Aztec Buffer User manual

OWNER’S MANUAL

21" & 27"

BUFFER

THE ANSWER

9758/08.10

201 COMMERCE DR VE • MONTGOMERYV LLE, PA 18936

215-393-4700 • 800-331-1423 • FAX 215-393-4800

201 COMMERCE DR VE • MONTGOMERYV LLE, PA 18936

215-393-4700 • 800-331-1423 • FAX 215-393-4800

AZTEC PRODUCTS WARRANTY

Aztec Products, Inc. warrants its products to be free from defects in material and workmanship for a

period of one year from the date of sale. All engines are warranted by the manufacturers ( onda or

Kawasaki) for a period of two years when engine maintenance schedules are followed.

The warranty does not apply to damage or failure caused by abuse, misuse, neglect, disassembly,

alteration, unauthorized modification or repair, lack of proper maintenance, theft or damage by

freight carriers. The warranty applies to parts, labor, and ground freight only. Aztec is not liable for

transportation to or from repair centers or travel for on-site repairs. Aztec Products, Inc. will not

be liable for incidental or consequential damages arising from the use of any of its products, whether

defective or not.

Aztec Products, Inc. agrees, at its discretion, to repair or replace at its own expense any product or

part(s) which examination proves to be defective in workmanship or materials provided that the

purchaser notifies Aztec Products, Inc. directly within the warranty period and follows the Return

Goods Policy. Engine repairs may be performed at engine manufacturer’s service centers. For your

closest center you may call the following numbers:

Kawasaki 616-949-6500 onda 800-426-7701

In order to obtain parts warranty, the following procedures must be followed:

1. Customer must call Aztec Products, Inc. for an RGA (Return Goods Authorization) Number.

2. We maintain the serial number, date of shipment or sale, and customer name on each piece of

equipment sold. If you were the purchaser, please reference that information on your request for

replacement or repair. If you purchased the equipment through a distributor, please contact them first.

If you are not satisfied, contact Aztec and give us the distributor name, purchase date, and the serial

number of the product.

3. The defective part must be returned via ground freight prepaid to Aztec Products, Inc. with an RGA

number accompanied by a copy to the original purchase invoice. Aztec is not responsible for the cost

of packaging inbound freight, nor inbound freight damage. Pack machine carefully.

4. Only Aztec Products, Inc. or its authorized dealers may make warranty repairs on Aztec Products,

Inc. products. Others do so at their own risk and expense.

5. We also offer to do warranty related repairs free of charge at our facility. Arrangements must be

made in advance as outlined above. We will not accept freight collect returns or returns that do not indi-

cate the RGA number on the packing list.

The need for proper maintenance and care for this product cannot be overstated. Poor maintenance,

neglect or abuse can prove to be very expensive.

You have purchased a quality product. Each of its components has been tested and approved for use

by Aztec Products, Inc. It is unlikely that you will ever have a warranty claim if you properly maintain

your machine.

This warranty is non-transferable.

AZTEC PRODUCTS, NC.

201 Commerce Drive • Montgomeryville, PA 18936 • 800-331-1423 • Fax 215-393-4800

EPA/Carb certified

Kawasaki

603cc Engine

MPORTANT SAFETY NSTRUCT ONS

READ and UNDERSTAND all instructions and

warnings before operating this machine!

Do not store or use gasoline or other

flammable vapors and liquids in the vicinity

of this machine. Always store equipment

away from heater rooms, boilers, gas-fired

water heaters or any other source of open

flame. Propane is highly flammable.

Always store LPG tanks (full or empty)

outside in a secure, well ventilated area.

NO SMOK NG, NO SPARKS, NO FLAMES

NEAR UN T OR LPG TANK.

Operate only in well ventilated areas. Buildings

must be provided with:

A. A continuous mechanical ventilation that

removes the products of combustion to the

outdoors of not less than 300 CFM for each

10,000 BTU or fraction thereof; or

B. Natural ventilation of not less than 300 CFM for

each 10,000 BTU input or fraction thereof,

based on a maximum of one-quarter air

exchange per hour for the net building volume.

f you smell LPG gas, stop the unit and check

for leaks. Also open windows, don’t touch

electrical switches, extinguish any open flames.

Call your gas supplier if no leaks are found.

Do not adjust the fuel system without the proper

analysis equipment.

Never tilt the equipment on its side for pad, belt

or brush replacement. t is designed to tilt back

on its rear wheel and handle for maintenance

and repair. A second person should aid in lifting

and securing equipment for repair.

Never tilt & transport while engine is running.

Keep hands and feet clear of all moving parts.

Never try to replace parts or repair equipment

with machine running.

Turn the gas off at the tank to kill the engine.

Remove the LPG tank and store it in an

approved area when not in use. A “NO

SMOK NG” sign should be permanently

displayed at the storage area.

Always vent an over-full bottle using the tank’s

bleed valve, out of doors away from all closed

places and away from any fire or flame producing

device. Vent until the white vapor turns clear.

Keep all objects clear of the exhaust system

during and after operation.

Do not leave this machine unattended while

the engine is running.

Do not operate equipment in one location for

more than a few seconds. Damage to floor

surface can occur.

Always store equipment away from possible

damage by falling objects in warehouse-type

areas. Always store LPG tanks outside in a

secure, well-ventilated area.

When the LPG tank is attached to the machine

and not running, the operator should not

leave the machine unattended except for

short periods of time such as rest stops,

washroom or meal stops.

The operator must completely understand all

instructions, warnings and operating

procedures before using this machine.

The manufacturer’s warranty will be voided if

the machine is not maintained in accordance

with this manual’s recommended

maintenance instructions and the engine

manufacturer’s recommended maintenance

procedures. Failure to do so may cause

damage to the machine, equipment,

furniture, buildings or personal injury!

A maintenance record should be kept indicating

date of service, hours on engine, and work

done.

TRANSPORT & PREPARAT ON

Follow the instructions given in this booklet,

the Engine’s Owners Manual and the training

given by your supervisor for the safe

operation of this machine. Failure to do so

can result in personal injury and/or damage

to the machine or property.

DO NOT OPERATE TH S MACH NE N AN

EXPLOS VE ENV RONMENT!

TH S PROPANE MACH NE S NTENDED

FOR COMMERC AL USE.

PG. 2 T E ANSWER T E ANSWER PG. 15

NOTES

WARN NG

Do not use “T” handle when attempting to tilt

back machine for service or cleaning. The

“T” handle is designed for control during

operation only.

Do not use excessive vertical pressure.

. PREPARAT ON

A. Check that the suggested maintenance

schedule has been observed:

All machines are equipped with a multi-function

maintenance meter. The functions include the

following: hour meter, service alert and tachometer.

(See Engine Maintenance Meter Instructions on p4).

B. Check the engine oil before every operation:

Make sure the machine is level when checking the

oil. Always take 2 readings of the dipstick before

adding oil. If the oil level is below the full mark, add

just enough oil to the engine to bring the oil level

up to the full mark. Never over fill. Follow the

guidelines in your Engine Owners Manual. Check

for foreign material on the dipstick.

C. Properly fill and check your LPG tank and

all LPG fuel lines for leaks:

1. Every tank has been pressure and leak

tested. owever, every time a tank is filled

and/or connected to the machine it should be

soap tested. All LPG lines must be pressurized

and every inch of line and connections must be

sprayed. If you find a leak, make the proper

repairs before operating the machine.

NOTE: The connection and disconnection of

the LPG tank must be done in a well ventilated

area with NO source of ignition within 10 feet

(3 meters) from the point of connection.

2. Never over fill the LPG tank! The LPG tank

is designed to hold just 20 pounds of propane.

Make sure to weigh the tank as it is being

filled. The gross weight of a full tank should

not exceed 48 pounds. If while operating the

machine, you notice frost forming on the LPG

lines or the regulator, your tank has been over

filled. If you continue to operate the machine

in this condition, damage will occur. The

excess propane in the tank must be removed

before normal operations resume. The

bleeding of a propane tank should be done in a

safe location outside the building. In some

cases the regulator must defrost before

restarting the engine.

D. Connecting the high pressure hose to the

LPG Tank:

Make sure the couplers are in line and screwed

together hand tight. If this is not done properly,

fuel will not pass through to the regulator. Never

complete the connection of the tanks to the

machine by using a wrench. Always do it by

hand. Listen for the rush of fuel to the lock-out

device when you open the tank valve. If you

hear this, it indicates a good connection has

been made at the tank.

NEVER CHANGE OR ALTER THE PROPANE

CONTROL EQU PMENT!

E. nstall fresh pads or brushes before every job:

To install a fresh pad, set the machine down in

the rear. Unscrew and remove the pad-centering

ring. Remove the old pad and center the new

pad onto the pad driver. Reinstall the pad-

centering ring. Never “flip” a pad. Keep the

same side down throughout the life of the pad.

Even after a pad is cleaned, you can tell the

down side by the centering ring indentation.

This practice will increase the pad life and help

maintain a properly functioning pad driver.

NEVER T LT A MACH NE ON TS S DE!

. START NG THE ENG NE

A. Open propane (LPG) tank valve (counter

clockwise).

B. Set throttle control at idle.

C. Battery start – turn key to the start position &

move throttle toward fast position. If engine

does not start, release key and return to step “B”.

D. Electric start – push “Start” button and move

throttle toward fast position until engine

starts. Starter should not be engaged for

more than 10 seconds at a time.

•When a propane tank is overfilled it may

temporarily cause the fuel regulator to

malfunction. Remove the tank to a well

ventilated location. Release some gas until

the cloud disappears and escaping gas is

“clear”. Reinstall tank.

• All machines are equipped with tamper

proof fuel systems. f a fuel problem

exists, contact an authorized service

center.

T E ANSWER PG. 3

PG. 14 T E ANSWER

NOTES

WARN NG

PG. 4 T E ANSWER

•Propane tanks should be removed &

stored in a protected off site area.

. OPERAT ON

Provide and use ear protection during

operation.

Never let an untrained person operate or

perform repairs on the machine. They may hurt

themselves, damage the floor or the

equipment.

Engine speed not to exceed 3400 RPM.

This machine is not suitable for picking up

hazardous dust.

Do not use on surfaces with a gradient

exceeding 2%.

V. STOPP NG THE ENG NE

Turn the propane tank valve clockwise to a closed

position and turn the key OFF.

NOTE: The exhaust system will be very hot and

takes several minutes to cool, so keep yourself

and all materials clear.

V. PROCEDURES

Follow machine (straight ahead) at moderate

walking speed. Keep moving.

• Do not operate the machine in one location

for more than a few seconds — it will

damage — “burn” the finish.

• When operation is completed remove tank

and store in a secure, protected off site

(preferably outdoor) location.

• Do not use for scrubbing operations.

• Never tilt back machine to maintenance

position while engine is running.

• Never reach under protective shroud when

engine is running.

V . MA NTENANCE

A. Machine & engine maintenance

1. Refer to engine manufacturer’s owners

manual and comply completely with the

instructions. Change the oil and filter according

to the Engine Owners Manual.

2. Keep a good service log on each machine

with the date, hour meter reading, type(s) of

service performed and the name of the person

who performed them.

3. Clean the entire unit after each use. When

cleaning the unit, check for possible loose nuts

and bolts.

B. Engine maintenance meter

This multi-function meter acts as a preventive

maintenance tool, which benefits you with

increased fuel economy, less down-time and

longer engine life.

The meter’s displays are:

Hour Meter: Displays total run hours when

machine is off.

Tachometer: Indicates engine RPM during

operation.

Service Alert: The display flashes to alert you to

lube and change the oil at 25 hour intervals. The

service alert only flashes during operation and it

warns you to change the oil for only two hours.

After the two hours is reached, the alert will

automatically reset to the next 25 hour interval.

Therefore, it is recommended that a separate

maintenance log be kept to track oil changes.

Remember that being safe is a full-time, every

day job. Follow all information posted on the

machine and the LPG tank.

Never allow anyone to operate this machine

who has not read or cannot understand the

given instructions.

C. Troubleshooting the electrical system

1. Check all wire connections for obvious

problems. Remove LPG tank, then remove

battery box cover. Check all connections visibly

and physically. If any “loose”, damaged or

unconnected wires are noticed, replace or

repair as needed.

2. Check the battery posts and wires. Always

wear a face shield, safety glasses and

protective clothing when working around a

battery! The gases can be explosive and the

acid is highly corrosive to metals, cloth and

ALL UMAN TISSUE (skin, eyes, etc.) If the

battery post(s) are corroded, remove the wires

and clean posts and wires. Applying some axle

grease on the posts of the battery after they are

cleaned will slow down the battery corrosion

process.

If nothing obvious is noted, a more detailed

investigation is warranted. Before any such

troubleshooting begins, the following things

should be done:

a. Replace propane LPG tank with one from

a machine that runs.

T E ANSWER PG. 13

NOTES

T E ANSWER PG. 5

b. Charge the battery or provide an absolute

source of 12 volt DC power capable of 50

amperes total output. (A pair of good

jumper cables from your car or truck battery

will suffice.) Equip yourself with an

inexpensive 12 volt test light.

c. If the trouble seems to be in the electrical

control equipment, you may wish to

disconnect the starter from the system so

as to check the system without spinning

the engine.

d. Battery rundown. A common problem

is letting the battery run down. What

usually happens is that it takes the crew a

few jobs to get used to the whole system,

so the machine is stopped and started

quite often. Key left in on position, when

engine is turned off, will result in battery

running down – dying.

D. Belt nspection & Replacement

nspection

• Fold T- andle to forward position

• Tilt machine back on rear of body & handle

• If belt is worn, cracked or shredding, belt

needs to be replaced.

Replacement

• Place 3/4" wrench on end of the shaft on the

top of the buffer body.

• Turn pad driver counter-clockwise to

remove.

• Take belt off by turning 3/4" wrench on shaft

and removing belt from pad driver pulley

and engine crank pulley.

• Check pad driver pulley & engine crank

pulley for correct alignment.

• Install new belt on engine crank pulley &

pad driver pulley, using 3/4" wrench.

• Install belt on tension pulley

• Install pad drive onto shaft, and return

buffer to operating position.

E. Adjusting Pad Pressure

The pad pressure may be adjusted by moving

the wheels:

• Forward to reduce weight on the buffer pad

• Backward to increase the weight

This adjustment may be required to adjust to

different floor finishes or to the weight variance

of aluminum or steel propane tanks.

KAWASAK ENG NES

Tune-up Specifications

ITEM SPECIFICATIONS

Ignition Timing Unadjustable

Spark Plugs: Champion – RCJ8Y

Gap 0.75 mm (0.30 in)

Low Idle Speed 1500 RPM

igh Idle Speed 3400 RPM

Valve Clearance IN: 0.10-0.15 mm

(0.004-0.006 in)

EX: 0.10-0.15 mm

(0.004-0.006 in)

Other No other adjustment

Specifications needed

NOTE: igh and low idle speeds may vary

depending on the equipment on which the engine

is used. Refer to the equipment specifications.

Engine Oil

Check the engine oil daily before starting the

engine otherwise shortage of the engine oil may

cause serious damage to the engine such as

seizure.

• Place the engine on a level surface. Clean the

area around the oil gauge before removing it.

• Remove the oil gauge and wipe it with a

clean cloth.

• Pour the oil slowly to “FULL” mark on the oil

gauge.

• Insert the oil gauge into the tube WIT OUT

SCREWING IT IN.

• Remove the oil gauge to check the oil level.

The oil level should be between “ADD” and

“FULL” marks. Do not overfill.

• Install and tighten the oil gauge.

The following engine oils are recommended:

API Service Classification: SF, SG, S , or SJ.

Oil Viscosity

Choose the viscosity according to the

temperature as follows:

NOTE: Using multi grade oils (5W-20, 10W-30, and 10W-40)

will increase oil consumption. Check oil level more frequently.

-20˚C -10˚C 0˚C 10˚C 20˚C30˚C 40˚C

-4˚F 14˚F 32˚F 50˚F 68˚F 88˚F 104˚F

SAE5W-20

SAE30

SAE40

SAE10W-30/SAE10W-40

PG. 12 T E ANSWER

KAWASAK 603cc ENG NE

PART # DESCR PT ON PART # QTY

1. Foam at Filter 186-271964 (1)

2. Debris Screen 309-18540 (1)

3. Foam at Seal 175-7.75*9.25*1 (1)

4. Oil Pressure Switch 152-N3-0082 (1)

5. Oil Filter 309-49065-7007 (1)

6. Oil Drain Valve 312-504-0185 (1)

7. 1 / 4 x 1 1 / 4 Key 199-N NT-SE UND (1)

8. Crank Pulley 011-6-2780 (1)

9. Exhaust Manifold Gasket 309-11060-7016 (2)

10. Exhaust Manifold 152-603-MAN (1)

11. Catalytic Muffler 152-603-MUF (1)

12. Debris Screen Adapter 283-040-2250 (1)

13. Air Filter Element 309-11013-7049 (1)

14. Foam Pre Filter 309-11013-7046 (1)

PG. 6 T E ANSWER

Engine Oil Capacity

F381V 1.5 L (1.6 US qt.) when oil filter is not removed

F500V 1.7 L (1.8 US qt.) when oil filter is removed

F541V 1.7 L (1.8 US qt.) when oil filter is removed

Oil Change

Change oil after first 8 hours of operation.

Thereafter change oil every 50 hours.

• Run the engine to warm oil.

• Be sure the engine (equipment) is level.

• Stop the engine.

• Open the oil drain valve and drain the oil into

suitable container while engine is warm.

WARN NG!

Hot engine oil can cause severe burns. Allow

engine temperature to drop from hot to warm

level before draining and handling oil.

Oil Drain Plug

• Close the oil drain valve.

• Remove oil gauge and refill with fresh oil

(See “Recommended Oils” on p5).

• Check the oil level (see “Preparation” on p3

for oil level check).

Oil Filter Change

• Change the oil filter every 100 hours of

operation.

WARN NG!

Hot engine oil can cause severe burns.

Allow engine temperature to drop from hot

to warm level before attempting to remove

oil filter.

Before removing the oil filter, place a

suitable pan under filter connection.

• Drain engine oil into a suitable container.

• Rotate the oil filter (A) counterclockwise to

remove it.

• Coat a film of clean engine oil on seal of new

filter.

• Install new filter rotating it clockwise until

seal contacts mounting surface (B). Then

rotate filter 3/4 turn more by hand.

• Supply engine oil as specified.

• Run the engine for about 3 minutes, stop

engine, and check oil leakage around the filter.

• Add oil to compensate for oil level drop due to

oil filter capacity (See “Oil Level Check” on p3).

WARN NG!

Engine oil is a toxic substance. Dispose

of used oil properly. Contact your local

authorities for approved disposal methods

or possible recycling.

KAWASAK ENG NE BATTERY START W R NG D AGRAM

T E ANSWER PG. 11

PARTS L ST FOR BUFFER FUEL SYSTEM

PART # DESCR PT ON PART # QTY

1 QUICK COUPLER 152-700 1

2 LPG OSE 14" 267-P5561-14 1

LPG OSE 20" 267-P5561-0410 1

3 FUEL LOK-OUT (VACUUM) 152-300 1

4 90˚ FITTING 177-116B04 1

5 VACUUM OSE FITTING 166-62029 1

6 1 1/2" NIPPLE 177-56021 1

8 FUEL OSE FITTING 166-62039 1

9 FUEL LOK-OUT (12 VOLT) 152-N3-0173-1 1

10 FUEL REGULATOR (T60-E) 152-500 1

CAUT ON!

T E ANSWER PG. 7

KAWASAK ENG NE MA NTENANCE SCHEDULE

NTERVAL

MA NTENANCE Daily First 8 hr. Every 25 Hr. Every 50 hr. Every 100 hr. Every 200 hr. Every 300 hr.

Check and add engine oil •

Check for loose or lost nuts and screws •

Check for fuel and oil leakage •

Check battery electrolyte level •

Check or clean air intake screen •

Clean air cleaner foam element •

Clean air cleaner paper element •

Clean dust and dirt from cylinder and

cylinder head fins •

Tighten nuts and screws •

Change engine oil ••

Clean and gap spark plugs •

Change oil filter •

Replace air cleaner paper element •

Clean combustion chambers •

Clean and adjust valve clearance •*•

Clean and lap valve seating surface •

*After the 1st 50 hours

ENG NE TROUBLESHOOT NG

COMMON PROBLEMS & PROBABLE CAUSES SOLUT ONS

Engine cranks but will not start

• Fuel cylinder is empty Refill cylinder

• Shutoff valve is closed Open valve

• Clogged, obstructed, kinked or cut fuel or vacuum line Remove obstruction or replace line

• Spark plug lead disconnected Connect lead to spark plug

• Faulty choke or throttle settings Set controls to correct positions

• Faulty ignition coil Replace coil

• Faulty kill switch Replace switch

• Faulty regulator Replace regulator

Engine starts hard

• Faulty choke or throttle settings Set controls to correct position

• Clogged, obstructed, kinked or cut fuel or vacuum line Remove obstruction or replace line

• Faulty regulator Replace regulator

• Low compression Valves need adjustment

ave engine serviced by a trained technician

Engine will not crank

• Battery is discharged Charge or replace battery

• Loose or faulty connections or wires Tighten, repair or replace wires

• Faulty ignition key switch or starter control switch Repair or replace switch(es)

Engine overheats

• Incorrect fuel settings ave engine serviced

• Air intake filter screen or cooling fins clogged Clean and clear debris or replace filter

• Low oil level Check and add oil

Exhaust emissions or propane odor

• Carburetor or regulator setting incorrect ave engine serviced by a trained technician

• Dirty or clogged air filter Replace air filter

• Choke engaged Adjust to correct settings

• Loose fittings, clamps or hoses cracked, hoses cut or leaking Tighten or seal; check with soap and water solution,

if bubbles appear, part is still leaking; replace

PG. 10 T E ANSWER

PARTS L ST FOR BUFFER HANDLE ASSEMBLY

PART # DESCR PT ON PART # QTY

1 12V BATTERY 276-GTX14 1

2 (+) BATTERY CABLE 16.5" 153-6-16.5 1

3 BATTERY BOX BOTTOM COVER 283-11-2127B 1

4 3/8-16X1/2" EX BOLT 164-10107 2

5 BATTERY BOX BRACKET 011-6-2720 1

6 STARTER SOLENOID 296-SS581 1

7 VELCRO TANK STRAP 011-6-2705 1

8 TANK STRAP BRACKET LOOP 011-6-2715 2

10 1/4-20X1 1/2" EX BOLT 164-10015 1

11 T ROTTLE CABLE 196-60314 1

12 20 LB. LPG CYLINDER 293-20#STLMF 1

13 ANDLE GRIP 224-1 2

14 3/8-16X3" EX BOLT 164-10131 1

15 LOCK PIN 625-98404A385 1

16 LEFT ANDLE BRACKET 283-025-400 1

17 T- ANDLE 283-025-600 1

18 RIG T ANDLE BRACKET 283-025-500 1

19 3/8-16X1" EX BOLT 164-10115 4

20 ANDLE MAIN FRAME 011-6-2710 1

21 3/8-16 STOVER LOK NUT 164-22834 7

22 BATTERY BOX TOP COVER 283-11-2127T 1

23 (-) BATTERY CABLE 26" 153-6-26 1

24 KEY SWITC 312-308-0385 1

25 WIRE ARNESS 011-762-W K 1

26 1/4-20 FLANGE NUT 164-14FN 1

PG. 8 T E ANSWER

PARTS L ST FOR 21" BUFFER BODY ASSEMBLY

PART # DESCR PT ON PART # QTY

10 PAD RETAINER (CENTER LOK II) 201-LOK 1

11 PAD DRIVE UB 011-6-2740 1

12 WAS ER 011-6-2770 1

13 PAD DRIVER 011-7-2175 1

14 PAD DRIVER SUPPORT RING 011-6-2750 1

15 SPINDLE ASSEMBLY (WIT UB & BEARINGS) 011-6-2730 1

16 BELT 011-7-2190 1

17 TENSIONER PULLEY 011-6-2795A 1

18 BELT TENSIONER 011-6-2795 1

19 ITC PIN CLIP 011-6-2762 2

20 5" W EEL 156-ACPLY-5J3 2

21 CLEVIS PIN 011-6-2761 2

22 W EEL BRACKET 011-6-2760 2

23 SWIVEL CASTOR 011-6-2755 1

24 NUT 1/2-13X1 1/2 164-22008 1

25 BOLT 5/16-18X1 1/4 164-10065 4

26 BOLT 3/8-16X2 164-10123 1

27 BOLT 1/2-13X1 164-10211 4

28 21" ALUMINUM BODY FRAME 011-7-2100 1

29 21" MIG TY LOK 254-16*20.5 1

30 SPINDLE PULLEY (6 3/4") 011-7-2185 1

31 21" BEIGE PAD 250-PT21 1

T E ANSWER PG. 9

PARTS L ST FOR 27" BUFFER BODY ASSEMBLY

PART # DESCR PT ON PART # QTY

10 PAD RETAINER (CENTER LOK II) 201-LOK 1

11 PAD DRIVE UB 011-6-2740 1

12 WAS ER 011-6-2770 1

13 PAD DRIVER WIT MIG TY LOK 011-6-2765 1

14 PAD DRIVER SUPPORT RING 011-6-2750 1

15 SPINDLE ASSEMBLY (WIT UB & BEARINGS) 011-6-2730 1

16 BELT 011-6-2790 1

17 TENSIONER PULLEY 011-6-2795A 1

18 BELT TENSIONER 011-6-2795 1

19 ITC PIN CLIP 011-6-2762 2

20 5" W EEL 156-ACPLY-5J3 2

21 CLEVIS PIN 011-6-2761 2

22 W EEL BRACKET 011-6-2760 2

23 SWIVEL CASTOR 011-6-2755 1

24 NUT 1/2-13X1 1/2 164-22008 1

25 BOLT 5/16-18X1 1/4 164-10065 4

26 BOLT 3/8-16X2 164-10123 1

27 BOLT 1/2-13X1 164-10211 4

28 27" ALUMINUM BODY FRAME 011-6-2700 1

29 27" MIG TY LOK 254-205*26.25 1

30 SPINDLE PULLEY (7 1/2") 011-6-2785 1

31 27" BEIGE PAD 250-PT27 1

PG. 8 T E ANSWER

PARTS L ST FOR 21" BUFFER BODY ASSEMBLY

PART # DESCR PT ON PART # QTY

10 PAD RETAINER (CENTER LOK II) 201-LOK 1

11 PAD DRIVE UB 011-6-2740 1

12 WAS ER 011-6-2770 1

13 PAD DRIVER 011-7-2175 1

14 PAD DRIVER SUPPORT RING 011-6-2750 1

15 SPINDLE ASSEMBLY (WIT UB & BEARINGS) 011-6-2730 1

16 BELT 011-7-2190 1

17 TENSIONER PULLEY 011-6-2795A 1

18 BELT TENSIONER 011-6-2795 1

19 ITC PIN CLIP 011-6-2762 2

20 5" W EEL 156-ACPLY-5J3 2

21 CLEVIS PIN 011-6-2761 2

22 W EEL BRACKET 011-6-2760 2

23 SWIVEL CASTOR 011-6-2755 1

24 NUT 1/2-13X1 1/2 164-22008 1

25 BOLT 5/16-18X1 1/4 164-10065 4

26 BOLT 3/8-16X2 164-10123 1

27 BOLT 1/2-13X1 164-10211 4

28 21" ALUMINUM BODY FRAME 011-7-2100 1

29 21" MIG TY LOK 254-16*20.5 1

30 SPINDLE PULLEY (6 3/4") 011-7-2185 1

31 21" BEIGE PAD 250-PT21 1

T E ANSWER PG. 9

PARTS L ST FOR 27" BUFFER BODY ASSEMBLY

PART # DESCR PT ON PART # QTY

10 PAD RETAINER (CENTER LOK II) 201-LOK 1

11 PAD DRIVE UB 011-6-2740 1

12 WAS ER 011-6-2770 1

13 PAD DRIVER WIT MIG TY LOK 011-6-2765 1

14 PAD DRIVER SUPPORT RING 011-6-2750 1

15 SPINDLE ASSEMBLY (WIT UB & BEARINGS) 011-6-2730 1

16 BELT 011-6-2790 1

17 TENSIONER PULLEY 011-6-2795A 1

18 BELT TENSIONER 011-6-2795 1

19 ITC PIN CLIP 011-6-2762 2

20 5" W EEL 156-ACPLY-5J3 2

21 CLEVIS PIN 011-6-2761 2

22 W EEL BRACKET 011-6-2760 2

23 SWIVEL CASTOR 011-6-2755 1

24 NUT 1/2-13X1 1/2 164-22008 1

25 BOLT 5/16-18X1 1/4 164-10065 4

26 BOLT 3/8-16X2 164-10123 1

27 BOLT 1/2-13X1 164-10211 4

28 27" ALUMINUM BODY FRAME 011-6-2700 1

29 27" MIG TY LOK 254-205*26.25 1

30 SPINDLE PULLEY (7 1/2") 011-6-2785 1

31 27" BEIGE PAD 250-PT27 1

T E ANSWER PG. 7

KAWASAK ENG NE MA NTENANCE SCHEDULE

NTERVAL

MA NTENANCE Daily First 8 hr. Every 25 Hr. Every 50 hr. Every 100 hr. Every 200 hr. Every 300 hr.

Check and add engine oil •

Check for loose or lost nuts and screws •

Check for fuel and oil leakage •

Check battery electrolyte level •

Check or clean air intake screen •

Clean air cleaner foam element •

Clean air cleaner paper element •

Clean dust and dirt from cylinder and

cylinder head fins •

Tighten nuts and screws •

Change engine oil ••

Clean and gap spark plugs •

Change oil filter •

Replace air cleaner paper element •

Clean combustion chambers •

Clean and adjust valve clearance •*•

Clean and lap valve seating surface •

*After the 1st 50 hours

ENG NE TROUBLESHOOT NG

COMMON PROBLEMS & PROBABLE CAUSES SOLUT ONS

Engine cranks but will not start

• Fuel cylinder is empty Refill cylinder

• Shutoff valve is closed Open valve

• Clogged, obstructed, kinked or cut fuel or vacuum line Remove obstruction or replace line

• Spark plug lead disconnected Connect lead to spark plug

• Faulty choke or throttle settings Set controls to correct positions

• Faulty ignition coil Replace coil

• Faulty kill switch Replace switch

• Faulty regulator Replace regulator

Engine starts hard

• Faulty choke or throttle settings Set controls to correct position

• Clogged, obstructed, kinked or cut fuel or vacuum line Remove obstruction or replace line

• Faulty regulator Replace regulator

• Low compression Valves need adjustment

ave engine serviced by a trained technician

Engine will not crank

• Battery is discharged Charge or replace battery

• Loose or faulty connections or wires Tighten, repair or replace wires

• Faulty ignition key switch or starter control switch Repair or replace switch(es)

Engine overheats

• Incorrect fuel settings ave engine serviced

• Air intake filter screen or cooling fins clogged Clean and clear debris or replace filter

• Low oil level Check and add oil

Exhaust emissions or propane odor

• Carburetor or regulator setting incorrect ave engine serviced by a trained technician

• Dirty or clogged air filter Replace air filter

• Choke engaged Adjust to correct settings

• Loose fittings, clamps or hoses cracked, hoses cut or leaking Tighten or seal; check with soap and water solution,

if bubbles appear, part is still leaking; replace

PG. 10 T E ANSWER

PARTS L ST FOR BUFFER HANDLE ASSEMBLY

PART # DESCR PT ON PART # QTY

1 12V BATTERY 276-GTX14 1

2 (+) BATTERY CABLE 16.5" 153-6-16.5 1

3 BATTERY BOX BOTTOM COVER 283-11-2127B 1

4 3/8-16X1/2" EX BOLT 164-10107 2

5 BATTERY BOX BRACKET 011-6-2720 1

6 STARTER SOLENOID 296-SS581 1

7 VELCRO TANK STRAP 011-6-2705 1

8 TANK STRAP BRACKET LOOP 011-6-2715 2

10 1/4-20X1 1/2" EX BOLT 164-10015 1

11 T ROTTLE CABLE 196-60314 1

12 20 LB. LPG CYLINDER 293-20#STLMF 1

13 ANDLE GRIP 224-1 2

14 3/8-16X3" EX BOLT 164-10131 1

15 LOCK PIN 625-98404A385 1

16 LEFT ANDLE BRACKET 283-025-400 1

17 T- ANDLE 283-025-600 1

18 RIG T ANDLE BRACKET 283-025-500 1

19 3/8-16X1" EX BOLT 164-10115 4

20 ANDLE MAIN FRAME 011-6-2710 1

21 3/8-16 STOVER LOK NUT 164-22834 7

22 BATTERY BOX TOP COVER 283-11-2127T 1

23 (-) BATTERY CABLE 26" 153-6-26 1

24 KEY SWITC 312-308-0385 1

25 WIRE ARNESS 011-762-W K 1

26 1/4-20 FLANGE NUT 164-14FN 1

PG. 6 T E ANSWER

Engine Oil Capacity

F381V 1.5 L (1.6 US qt.) when oil filter is not removed

F500V 1.7 L (1.8 US qt.) when oil filter is removed

F541V 1.7 L (1.8 US qt.) when oil filter is removed

Oil Change

Change oil after first 8 hours of operation.

Thereafter change oil every 50 hours.

• Run the engine to warm oil.

• Be sure the engine (equipment) is level.

• Stop the engine.

• Open the oil drain valve and drain the oil into

suitable container while engine is warm.

WARN NG!

Hot engine oil can cause severe burns. Allow

engine temperature to drop from hot to warm

level before draining and handling oil.

Oil Drain Plug

• Close the oil drain valve.

• Remove oil gauge and refill with fresh oil

(See “Recommended Oils” on p5).

• Check the oil level (see “Preparation” on p3

for oil level check).

Oil Filter Change

• Change the oil filter every 100 hours of

operation.

WARN NG!

Hot engine oil can cause severe burns.

Allow engine temperature to drop from hot

to warm level before attempting to remove

oil filter.

Before removing the oil filter, place a

suitable pan under filter connection.

• Drain engine oil into a suitable container.

• Rotate the oil filter (A) counterclockwise to

remove it.

• Coat a film of clean engine oil on seal of new

filter.

• Install new filter rotating it clockwise until

seal contacts mounting surface (B). Then

rotate filter 3/4 turn more by hand.

• Supply engine oil as specified.

• Run the engine for about 3 minutes, stop

engine, and check oil leakage around the filter.

• Add oil to compensate for oil level drop due to

oil filter capacity (See “Oil Level Check” on p3).

WARN NG!

Engine oil is a toxic substance. Dispose

of used oil properly. Contact your local

authorities for approved disposal methods

or possible recycling.

KAWASAK ENG NE BATTERY START W R NG D AGRAM

T E ANSWER PG. 11

PARTS L ST FOR BUFFER FUEL SYSTEM

PART # DESCR PT ON PART # QTY

1 QUICK COUPLER 152-700 1

2 LPG OSE 14" 267-P5561-14 1

LPG OSE 20" 267-P5561-0410 1

3 FUEL LOK-OUT (VACUUM) 152-300 1

4 90˚ FITTING 177-116B04 1

5 VACUUM OSE FITTING 166-62029 1

6 1 1/2" NIPPLE 177-56021 1

8 FUEL OSE FITTING 166-62039 1

9 FUEL LOK-OUT (12 VOLT) 152-N3-0173-1 1

10 FUEL REGULATOR (T60-E) 152-500 1

CAUT ON!

T E ANSWER PG. 5

b. Charge the battery or provide an absolute

source of 12 volt DC power capable of 50

amperes total output. (A pair of good

jumper cables from your car or truck battery

will suffice.) Equip yourself with an

inexpensive 12 volt test light.

c. If the trouble seems to be in the electrical

control equipment, you may wish to

disconnect the starter from the system so

as to check the system without spinning

the engine.

d. Battery rundown. A common problem

is letting the battery run down. What

usually happens is that it takes the crew a

few jobs to get used to the whole system,

so the machine is stopped and started

quite often. Key left in on position, when

engine is turned off, will result in battery

running down – dying.

D. Belt nspection & Replacement

nspection

• Fold T- andle to forward position

• Tilt machine back on rear of body & handle

• If belt is worn, cracked or shredding, belt

needs to be replaced.

Replacement

• Place 3/4" wrench on end of the shaft on the

top of the buffer body.

• Turn pad driver counter-clockwise to

remove.

• Take belt off by turning 3/4" wrench on shaft

and removing belt from pad driver pulley

and engine crank pulley.

• Check pad driver pulley & engine crank

pulley for correct alignment.

• Install new belt on engine crank pulley &

pad driver pulley, using 3/4" wrench.

• Install belt on tension pulley

• Install pad drive onto shaft, and return

buffer to operating position.

E. Adjusting Pad Pressure

The pad pressure may be adjusted by moving

the wheels:

• Forward to reduce weight on the buffer pad

• Backward to increase the weight

This adjustment may be required to adjust to

different floor finishes or to the weight variance

of aluminum or steel propane tanks.

KAWASAK ENG NES

Tune-up Specifications

ITEM SPECIFICATIONS

Ignition Timing Unadjustable

Spark Plugs: Champion – RCJ8Y

Gap 0.75 mm (0.30 in)

Low Idle Speed 1500 RPM

igh Idle Speed 3400 RPM

Valve Clearance IN: 0.10-0.15 mm

(0.004-0.006 in)

EX: 0.10-0.15 mm

(0.004-0.006 in)

Other No other adjustment

Specifications needed

NOTE: igh and low idle speeds may vary

depending on the equipment on which the engine

is used. Refer to the equipment specifications.

Engine Oil

Check the engine oil daily before starting the

engine otherwise shortage of the engine oil may

cause serious damage to the engine such as

seizure.

• Place the engine on a level surface. Clean the

area around the oil gauge before removing it.

• Remove the oil gauge and wipe it with a

clean cloth.

• Pour the oil slowly to “FULL” mark on the oil

gauge.

• Insert the oil gauge into the tube WIT OUT

SCREWING IT IN.

• Remove the oil gauge to check the oil level.

The oil level should be between “ADD” and

“FULL” marks. Do not overfill.

• Install and tighten the oil gauge.

The following engine oils are recommended:

API Service Classification: SF, SG, S , or SJ.

Oil Viscosity

Choose the viscosity according to the

temperature as follows:

NOTE: Using multi grade oils (5W-20, 10W-30, and 10W-40)

will increase oil consumption. Check oil level more frequently.

-20˚C -10˚C 0˚C 10˚C 20˚C30˚C 40˚C

-4˚F 14˚F 32˚F 50˚F 68˚F 88˚F 104˚F

SAE5W-20

SAE30

SAE40

SAE10W-30/SAE10W-40

PG. 12 T E ANSWER

KAWASAK 603cc ENG NE

PART # DESCR PT ON PART # QTY

1. Foam at Filter 186-271964 (1)

2. Debris Screen 309-18540 (1)

3. Foam at Seal 175-7.75*9.25*1 (1)

4. Oil Pressure Switch 152-N3-0082 (1)

5. Oil Filter 309-49065-7007 (1)

6. Oil Drain Valve 312-504-0185 (1)

7. 1 / 4 x 1 1 / 4 Key 199-N NT-SE UND (1)

8. Crank Pulley 011-6-2780 (1)

9. Exhaust Manifold Gasket 309-11060-7016 (2)

10. Exhaust Manifold 152-603-MAN (1)

11. Catalytic Muffler 152-603-MUF (1)

12. Debris Screen Adapter 283-040-2250 (1)

13. Air Filter Element 309-11013-7049 (1)

14. Foam Pre Filter 309-11013-7046 (1)

PG. 4 T E ANSWER

•Propane tanks should be removed &

stored in a protected off site area.

. OPERAT ON

Provide and use ear protection during

operation.

Never let an untrained person operate or

perform repairs on the machine. They may hurt

themselves, damage the floor or the

equipment.

Engine speed not to exceed 3400 RPM.

This machine is not suitable for picking up

hazardous dust.

Do not use on surfaces with a gradient

exceeding 2%.

V. STOPP NG THE ENG NE

Turn the propane tank valve clockwise to a closed

position and turn the key OFF.

NOTE: The exhaust system will be very hot and

takes several minutes to cool, so keep yourself

and all materials clear.

V. PROCEDURES

Follow machine (straight ahead) at moderate

walking speed. Keep moving.

• Do not operate the machine in one location

for more than a few seconds — it will

damage — “burn” the finish.

• When operation is completed remove tank

and store in a secure, protected off site

(preferably outdoor) location.

• Do not use for scrubbing operations.

• Never tilt back machine to maintenance

position while engine is running.

• Never reach under protective shroud when

engine is running.

V . MA NTENANCE

A. Machine & engine maintenance

1. Refer to engine manufacturer’s owners

manual and comply completely with the

instructions. Change the oil and filter according

to the Engine Owners Manual.

2. Keep a good service log on each machine

with the date, hour meter reading, type(s) of

service performed and the name of the person

who performed them.

3. Clean the entire unit after each use. When

cleaning the unit, check for possible loose nuts

and bolts.

B. Engine maintenance meter

This multi-function meter acts as a preventive

maintenance tool, which benefits you with

increased fuel economy, less down-time and

longer engine life.

The meter’s displays are:

Hour Meter: Displays total run hours when

machine is off.

Tachometer: Indicates engine RPM during

operation.

Service Alert: The display flashes to alert you to

lube and change the oil at 25 hour intervals. The

service alert only flashes during operation and it

warns you to change the oil for only two hours.

After the two hours is reached, the alert will

automatically reset to the next 25 hour interval.

Therefore, it is recommended that a separate

maintenance log be kept to track oil changes.

Remember that being safe is a full-time, every

day job. Follow all information posted on the

machine and the LPG tank.

Never allow anyone to operate this machine

who has not read or cannot understand the

given instructions.

C. Troubleshooting the electrical system

1. Check all wire connections for obvious

problems. Remove LPG tank, then remove

battery box cover. Check all connections visibly

and physically. If any “loose”, damaged or

unconnected wires are noticed, replace or

repair as needed.

2. Check the battery posts and wires. Always

wear a face shield, safety glasses and

protective clothing when working around a

battery! The gases can be explosive and the

acid is highly corrosive to metals, cloth and

ALL UMAN TISSUE (skin, eyes, etc.) If the

battery post(s) are corroded, remove the wires

and clean posts and wires. Applying some axle

grease on the posts of the battery after they are

cleaned will slow down the battery corrosion

process.

If nothing obvious is noted, a more detailed

investigation is warranted. Before any such

troubleshooting begins, the following things

should be done:

a. Replace propane LPG tank with one from

a machine that runs.

T E ANSWER PG. 13

NOTES

Do not use “T” handle when attempting to tilt

back machine for service or cleaning. The

“T” handle is designed for control during

operation only.

Do not use excessive vertical pressure.

. PREPARAT ON

A. Check that the suggested maintenance

schedule has been observed:

All machines are equipped with a multi-function

maintenance meter. The functions include the

following: hour meter, service alert and tachometer.

(See Engine Maintenance Meter Instructions on p4).

B. Check the engine oil before every operation:

Make sure the machine is level when checking the

oil. Always take 2 readings of the dipstick before

adding oil. If the oil level is below the full mark, add

just enough oil to the engine to bring the oil level

up to the full mark. Never over fill. Follow the

guidelines in your Engine Owners Manual. Check

for foreign material on the dipstick.

C. Properly fill and check your LPG tank and

all LPG fuel lines for leaks:

1. Every tank has been pressure and leak

tested. owever, every time a tank is filled

and/or connected to the machine it should be

soap tested. All LPG lines must be pressurized

and every inch of line and connections must be

sprayed. If you find a leak, make the proper

repairs before operating the machine.

NOTE: The connection and disconnection of

the LPG tank must be done in a well ventilated

area with NO source of ignition within 10 feet

(3 meters) from the point of connection.

2. Never over fill the LPG tank! The LPG tank

is designed to hold just 20 pounds of propane.

Make sure to weigh the tank as it is being

filled. The gross weight of a full tank should

not exceed 48 pounds. If while operating the

machine, you notice frost forming on the LPG

lines or the regulator, your tank has been over

filled. If you continue to operate the machine

in this condition, damage will occur. The

excess propane in the tank must be removed

before normal operations resume. The

bleeding of a propane tank should be done in a

safe location outside the building. In some

cases the regulator must defrost before

restarting the engine.

D. Connecting the high pressure hose to the

LPG Tank:

Make sure the couplers are in line and screwed

together hand tight. If this is not done properly,

fuel will not pass through to the regulator. Never

complete the connection of the tanks to the

machine by using a wrench. Always do it by

hand. Listen for the rush of fuel to the lock-out

device when you open the tank valve. If you

hear this, it indicates a good connection has

been made at the tank.

NEVER CHANGE OR ALTER THE PROPANE

CONTROL EQU PMENT!

E. nstall fresh pads or brushes before every job:

To install a fresh pad, set the machine down in

the rear. Unscrew and remove the pad-centering

ring. Remove the old pad and center the new

pad onto the pad driver. Reinstall the pad-

centering ring. Never “flip” a pad. Keep the

same side down throughout the life of the pad.

Even after a pad is cleaned, you can tell the

down side by the centering ring indentation.

This practice will increase the pad life and help

maintain a properly functioning pad driver.

NEVER T LT A MACH NE ON TS S DE!

. START NG THE ENG NE

A. Open propane (LPG) tank valve (counter

clockwise).

B. Set throttle control at idle.

C. Battery start – turn key to the start position &

move throttle toward fast position. If engine

does not start, release key and return to step “B”.

D. Electric start – push “Start” button and move

throttle toward fast position until engine

starts. Starter should not be engaged for

more than 10 seconds at a time.

•When a propane tank is overfilled it may

temporarily cause the fuel regulator to

malfunction. Remove the tank to a well

ventilated location. Release some gas until

the cloud disappears and escaping gas is

“clear”. Reinstall tank.

• All machines are equipped with tamper

proof fuel systems. f a fuel problem

exists, contact an authorized service

center.

T E ANSWER PG. 3

PG. 14 T E ANSWER

NOTES

WARN NG

MPORTANT SAFETY NSTRUCT ONS

READ and UNDERSTAND all instructions and

warnings before operating this machine!

Do not store or use gasoline or other

flammable vapors and liquids in the vicinity

of this machine. Always store equipment

away from heater rooms, boilers, gas-fired

water heaters or any other source of open

flame. Propane is highly flammable.

Always store LPG tanks (full or empty)

outside in a secure, well ventilated area.

NO SMOK NG, NO SPARKS, NO FLAMES

NEAR UN T OR LPG TANK.

Operate only in well ventilated areas. Buildings

must be provided with:

A. A continuous mechanical ventilation that

removes the products of combustion to the

outdoors of not less than 300 CFM for each

10,000 BTU or fraction thereof; or

B. Natural ventilation of not less than 300 CFM for

each 10,000 BTU input or fraction thereof,

based on a maximum of one-quarter air

exchange per hour for the net building volume.

f you smell LPG gas, stop the unit and check

for leaks. Also open windows, don’t touch

electrical switches, extinguish any open flames.

Call your gas supplier if no leaks are found.

Do not adjust the fuel system without the proper

analysis equipment.

Never tilt the equipment on its side for pad, belt

or brush replacement. t is designed to tilt back

on its rear wheel and handle for maintenance

and repair. A second person should aid in lifting

and securing equipment for repair.

Never tilt & transport while engine is running.

Keep hands and feet clear of all moving parts.

Never try to replace parts or repair equipment

with machine running.

Turn the gas off at the tank to kill the engine.

Remove the LPG tank and store it in an

approved area when not in use. A “NO

SMOK NG” sign should be permanently

displayed at the storage area.

Always vent an over-full bottle using the tank’s

bleed valve, out of doors away from all closed

places and away from any fire or flame producing

device. Vent until the white vapor turns clear.

Keep all objects clear of the exhaust system

during and after operation.

Do not leave this machine unattended while

the engine is running.

Do not operate equipment in one location for

more than a few seconds. Damage to floor

surface can occur.

Always store equipment away from possible

damage by falling objects in warehouse-type

areas. Always store LPG tanks outside in a

secure, well-ventilated area.

When the LPG tank is attached to the machine

and not running, the operator should not

leave the machine unattended except for

short periods of time such as rest stops,

washroom or meal stops.

The operator must completely understand all

instructions, warnings and operating

procedures before using this machine.

The manufacturer’s warranty will be voided if

the machine is not maintained in accordance

with this manual’s recommended

maintenance instructions and the engine

manufacturer’s recommended maintenance

procedures. Failure to do so may cause

damage to the machine, equipment,

furniture, buildings or personal injury!

A maintenance record should be kept indicating

date of service, hours on engine, and work

done.

TRANSPORT & PREPARAT ON

Follow the instructions given in this booklet,

the Engine’s Owners Manual and the training

given by your supervisor for the safe

operation of this machine. Failure to do so

can result in personal injury and/or damage

to the machine or property.

DO NOT OPERATE TH S MACH NE N AN

EXPLOS VE ENV RONMENT!

TH S PROPANE MACH NE S NTENDED

FOR COMMERC AL USE.

PG. 2 T E ANSWER T E ANSWER PG. 15

NOTES

WARN NG