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System • If the valve seating pattern is not within limits, re-cut the valve seat and valve face with the following parameters: Valve Seat (Intake & Exhaust) Seat: 45°...
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Page 44: Cylinder Head Replacement
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Valve Guide Inside Diameter Service Limit (Intake & Exhaust): Inlet, Exhaust 6 08 mm (0 239 in ) Valve Spring Free Length Service Limit: Inlet, Exhaust 31 0 mm (1 22 in ) Cylinder Head Replacement The cylinder head replacement procedure is generally the reverse of the disassembly procedures Use the... - Page 45 New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Bolt Make sure the piston is at top-dead-center so that both cams are at their lowest (valves would be closed) Insert the push rods into the lifter valleys and make sure they are seated in the tappet hollows Flat Apply a light film of oil to the rocker eccentric collars.
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Page 46: Engine Specifications
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Engine Specifications Specification Item Type of Engine Forced air-cooled, vertical shaft, OHV, 4-stroke gasoline engine Cylinder Layout 90 V-Twin Bore × Stroke 73 mm × 72 mm (2.87 in. × 2.84 in.) Piston Displacement 603 cm³... - Page 47 New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Item Service Limit Valve Spring Free Length: Intake, Exhaust 31.0 mm (1.22 in.) Rocker Arm Push Rod Runout: Intake, Exhaust TIR 0.5 mm (0.02 in.) Rocker Shaft Outside Diameter: Intake, Exhaust 10.91 mm (0.430 in.)
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Page 48: Special Tools
New & Reconditioned Equipment & Parts- www.southeasternequipment.net Service Manual – PBU Propane Floor Burnisher Engine System Special Tools Fuel Mixture Kit The fuel mixture kit contains an oxygen sensor for machines not equipped with the CarbGard system It also contains an oxygen sensor tab for systems that are equipped with CarbGard The volt meter has a special probe to connect to the oxygen sensor tap Volt Meter Sensor...
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