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General Information

Service Manual – PBU Propane Floor Burnisher

Model

21KBCATCL

Part Number

56381454

Pad Size

21” (53 CM)

Engine

603CC KAWASAKI

Catalytic

Muffler

Yes

Carb Gard

Clutch

Centrifugal

Pad Speed

Eng. @ 3600

RPM

2100 RPM

Pad Speed

Eng. @ 3000

RPM

1750 RPM

Propane Tank 20 lb. (9.1 kg) Capacity, 80% Safety Fill
Auto Fuel

Shutoff

Yes

Low Oil

Shutdown

Yes

Hour Meter

Yes

Sound

Pressure

(ISO 11201)

87 dB LpA, 3dB KpA

Agency

Approvals

EPA plus UL Approved Propane Components

"CARB

Certified

(California

Air Resource

Board)"

Yes

Weight

218 lbs / 99 kg.

Length

51.5” (131.8 cm)

Width

23.3” (59 cm)

Height

43” (109.2 cm)

Warranty

2 Years Parts & Labor

Содержание 21KB

Страница 1: ...hines 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 21KB 21KBCAT 21KBCATCL 27KB 27KBCL 27KBCAT 21KBCATCLFC 27KBCATCLDC 21KBCATCLST MPS 1721 MPS 1727 ...

Страница 2: ... Mounting Position Some 27 Inch Models 16 Replace Drive Clutch 18 Electrical System 19 Functional Description 19 Carb Gard 19 Carb Gard Normal Operation 19 Component Locations 20 Troubleshooting 20 Oxygen Sensor Test 20 Wiring Diagrams 22 Engine System 24 Functional Description 24 Ignition System 24 Ignition System Operation Theory 24 Maintenance and Adjustments 25 Air Cleaner Element Cleaning and...

Страница 3: ...oting Guide 39 Starter Motor Troubleshooting Guide 43 Removal and Installation 44 Ignition Coil Removal 44 Ignition Coil Installation 44 Spark Plug Removal 46 Spark Plug Installation 46 Spark Plug Cleaning and Inspection 46 Spark Plug Gap Inspection 46 LP Regulator Replacement Before Serial Number 3000083761 47 LP Regulator Replacement After Serial Number 3000083760 52 Replace Engine 54 Specificat...

Страница 4: ...n History November 2011 Engine Fuel System and RPM changes 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 instruc...

Страница 5: ...anual 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 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 combusti...

Страница 6: ...s 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 market 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 concentra...

Страница 7: ...missions 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 engine 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 rea...

Страница 8: ... when ordering parts Model Name Part No Part number of the machine which is often referred to as the Model Number and Serial Number Nameplate Figure 1 Nameplate Location Figure 2 Nameplate Location Operator Controls Ignition Key Engine Hourmeter Ignition Key Engine Hourmeter Carb Gard Indicators Figure 4 Controls Non Carb Gard Figure 5 Controls Carb Gard ...

Страница 9: ...Regulator LP Lock Off Valve Starter Air Cleaner Cover Oxygen Sensor Muffler Air Cleaner Element Carburetor Oil Fill and Dip Stick Oil Pressure Switch Oil Filter Battery Location with Dust Control Carb Gard Controller Battery Location without Dust Control Carb Gard Control Panel Figure 3 Major Components ...

Страница 10: ...PM Pad Speed 1750 RPM Pad Speed 1250 RPM Pad Speed 1250 RPM Pad Speed 1250 RPM Propane Tank 20 lb 9 1 kg Capacity 80 Safety Fill Auto Fuel Shutoff Yes Yes Yes Yes Yes Low Oil Shutdown Yes Yes Yes Yes Yes Hour Meter Yes Yes Yes Yes Yes Sound Pressure ISO 11201 87 dB LpA 3dB KpA Productivity Rate 25 000 ft2 hr 2 322 m3 hr 25 000 ft2 hr 3 066 m3 hr Agency Approvals EPA plus UL Approved Propane Compon...

Страница 11: ... 1750 RPM 1250 RPM 1170 RPM 1170 RPM 1170 RPM Propane Tank 20 lb 9 1 kg Capacity 80 Safety Fill Auto Fuel Shutoff Yes Yes Yes Yes Yes Low Oil Shutdown Yes Yes Yes Yes Yes Hour Meter Yes Yes Yes Yes Yes Sound Pressure ISO 11201 87 dB LpA 3dB KpA Agency Approvals EPA plus UL Approved Propane Components CARB Certified California Air Resource Board Yes Yes Yes Yes Yes Weight 292 lbs 132 5 kg 302 lbs 1...

Страница 12: ...3600 RPM 2100 RPM Pad Speed Eng 3000 RPM 1750 RPM Propane Tank 20 lb 9 1 kg Capacity 80 Safety Fill Auto Fuel Shutoff Yes Low Oil Shutdown Yes Hour Meter Yes Sound Pressure ISO 11201 87 dB LpA 3dB KpA Agency Approvals EPA plus UL Approved Propane Components CARB Certified California Air Resource Board Yes Weight 218 lbs 99 kg Length 51 5 131 8 cm Width 23 3 59 cm Height 43 109 2 cm Warranty 2 Year...

Страница 13: ...nge engine oil Change oil filter Clean air cleaner foam element Replace air cleaner paper element Check pad driver for loose parts Check belt for wear or slippage Check engine pulley for tightness Check wheel bolts Check engine mount bolts Check handle bolts Check for leakage of engine oil at the various seals Change dust control filter Check and adjust engine valve clearance Clean and lap valve s...

Страница 14: ...hing disc assembly bearing Brace wrench against adjacent bolt to prevent the bearing from rotating Figure 6 Grip Bolt Burnishing Disc Assembly Figure 7 Remove Pad Gripper Assembly 2 Rotate the pad gripper assembly counter clockwise to remove 3 To replace thread pad gripper assembly onto shaft and rotate clockwise until secure Figure 8 Replace Pad Gripper Assembly Maintenance and Adjustments ...

Страница 15: ...Idler Assembly Figure 11 Pull Down on 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 pull...

Страница 16: ...g 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 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 ...

Страница 17: ...arc 3 11 16th 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 6 Install tensioner mounting bolt through the new hole just made and install the tensioner finger tight 7 Plug the old mounting bolt hole using a bolt and nut 8 Tighten...

Страница 18: ... or socket to remove the bolt that secures the clutch Remove clutch 3 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 torque the bolt to 40 ft lb Clutch Bolt Washer Figure 12 Replace Clutch 9 Using a large wrench on the large nut of the tensioner a...

Страница 19: ...perate 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...

Страница 20: ...e the air intake filter Jumper Wire Connect Positive Connect Ground Air Intake Filter Oxygen Sensor Test Troubleshooting Check the following if unexplained engine shutdown occurs Oil pressure switch function assumes engine can be restarted Fuel lock off solenoid function Primary regulator pressure If too high the regulator may require replacement If the primary regulator pressure is within specifi...

Страница 21: ...T YOUR HAND 9 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 forced to run lean If the oxygen sensor does not produce these VDC values when tested it should be replaced ...

Страница 22: ...L BURRS AND SHARP EDGES APPROVED APPROVED APPROVED CHECKED SIZE CODE TITLE PLYMOUTH MINNESO DRAWN PROJ ENG BILL OF MATERIAL NILFISK ADVANCE DIAGRAM WI 56381417 PMO WGL SWITCH POSITION CONTINUITY 1 OFF 2 RUN 3 START G M L B L B S VOLTAGE REGULATOR RECTIFIER ALTERNATOR STATOR 10 7 10 10 7 10 10 7 A 06050 FUSE SLOBLOW 15 AMP FUSE SLOBLOW 15 AMP IGNITION COIL IGNITION COIL ENGINE SWITCH ENGINE SWITCH ...

Страница 23: ...STATOR O2 SENSOR DIAGRAM WI 5638 PMO WGL PBU STRIPER NONE SWITCH POSITION CONTINUITY 1 OFF 2 RUN 3 START G M L B L B S A 06050 10 7 1 10 7 10 10 7 10 56381E53 BLK RED RED ORN RED RED ORN BLK BRN BRN YEL YEL GRY BLK BLK GRN GRN YEL YEL YEL WHT GRY RED BLK GRY WHT RED BRN IGNITION COIL IGNITION COIL FUSE SLOBLOW 15 AMP FUSE SLOBLOW 15 AMP HOURMETER HOURMETER B B M STARTER MOTOR M STARTER MOTOR SOLEN...

Страница 24: ...em Operation Theory 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 is 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 turn...

Страница 25: ...is routed to ground not allowing igniting operation Cleaning of paper air cleaner elements is 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 Note Operating in dusty condition may require more frequent maintenance than shown in the chart above Remove the foam and paper elements Clean the foam eleme...

Страница 26: ...bon deposits from the cylinder head and the exhaust port with a suitable tool A Note To avoid gouging use scrapers 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 Engine Top End Cylinder Head Cleaning Warning Clean the cylinder head in a well ventilated area and take care that there are no sparks or flame an...

Страница 27: ...A of the compression stroke Figure 22 Cylinder Head Assembly Removal Remove Rocker Arm Push Rod Rocker Arm Bracket Loosen the cylinder head bolts 1 4 turn in the sequence as shown in the figure Caution If the 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 Note Mark the push rods ...

Страница 28: ...ut new gaskets and the cylinder head assemblies on each cylinder Note As the head gaskets are coated with sealing agents be careful not to damage the surfaces Figure 25 Set Piston at TDC Tighten the cylinder head bolts following the tightening sequence as shown in the figure Torque Cylinder Head Bolts 27 4 N m 2 8 kgf m 20 ft lb Caution A torque wrench must be used to assure proper torque Improper...

Страница 29: ...b Install the removed parts Figure 28 Lift Hook Engine Top End Valve Clearance Inspection Note Valve clearance must be checked when the engine is cold at room temperature Remove the rocker covers Place the piston at the 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 le...

Страница 30: ...t Valve Clearance when cold Intake Exhaust 0 10 0 15 mm 0 004 0 006 in Figure 31 Check Valve Clearance Valve Clearance Adjustment Since valve repairs change the valve clearance adjust the valve clearance to the specification Turn the crankshaft in proper direction until the piston is at the TDC of the compression stroke as described above Loosen the locknut A and adjusting bolt B Insert a 0 05 mm ...

Страница 31: ...nd 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 Pull the valve out and check the seating pattern on the valve head It must be the correct width A and even all the way around Note ...

Страница 32: ...ng the engine with the oil level low Then at your earliest convenience change the oil completely If the oil level is FULL range F drain the excess oil by loosening the quick drain fitting Engine Oil Change Change the oil after 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 Place the unit on a level surface Use a ...

Страница 33: ...rade 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 is damaged When checking the oil level do not turn oil filler cap on threads Note Some increase in oil consumption ma...

Страница 34: ...e Electrode D Spark Plug Gap Inspection 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 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...

Страница 35: ...ers 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 Figure 44 Remove Air Cleaner Cover Figure 45 Remove Intake and Element Assy Figure 46 Remove Intake Hose and Foam Element ...

Страница 36: ...y 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 is not recommended Each air cleaner element should be replaced with a new air cleaner element according to the maintenance schedule Figure 47 Install Element Figure 48 Install Hose Tighten Clamp Fi...

Страница 37: ...er M14 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 Keep the plugs as far away as possible from the plug holes Compression Measurement Figure 50 Compression Measurement 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 1...

Страница 38: ...e 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...

Страница 39: ...Engine System 39 Service Manual PBU Propane Floor Burnisher Engine Troubleshooting Guide This chart describes typical troubleshooting procedures from engine manual ...

Страница 40: ...Engine System 40 Service Manual PBU Propane Floor Burnisher ...

Страница 41: ...Engine System 41 Service Manual PBU Propane Floor Burnisher ...

Страница 42: ...Engine System 42 Service Manual PBU Propane Floor Burnisher ...

Страница 43: ...e and equip ment during test CAUTION If starter does not stop by engine switch OFF disconnect negative cable from battery as soon as possible 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 Ca...

Страница 44: ... 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 ignition coil and left pole plate of magnet E between center of ignition coil and right pole plate of magnet Figure 51 Component R...

Страница 45: ... 60 kgf m 52 in lb Note Use the above procedure to insure proper coil air gap Fit the ignition 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 ignition coil lead C with the band D Figure 53 Air Gap Figure 54 Fit Leads Install Cap Figure 55 Attach Leads ...

Страница 46: ... 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 sc...

Страница 47: ...llips screwdriver turn the butterfly valve adjustment screw clockwise until resistance is felt Then turn the screw counterclockwise 1 1 4 turns Butterfly Valve Adjustment Screw Figure 57 Regulator Adjustment Screw 1 4 In Regulator 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 meas...

Страница 48: ...ferring to the tachometer use a 3 32 inch Allen wrench to turn the regulator adjustment screw to achieve the highest engine RPM at idle 7 After achieving the highest engine RPM turn the regulator adjustment screw counterclockwise two full turns Butterfly Valve Adjustment Screw Figure 60 Regulator Adjustment Screw 8 Using a Phillips screwdriver and the tachometer turn the butterfly valve adjustment...

Страница 49: ...gainst handle to achieve the highest possible engine RPM Figure 64 High Speed Throttle Screw Figure 63 Throttle Lever Models with Clutch Jam Nut High Speed Throttle Set Screw 11 Loosen the jam nut that secures the high speed throttle set screw Using the tachometer adjust the high speed throttle set screw so that the engine runs at 3500 to 3600 RPM when the throttle lever is fully advanced Tighten ...

Страница 50: ...ssary 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 13 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 Fig...

Страница 51: ...nacceptable repeat the procedure above beginning at Step 2 16 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 Figure 70 Cap Compressed Into Opening Figure 68 Idle Speed Set Screw Jam Nut Idle Speed Throttle Set Screw Plate 14 The idle speed ...

Страница 52: ... 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 1 4 In Regulator Screw Idle Stop Screw Tools required Pulse tachometer 3 32 and 3 16 inch Allen wrench Phillips screwdriver Hammer Exhaust gas analyzer Punch large LP Regulator Replacement After Serial Number 3000083760 After replacing the regulator the idle mixture reg...

Страница 53: ...lyst at 1600 1700 RPM CO 0 2 HC 500ppm NOx 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 o...

Страница 54: ...e Floor Burnisher Replace Engine The engine is secured to the unit frame by three bolts Engine Mounting Bolts When replacing the engine apply 242 Loctite to the three engine mounting bolts and torque to 31 ft lb Figure 71 Engine Mounting Bolts ...

Страница 55: ...with regulator Spark Plug NGK BPR4ES Carburetor Float type fixed main jet internally vented single barrel Fuel Pump Diaphragm type pulse pump Air Cleaner Dual stage element dry type Governor Flyweight all speed governor Lubrication System Pressure feed by positive displacement pump Oil Type 30HD or 10W30 API rating SJ or higher Oil Filter Cartridge type full flow filter Oil Capacity when engine is...

Страница 56: ... 866 in Piston Ring Groove Clearance Top 0 12 mm 0 0047 in Second 0 12 mm 0 0047 in Piston Ring Thickness Top 1 1 mm 0 043 in Second 1 1 mm 0 043 in Piston Ring End Gap Top 0 7 mm 0 028 in Second 0 9 mm 0 035 in Oil 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 Diameter 16 05 mm 0 632 in Cylinder Ins...

Страница 57: ...wn in the table Ignition Coil Winding Resistance Figure 72 Ignition Coil Inspection Special Tools Exhaust Gas Analyzer 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 ...

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