Nilfisk-Advance PBU 21KACAT User manual

PBU Propane Floor Burnisher
04/15 Form No. 56043169
Service Manual
Model Numbers:
56384165 PBU 21KACAT
56384166 PBU 27KACAT 56384167 PBU 21KACATCLDC 56384168 PBU 27KACATCLDC
English
21 KACAT
Base Model
27 KACAT
Base Model
21 KACAT CLDC
Dust Control Model
27 KACAT CLDC
Dust Control Model
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Contents iiService Manual – PBU Propane Floor Burnisher
Contents
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General Machine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Service Manual Purpose and Application . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Other Reference Manuals and Information Sources . . . . . . . . . . . . . . . . . . . . 4
Document Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General Safety Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Burnishing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Functional Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Clutch Circuit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Burnishing Pad Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Burnishing Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Clutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Maintenance Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cooling Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Intake Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Oil and Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Spark Plug Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Throttle Cable Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Throttle High Idle Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Carburetor Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fuel Regulator/Fuel Mixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Low Idle Mixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
High Idle (Full Load) Mixture . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Mufer/Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Ignition/Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
CarbGard System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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Contents iiiService Manual – PBU Propane Floor Burnisher
Top End, Heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Cooling Fan Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Valve Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Cylinder Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Cylinder Head Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 41
Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Valve and Seat Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Cylinder Head Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Engine Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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General Information 4Service Manual – PBU Propane Floor Burnisher
General Information
General Machine Description
The PBU machine is a propane-powered oor burnisher, with replaceable pads for burnishing oor surfaces.
The machine is manually propelled, and the bufng pad rotates at high speed to produce high gloss oor
surfaces. The PBU is powered by a 4-stroke, air-cooled, v-twin, propane-engine. When equipped with the
Carb Gard system, an oxygen sensor monitors exhaust oxygen content for an indication of relative air/fuel
mixture. If the mixture exceeds an allowable limit for more than one minute, Carb Gard will shut down the
engine.
Service Manual Purpose and Application
This Service Manual is a resource for professional service technicians. It provides information for
understanding how the machine operates, where components are located, basic troubleshooting,
maintenance and mechanical service operations.
The cover page of this manual lists each machine part number that the manual applies to. Compare the part
number of the machine you are working on to the model numbers listed on the cover page to be sure you are
using the correct manual.
Other Reference Manuals and Information Sources
The following documents contain parts information and instructions for machine operation:
• Instructions for Use: LT071600_A and LT071500_A
Document Revision History
April 2015, Initial Release
Safety Information
Symbols
It is important for you to read and understand this manual. The information it contains relates to protecting
your safety and preventing problems. The symbols below are used to help you recognize this information.
Danger: Indicates a potentially hazardous situation which, if not avoided, will result in death or
serious injury.
Warning: Indicates a potentially hazardous situation which, if not avoided, could result in death
or serious injury.
Caution: Indicates a potentially hazardous situation which, if not avoided, could result in minor
or moderate injury.
Caution: When used without the Safety Alert Symbol, indicates a potential situation which, if not
avoided, could result in property or machine damage.
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General Information 5Service Manual – PBU Propane Floor Burnisher
General Safety Messages
Anyone operating the machine should read the following carefully and be informed of potentially dangerous
operating conditions. Operators should be familiar with the location and use of all safety devices on the
machine. Do not use the machine if it is not in proper operating condition, and report any damage or
operation faults immediately.
Danger:
−Never operate this machine without proper ventilation. It is the responsibility of the
machine operator, machine owner, and the site manager to ensure that the air exchange
system where the machine is to be used is in compliance with local building codes and is
operating properly. Failure to operate this machine in a well-ventilated area could lead
to sickness, injury, or death from carbon monoxide exposure.
−This machine emits Carbon Monoxide (CO), which is colorless, odorless, non-irritating
gas. The rst symptoms of CO exposure include headache, drowsiness, dizziness, and
nausea. If you should experience any of these symptoms while operating the machine,
shut off the machine and go outside to get fresh air. Have the machine tested for CO
emissions by a qualied service technician before using it again.
−Prolonged or high exposure to CO may result in vomiting, confusion, and collapse in
addition to loss of consciousness and muscle weakness. If such symptoms occur, call
911 for emergency medical attention. If you have experienced these symptoms, DO NOT
operate this machine or any other propane machine again until cleared by a physician.
Excessive exposure to CO can result in death.
Warning:
−Propane is a highly ammable fuel. Keep open ames and ignition sources away from
the machine and propane tanks. Do not store propane cylinders inside a building. If you
smell propane, shut off the machine immediately and take it outside the building.
−Do not use a liquid withdraw propane cylinder or overll a cylinder to cause it to supply
propane in liquid form. This machine is intended to use propane in vapor form. Liquid
propane will damage the system and poses a risk of re. This machine uses a 20lb
(9.1kg) capacity aluminum or steel cylinder, which meets the DOT 4E240 standards.
Filling should be done only by a qualied propane dealer. Fill through the service valve
only. A properly lled cylinder should not exceed 80% of the rated capacity.
Caution:
−Do not make unauthorized modications or alterations to this machine. Nilsk-Advance
assumes no liabilities for injury or damage resulting from an unauthorized modication
or alteration to the machine. Any unauthorized modication or alteration to this
machine voids all warranties.
−To reduce the risk of burns, stay clear of the engine and exhaust until the machine has
cooled.
−When servicing machine, stay clear of moving parts, and do not wear loose clothing.
Block machine wheels before raising or jacking up machine. Use hoist stands that will
support the weight of the machine. Wear eye and ear protection. Disconnect battery
connections before servicing machine. Use only Nilsk-Advance authorized replacement
parts.
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General Information 6Service Manual – PBU Propane Floor Burnisher
Nameplate
The machine nameplate is located
on the interior face of the handle
upright, and contains the machine
model and serial number.
Component Locations
The following images show the locations of some of the primary components of the machine.
• Starter Solenoid
• Starter
• Voltage Regulator
• Propane Regulator
• Fuel Cutoff Valve
• Oil Dipstick
• Oil Pressure Sensor
• Oil Filter
• Mufer
• Air Filter
• Carburetor
Starter
Solenoid
Battery
Oil
Dipstick
Oil
Filter
Oil Pressure
Sensor
Starter
Voltage
Regulator
Propane
Regulator
Fuel
Cutoff
Muffler
Air Filter
Carburetor
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General Information 7Service Manual – PBU Propane Floor Burnisher
Specications
(See other system chapters for specications not listed here.)
Model 21KACAT 27KACAT 21KACAT CLDC 27KACAT CLDC
Part Number 56384165 56384166 56384167 56384168
Pad Size 21” (53 cm) 27” (68 cm) 21” (53 cm) 27” (68 cm)
Engine 603cc, Air Cooled, KAWASAKI FS481V
Engine Oil SAE 30 w/ API Service SH or SJ, 1.8qt (1.7L) w/ lter, 1.6qt (1.5L) w/o lter
Spark Plug Part # 56384271, 0.025 in. (0.635 mm) Gap
Carb Gard No No Yes Yes
Clutch None None Magnetic Magnetic
Pad Speed
Eng. @ 3500 RPM 2000 RPM 1500 RPM 2000 RPM 1500 RPM
Propane Tank 20 lb. (9.1 kg) Vapor Withdrawl
Auto Fuel Shutoff Yes Yes Yes Yes
Low Oil Shutdown Yes Yes Yes Yes
Hour Meter Yes Yes Yes Yes
Sound Pressure <89 dB(A)
Productivity Rate 25,000 ft2/hr
(3,066 m2/hr) 33,000 ft2/hr (3,660 m2/hr) 25,000 ft2/hr (3,066 m2/hr) 33,000 ft2/hr (3,660 m2/hr)
Agency Approvals EPA, ULApproved Propane Comp. EPA, ULApproved Propane Comp.
CSAApproved
"CARB Certied
(California Air Re-
source Board)"
Yes Yes Yes Yes
Weight
(w/o cylinder) 187 lbs. / 85 kg. 200 lbs. / 91 kg. 187 lbs. / 85 kg. 200 lbs. / 91 kg.
Length 56” (142.4 cm) 61.5” (156.2 cm) 56” (142.4 cm) 61.5” (156.2 cm)
Width 23.5” (59.7 cm) 30.5” (77.5 cm) 23.5” (59.7 cm) 30.5” (77.5 cm)
Height 39.5” (100 cm) 41.0” (104 cm) 39.5” (100 cm) 41.0” (104 cm)
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General Information 8Service Manual – PBU Propane Floor Burnisher
Maintenance Schedule
ITEM
Interval
Daily 8 Hour
(Break In) Every 25
Hours
Every
50
Hours
Every
100
Hours
Every
200
Hours
Every
300
Hours
Check or clean air intake screen •
Check for fuel and oil leakage •
Check for loose or lost nuts and
screws •
Tighten nuts and screws •
Check battery electrolyte level •
Check and add engine oil •
Change engine oil • •
Change oil lter •
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 lter •
Check and adjust engine valve
clearance •
Clean and lap valve seating surface •
Clean dust and dirt from cylinder
and cylinder head ns
•
Clean and re-gap spark plugs •
Clean combustion chambers •
Return machine to authorized
service center for overall checkup. •
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Burnishing System 9Service Manual – PBU Propane Floor Burnisher
Burnishing System
Functional Description
The burnishing system consists of a replaceable burnishing pad and pad holder, which is driven by a belt
from the engine’s output shaft. Belt tension is controlled by a spring loaded idler pulley. Some units are
equipped with a clutch on the engine output shaft to disconnect the drive pulley when not in use. The clutch
is electrically actuated, and controlled by a switch on the operator’s handle. Units equipped with dust control
have an aluminum shroud which covers most of the burnisher drive components.
Component Locations
• Burnishing Disk Pulley
• Tensioner/Idler Pulley
• Drive Belt
• Engine Shaft
• Drive Pulley
• Drive Pulley with Clutch
Burnishing
Disk Pulley
Drive Belt
Tensioner/
Idler Pulley
Engine Shaft/
Drive Pulley
Drive Pulley
With Clutch
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Burnishing System 10Service Manual – PBU Propane Floor Burnisher
Troubleshooting
Problem Cause Correction
• Burnishing pad turns
slow
• Machine seems
underpowered
When the drive belt slips
the pad will rotate slower
than normal. Even though
this doesn’t actually affect
the engine, it can seem
like the engine has lost
power.
• Inspect the drive belt for glazing (smooth glassy
surface on the tapered faces). Replace the drive
belt if glazed.
• Inspect the belt tensioner for proper operation,
and that the drive belt appears to be properly
tensioned. Clean or replace the tensioner if it
cannot maintain proper belt tension.
• If so equipped, inspect the drive clutch for
slipping. See below for more details.
For clutch-equipped
machines, the burnishing
pad does not engage, is
slow to engage, sporadic,
or turns slowly.
A problem with the clutch
will present itself with
one of these symptoms.
Either the clutch is faulty
or it is not getting a proper
electrical connection.
• See below for troubleshooting.
Clutch Circuit Troubleshooting
1. Check that the battery voltage is at least 12 volts. If
below 12 volts, troubleshoot the battery and charging
system rst.
2. Disconnect the clutch cable connector and measure
the resistance of the coil. If the resistance is outside
of the range of 2.5 to 3.1 ohms, replace the coil.
3. Next, check for an open circuit with the key switch in
the on-position and the clutch switch engaged. This
can be completed with the clutch cable unplugged for
easier access to voltage test points. You should nd:
• 12 volts between the 2 contacts in the clutch
connector
• 12 volts between either connector at the clutch
switch and a chassis ground point
4. Reconnect the clutch connector and look for a high
resistance path (excessive voltage drop). Repeat step 3 with the
clutch connected. If any of the voltages are signicantly lower
than the previous measurements, there is a poor or corroded
connection in the wiring.
5. If no electrical problems were found, remove the clutch as
described on page 13.
12V
12V
3Ω
Clutch
Connector
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Burnishing System 11Service Manual – PBU Propane Floor Burnisher
Removal and Installation
Burnishing Pad Holder
The burnishing pad holder may need to be replaced if it becomes
damaged and no longer holds the burnishing pad securely. It may
also need to be removed as a prerequisite to other maintenance
procedures.
1. Close the propane service valve and remove the propane
tank.
2. Stand the machine on its back in the pad change position.
3. Remove the burnishing pad from the pad holder.
4. Place a 3/4" open end wrench on the top of the burnishing
shaft to hold the shaft from turning.
5. Wear gloves to protect your hands from the gripping
spines on the pad holder.
6. Unscrew the pad holder from the shaft in a normal
counterclockwise direction.
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Burnishing System 12Service Manual – PBU Propane Floor Burnisher
Drive Belt
The drive belt needs to be replaced if it becomes worn, frayed, or glazed. Glazing is caused by the belt
slipping against the pulleys, which causes the belt to slip even more. A glazed belt has a shiny texture of the
sloped edges that contact the pulleys.
1. Close the propane valve, tip the machine up into the pad
change position, and remove the Burnishing Pad Holder
described on page 11
2. For models with Dust Control, remove the pulley cover
by removing the 4 screws, washers, and lock washers.
3. For machines with dust control, loosen but do not
remove, the tensioner arm bolt so the belt can
t between the idler pulley and the dust shroud.
Skip step 4 below.
Tension
Arm Bolt
Burnishing
Pad Shaft
4. Place a 9/16” box wrench on the idler pulley
shaft bolt, and rotate the tensioning arm
counterclockwise to de-tension the drive belt.
5. Roll the belt off the main pulley. It may be helpful
to use a screw driver to get it started.
6. Remove the belt from the engine pulley.
• For Dust Control models, remove the belt from
above the dust shroud by pulling it out toward
the engine pulley.
• You may need to loosen the tensioner pulley
mounting bolt to permit the belt to t between
the pulley and dust shroud. When repositioning
the tensioner, make sure the alignment pin is
inserted into the hole in the burnishing deck.
7. Before replacing the belt, check the movement of
the tensioning arm to make sure it moves freely.
Pulley
Cover Dust Control Model
Burnishing
Spindle
Idler
Pulley
9/16”
Wrench
Screw
Driver
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Burnishing System 13Service Manual – PBU Propane Floor Burnisher
Burnishing Clutch
The burnishing clutch is an optional accessory on models with dust control. It is a 12 volt magnetically
actuated clutch that disengages the burnishing drive when not in use.
1. Close the propane valve, tip the machine into the pad change position, and remove the Burnishing Pad
Holder described on page 11
2. Before removing the drive belt, you may want
to loosen (but don’t remove) the clutch retaining
bolt. With the belt in place, the burnishing pulley
can be used to help keep the motor shaft from
rotating while you loosen the bolt if the clutch is
engaged.
• If available, an impact driver works best for
loosening the bolt while taking the least amount
of effort to keep the motor shaft from turning.
3. Remove the Drive Belt described on page 12.
4. Disconnect the clutch cable connector located
behind the propane regulator.
5. Loosen the 3 engine mounting bolts just enough
to raise the engine and extract the clutch cable through the opening in the deck.
• Alternatively, you could remove the clutch wires from the cable connector and remove the cable
without lifting the engine.
6. Finish removing the clutch retaining bolt and remove the clutch from the motor shaft.
7. During replacement:
• Make sure the spacer washer is in place on the engine shaft between the engine and the clutch.
• Use Loctite 243 on the clutch retaining bolt.
• Torque the clutch retaining bolt to 40 ft-lbs.
Clutch Switch
1. Remove the 4 screws that secure the cover to
the switch enclosure and remove the cover and
switch.
2. Disconnect the two wires from the switch. During
replacement, note that there is no polarity for the
wires.
3. Slide the switch off the 2 mounting pins.
Retaining
Bolt
Engine
Bolts (3)
Clutch
Cable
Mounting
Pins
Clutch
Switch
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Engine System 14Service Manual – PBU Propane Floor Burnisher
Engine System
Component Locations
• Starter Solenoid
• Starter
• Voltage Regulator
• Propane Regulator
• Fuel Cutoff Valve
• Oil Dipstick
• Oil Pressure Sensor
• Oil Filter
• Mufer
• Air Filter
• Carburetor
Starter
Solenoid
Battery
Oil
Dipstick
Oil
Filter
Oil Pressure
Sensor
Starter
Voltage
Regulator
Propane
Regulator
Fuel
Cutoff
Muffler
Air Filter
Carburetor
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Engine System 15Service Manual – PBU Propane Floor Burnisher
Maintenance and Adjustments
This section includes maintenance and adjustment procedures associated with routine maintenance.
Additional procedures are located within the mechanical sections of this chapter.
Maintenance Specications
The table below contains a quick reference for common maintenance parameters. Also refer to the complete
list of Specications described on page 7 and the Engine Specications described on page 46.
Quick Reference Parameters
Parameter Value Reference
Low Idle Speed 1800 - 2000 rpm page 25
High Idle Speed 3400 - 3450 rpm @ 21”
3450 - 3550 rpm @27” page 25
Oil Grade SJ or higher
page 17
Viscosity SAE 30
Capacity w/o lter 1.5L (1.6 US qt)
Capacity w/ lter 1.7L (1.8 US qt)
Spark Plug NGK BPR4ES page 18Spark Plug Gap 0.6 mm (0.025 in)
Spark Plug Torque 22 N•m (16 ft•lb)
Coil Air Gap 0.2 - 0.4 mm
(0.008 - 0.016 in.) page 33
Valve Clearance 0.10 - 0.15 mm
(0.004 - 0.006 in.) page 38
Min. Cyl. Compression 483 kPa (70 psi) page 35
Cooling Air Filter
The cooling lter should be cleaned every 1 engine-hour.
It is also a good practice to clean the cooling air lter
when ever the machine is serviced. Restrictions in the
airow can result in the engine to run hotter than normal.
1. Carefully pull the lter off the top of the engine,
taking care not to damage the Velcro fasteners.
2. Brush off large debris from the lter surface.
3. The lter may be washed with light detergent (dish
soap) and water.
4. Squeeze out excess water. Do not wring the lter as
this can tear the foam or damage the Velcro tabs.
5. Set the lter aside to dry before reinstalling it.
Cooling
Filter
Hook and
Loop Tabs
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Engine System 16Service Manual – PBU Propane Floor Burnisher
Intake Air Filter
The engine air intake has a 2-stage air lter: A washable pre-lter and a disposable main lter. The main
lter prevents ne dust from entering the engine, and the pre-lter increases the life of the main lter by
keeping coarse debris from clogging the lter.
1. Rotate the two knobs on the lter cover 1/4-turn
counterclockwise, and remove the cover.
2. Loosen the upper clamp and remove the lter
from the plenum, or optionally, loosen the lower
clamp and lift the lter and air plenum up off the
carburetor. You may nd this easier than trying
to remove the lter from the plenum.
3. Slide the foam pre-lter off the main lter. The
pre-lter may be washed with mild soap (dish
soap) and water.
4. Thoroughly dry the pre-lter.
• Do not wring the lter, as this can tear the foam.
• Do not install the pre-lter over the main lter unless
it is completely dry. Moisture from the pre-lter can
damage the paper of the main lter.
• Replace the pre-lter if it becomes torn or damaged.
5. If the main lter is relatively clean, it can be vacuumed
off and replaced (do not use compressed air). However, if
the lter media appears darkened, it should be replaced.
6. Make sure the pre-lter is completely dry, and reinstall
it over the main lter.
7. Reinstall the main lter assembly onto the engine.
Filter
Cover
Engine
Filter
Upper
Clamp
Lower
Clamp
Air
Plenum
Main
Filter
Pre-Filter
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Engine System 17Service Manual – PBU Propane Floor Burnisher
Oil and Filter Change
The oil should be changed every 50 engine-hours, and the oil and lter should be changed every 100 engine-
hours (every other oil change).
Oil Change Parameters
Oil Grade SJ or higher
Viscosity SAE 30
Capacity w/o lter 1.5L (1.6 US qt)
Capacity w/ lter 1.7L (1.8 US qt)
1. Run the engine for a couple minutes to warm it, but not so hot that it is difcult to work on.
2. Tilt the machine back on its rear casters (pad
off the oor), and chock the wheels to keep it
from rolling.
3. Remove the end cap from the oil drain, and
place a 1/2” plastic tube on the oil drain to
extend the drain away from the burnishing
deck.
4. Place a container under the end of the tube to
capture the used oil.
5. Rotate the quick-release oil drain valve
1/8-turn and pull it outward about 1/2-inch
to release the valve. The oil should begin to
drain into the catch container.
6. Continue to drain as much of the old oil as
possible until the tube stops dripping.
7. Close the quick-release valve, remove the
tube, and replace the drain cap.
8. If the oil lter is not being changed, skip to
step 14 below.
9. Slightly loosen the oil lter using a small oil
lter wrench.
• If necessary, disconnect the oil pressure
sensor wires to avoid bending the terminals.
10. Tilt the burnisher slightly on its left side to avoid dripping oil on the engine crankcase.
11. Finish removing the oil lter, taking care keep it upright, as it contains a signicant amount of oil.
12. Using your nger, apply a small amount of clean oil to the O-ring on the new oil lter to lubricate it, and
install the new lter.
13. Tighten the oil lter to 11.8 N•m (8.5 ft•lbs), or approximately 3/4-turn more after the O-ring rst
touches the crankcase. Do not overtighten the oil lter.
14. Remove the dipstick and add oil (see capacity above) through the ll spout.
15. Run the engine for about a minute and recheck the dipstick level.
Drain Cap
Drain Valve
Oil Filter
Dipstick and
Fill Spout
Oil Pressure
Sensor
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Engine System 18Service Manual – PBU Propane Floor Burnisher
Spark Plug Change
Spark plugs provide a view into the health of the engine. When changing spark plugs it is a good idea to
make note of the condition of the plugs to see if the engine is operating properly. Normal spark plugs will
generally have a light tan or gray color around the electrode. If the spark plugs have a different appearance,
additional engine troubleshooting should be completed. There are many different signs of an unhealthy
engine, but the two most common signs are blackened spark plugs. If the tips are blackened with a dry
soot, it is a sign the engine is running rich. If the spark plugs are blacked and wet-looking, it is a sign of oil
consumption.
#1 Cylinder #2 Cylinder
Plug Wire
Boot Plug Wire
Boot
Plug Type: Quantity-2, NGK BPR4ES
Plug Gap: 0.6 mm (0.025 in)
Socket Size: 13/16-inch
1. Pull the plug wire boot off the spark plug. Take care not to pull the boot from
the wire.
2. Using a 13/16” spark plug socket, remove the spark plug from the cylinder.
3. Inspect the gap on the new plugs. The manufacturer’s default gap is 0.032”
(0.8 mm), which is beyond specications for the Kawasaki engine, and must be
re-gapped.
4. Install the new spark plug. Make sure to thread the spark plug by hand to
avoid cross threading.
5. Tighten the spark plugs to 22 N•m (16 ft•lb).
6. Reconnect the plug wire boots. You should feel a slight click as the boot snaps
over the tip of the spark plug. Give the boot a slight tug to make sure it is
properly connected.
Plug Gap
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Engine System 19Service Manual – PBU Propane Floor Burnisher
Troubleshooting
The following troubleshooting decision tree is courtesy of Kawasaki and contains information relating to
both gasoline and propane engines.
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Engine System 20Service Manual – PBU Propane Floor Burnisher
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