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PBU Propane Floor Burnisher
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
21KB
21KBCAT
21KBCATCL
27KB
27KBCL
27KBCAT
21KBCATCLFC-
27KBCATCLDC
21KBCATCLST
03/11 Revised 07/12 Form No. 56043153
MPS-1721
MPS-1727
English
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Table of Contents
Troubleshooting
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Related Manuals for Nilfisk-Advance 21KB
Summary of Contents for Nilfisk-Advance 21KB
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Page 1: Service Manual
27KBCAT 21KBCATCLFC- MPS-1721 27KBCATCLDC MPS-1727 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 English 03/11 Revised 07/12 Form No. 56043153... -
Page 2: Table Of Contents
Service Manual: PBU Floor Burnisher Contents General Information Service Manual Purpose and Application Document Revision History Other Reference Manuals Conventions Transporting the Machine Cautions and Warnings General Machine Description Nameplate Operator Controls Know Your Machine — Major components: Specifications Maintenance Schedule Burnishing System Maintenance and Adjustments Replace burnishing disc pad gripper assembly... - Page 3 Service Manual: PBU Floor Burnisher Electrical System Spark Plug Cleaning and Inspection Air Cleaner Element Removal Element Installation Element Cleaning and Inspection Troubleshooting Compression Measurement Engine Troubleshooting Guide Starter Motor Troubleshooting Guide Removal and Installation Ignition Coil Removal Ignition Coil Installation Spark Plug Removal Spark Plug Installation Spark Plug Cleaning and Inspection...
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Page 4: General Information
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 (21KBCATCLDC), 56381409 (27KBCATCLDC) •... -
Page 5: Transporting The Machine
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. • All access doors and covers are secured (tape and strap as needed). Cautions and Warnings Danger! It 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... - Page 6 Service Manual – PBU Propane Floor Burnisher General Information 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 defects or other reproductive harm.
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Page 7: General Machine Description
Service Manual – PBU Propane Floor Burnisher General Information Warning: The proper maintenance of equipment is vital to safe operation. LPG engines 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. -
Page 8: Nameplate
Service Manual – PBU Propane Floor Burnisher General Information Nameplate The nameplate contains important identification information which will be needed when ordering parts: Model (Name), Part No. (Part number of the machine which is often referred to as the “Model Number”), and Serial Number. -
Page 9: Know Your Machine - Major Components
Service Manual – PBU Propane Floor Burnisher General Information Know Your Machine — Major components: LP Regulator Starter LP Lock Off Valve Air Cleaner Air Cleaner Cover Element Oxygen Sensor Carburetor Muffler Oil Fill and Dip Stick Carb Gard Controller Oil Pressure Battery Location Switch... -
Page 10: Specifications
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 Pad Size 21” (53 cm) 21” (53 cm) 27”... - Page 11 Service Manual – PBU Propane Floor Burnisher General Information Model 21KBCATCLDC 27KBCATCLDC 27KBCATCLST MPS-1721 MPS-1727 Part Number 56381408 56381409 56381410 56381412 56381413 Pad Size 21” (53 CM) 27” (68 cm) 21” (53 CM) 21” (53 CM) 27” (68 cm) Engine 603CC KAWASAKI Catalytic Muffler...
- Page 12 Service Manual – PBU Propane Floor Burnisher General Information Model 21KBCATCL Part Number 56381454 Pad Size 21” (53 CM) Engine 603CC KAWASAKI Catalytic Muffler Carb Gard Clutch Centrifugal Pad Speed 2100 RPM Eng. @ 3600 Pad Speed 1750 RPM Eng. @ 3000 Propane Tank 20 lb.
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Page 13: Maintenance Schedule
Service Manual – PBU Propane Floor Burnisher General Information Maintenance Schedule Interval Daily 8 Hour Every Every Every Every Every (Break In) ITEM Hours Hours Hours Hours Hours Check or clean air intake screen • Check for fuel and oil leakage •... -
Page 14: Burnishing System
Service Manual – PBU Propane Floor Burnisher Burnishing System Burnishing System Maintenance and Adjustments Replace burnishing disc pad gripper assembly. 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. -
Page 15: Replace Burnishing Disc Assembly Drive Belt
Service Manual – PBU Propane Floor Burnisher Burnishing System Replace Burnishing Disc Assembly Drive Belt. An idler assembly is used to keep the burnishing disc drive belt tight. The idler assembly must be rotated slightly to free the belt for removal. Idler Assembly Figure 9 Idler Assembly, No Clutch... -
Page 16: Replace Drive Belt Tensioner
Service Manual – PBU Propane Floor Burnisher Burnishing System 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 “... - Page 17 Service Manual – PBU Propane Floor Burnisher Burnishing System 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.
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Page 18: Replace Drive Clutch
Service Manual – PBU Propane Floor Burnisher Burnishing System 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. -
Page 19: Electrical System
Service Manual – PBU Propane Floor Burnisher Electrical System 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. -
Page 20: Component Locations
Service Manual – PBU Propane Floor Burnisher Electrical System Component Locations Carb Gard Carb Gard Controller Oxygen Sensor Carb Gard 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). •... - Page 21 Service Manual – PBU Propane Floor Burnisher Electrical System Use a sturdy, clean, flat object to partially block the air intake. (NOT YOUR HAND.) Note the multimeter reading while the air intake is restricted at high idle. 10. 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...
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Page 22: Wiring Diagrams
Service Manual – PBU Propane Floor Burnisher Electrical System Wiring Diagrams... - Page 23 Service Manual – PBU Propane Floor Burnisher Electrical System...
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Page 24: Engine System
Service Manual – PBU Propane Floor Burnisher Engine System Engine System Functional Description Ignition 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... -
Page 25: Maintenance And Adjustments
Service Manual – PBU Propane Floor Burnisher Engine System When the base current is flowing, the trigger sensor (TS1) detects optimum time (peak current) to shut off the transistor 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. -
Page 26: Engine Top End, Cylinder Head Cleaning
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. • If a cracks is present in the cylinder head, replace it. - Page 27 Service Manual – PBU Propane Floor Burnisher Engine System • 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. Figure 21 Cylinder Head Assembly Removal • When removing the #1, #2 cylinder head, set each piston at the top dead center (T.D.C) [A] of the compression stroke.
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Page 28: Engine Top End, Cylinder Head Assembly Installation
Service Manual – PBU Propane Floor Burnisher Engine System Engine Top End, Cylinder Head Assembly Installation • Clean the mating surfaces of the cylinder heads and cylinders. • Replace the gaskets with new ones. • Install the dowel pins [A] Figure 24 Install Dowel Pins • Set each piston at the T.D.C [A] of the compression stroke. • Put new gaskets and the cylinder head assemblies on each cylinder. -
Page 29: Engine Top End, Valve Clearance Inspection
Service Manual – PBU Propane Floor Burnisher Engine System • 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) Figure 27 Rocker Cover Bolt Tightening Sequence • Install: –... -
Page 30: Valve Clearance Adjustment
Service Manual – PBU Propane Floor Burnisher Engine System 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 (360°) clockwise and face the left projection with the right leg again. Figure 30 Check Closing of Valves • 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. -
Page 31: Valve Seat Inspection
Service Manual – PBU Propane Floor Burnisher Engine System • 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·lb) • Do not overtighten the valve clearance adjusting locknuts. • After the valve clearance adjustment, measure the valve clearance again. Readjust the valve clearance if necessary. Figure 33 Tighten Locknut Valve Seat Inspection • 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. -
Page 32: Lubrication System
Service Manual – PBU Propane Floor Burnisher Engine System Lubrication System Engine Oil Level Inspection ◦ 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. ◦ 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. -
Page 33: Oil Filter Replacement
Service Manual – PBU Propane Floor Burnisher Engine System • 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] Figure 39 Oil Types and Temperatures 1.7 L (1.8 US qt) -
Page 34: Electrical System
Service Manual – PBU Propane Floor Burnisher Engine System • 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 kgf·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 • Stop the engine and check the oil level (see Engine Oil Level Inspection). -
Page 35: Air Cleaner
Service Manual – PBU Propane Floor Burnisher Engine System Air Cleaner Element Removal • Turn the fasteners [A] clockwise. • Remove the air cleaner cover [B]. Figure 44 Remove Air Cleaner Cover • Loosen the clamp [A]. • Remove the intake hose [B] together with the element assembly [C]. Figure 45 Remove Intake and Element Assy • Loosen the clamp [A]. • Remove: Intake Hose [B] Foam Element [C] Figure 46 Remove Intake Hose and Foam Element... -
Page 36: Element Installation
Service Manual – PBU Propane Floor Burnisher Engine System 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] is horizontally installed. Figure 47 Install Element • Install the intake hose [A], and tighten the clamp [B]. Figure 48 Install Hose, Tighten Clamp • Install the air cleaner cover [A]. • Turn the fasteners [B] counterclockwise. Element Cleaning and Inspection Cleaning of paper air cleaner elements is not recommended. Each air cleaner element should be replaced with a new air cleaner element according to the... -
Page 37: Troubleshooting
Service Manual – PBU Propane Floor Burnisher Engine System 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 • Fuel lock off solenoid failure • Oxygen sensor (see Carb Gard) Compression Measurement • Before measuring compression, do the following. - Page 38 Service Manual – PBU Propane Floor Burnisher Engine System • 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. • If the compression is higher than the specified value, the piston rings, cylinder and valves are probably in good condition. If the compression is 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.
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Page 39: Engine Troubleshooting Guide
Service Manual – PBU Propane Floor Burnisher Engine System Engine Troubleshooting Guide This chart describes typical troubleshooting procedures (from engine manual). - Page 40 Service Manual – PBU Propane Floor Burnisher Engine System...
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Page 43: Starter Motor Troubleshooting Guide
10-6 TROUBLESHOOTING Service Manual – PBU Propane Floor Burnisher Engine System Starter Motor Troubleshooting Guide 1. Disconnect spark plug caps from the spark plugs. Starter Motor Troubleshooting Guide 2. Turn engine switch to “START” position and check condition. 1. Disconnect spark plug caps from the spark plugs. WARNING 2. Turn engine switch to “START” position and check condition. -
Page 44: Removal And Installation
Service Manual – PBU Propane Floor Burnisher Engine System Removal and Installation Ignition Coil Removal • Remove the fan housing (see Flywheel and Stator 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] Figure 51 Component Removal 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... - Page 45 Service Manual – PBU Propane Floor Burnisher Engine System Ignition Coil Air Gap 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) Note: Use the above procedure to insure proper coil air gap. Figure 53 Air Gap • Fit the ignition coil leads [A] to the each engine shroud groove [B].
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Page 46: Spark Plug Removal
Service Manual – PBU Propane Floor Burnisher Engine System 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. -
Page 47: Lp Regulator Replacement Before Serial Number 3000083761
Service Manual – PBU Propane Floor Burnisher Engine System 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 inch Allen wrench • Phillips screwdriver • Hammer • Exhaust gas analyzer • Punch - large 1. Set the butterfly valve adjustment screw on the carburetor (mixer). - Page 48 Service Manual – PBU Propane Floor Burnisher Engine System 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. Pulse Tachometer Figure 59 Connect Pulse Tachometer 6. Return to idle. While referring to the tachometer, use a 3/32 inch Allen wrench to turn the regulator adjustment screw to achieve the highest engine RPM at idle. Regulator Adjustment After achieving the highest engine RPM, Screw...
- Page 49 Service Manual – PBU Propane Floor Burnisher Engine System 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 Advance highest possible engine RPM. Throttle Lever Figure 62 Throttle Lever, Models without Clutch Pull Throttle Lever Up...
- Page 50 Service Manual – PBU Propane Floor Burnisher Engine System 12. Check the tightness of the throttle cable clamp. If necessary, tighten the throttle cable housing clamp screws to firmly secure the throttle cable housing. Do not over-tighten. The throttle lever must be able to freely advance or retract the throttle cable. Cable Housing Clamp Screws Figure 65 Throttle Cable Housing Clamp Screws 13. Move throttle lever to idle position.
- Page 51 Service Manual – PBU Propane Floor Burnisher Engine System 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. Idle Speed Throttle Set Adjust the idle speed throttle set screw so that it Screw does not make contact with the plate.
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Page 52: Lp Regulator Replacement - After Serial Number 3000083760
Service Manual – PBU Propane Floor Burnisher Engine System 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 1. Set the idle mixture “regulator screw”... - Page 53 Service Manual – PBU Propane Floor Burnisher Engine System 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 1600-1700 RPM: Regulator CO < 0.02% [goal .007], HC < 50ppm, NOx < 60ppm Idle Mixture Adjustment b. Muffler without Catalyst at 1600-1700 RPM: Screw CO < 0.2%, HC < 500ppm, NOx < 80ppm 5. Push the throttle to high speed and run for 15 seconds.
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Page 54: Replace Engine
Service Manual – PBU Propane Floor Burnisher Engine System Replace Engine The engine is secured to the unit frame by three bolts. Engine Mounting Bolts Figure 71 Engine Mounting Bolts When replacing the engine, apply 242 Loctite to the three engine mounting bolts and torque to 31 ft-lb. -
Page 55: Specifications
Service Manual – PBU Propane Floor Burnisher Engine System Specifications Engine Specifications Item Specification 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 56 Service Manual – PBU Propane Floor Burnisher Engine System Item Service Limit Valve Stem Runout: TIR 0.05 mm (0.002 in.) Intake, Exhaust Valve Stem Diameter Intake 5.95 mm (0.234 in.) Exhaust 5.93 mm (0.233 in.) Valve Guide Inside Diameter: Intake, Exhaust 6.08 mm (0.239 in.) Valve Spring Free Length: Intake, Exhaust...
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Page 57: Ignition Coil Specifications
Service Manual – PBU Propane Floor Burnisher Engine System Item Service Limit Valves Guide Inside Diameter: Intake, Exhaust 6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in.) Cylinder Inside Diameter: 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 coil winding resistance as...
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