ENGINE KIT-MUFF RETRO

Transcription

1 ITEM PART NO. QTY DESCRIPTION Fitting-Pipe To Hose Scr-Hex 1/4-20 X Scr, Soc Hd 3/8-16 X Scr, Hex Thd To Hd M X 20mm Clamp- Hose Sae # Clamp, Hose Support Regulator-Lpg Lockoff-12v Elbow-90 Barb Male 14 1 Engine Assy-Kaw 12v Manifold-Exhaust Muffler ( ) Muffler-Catalyst-11 ( ) Washer, Lock 3/ Clamp-Exhaust ENGINE KIT-MUFF RETRO PBU Burnishers Models: 08987B, 08989B ENGINE KIT-CAT RETRO PBU Burnishers Models: 08012B, 08945B, 08947B, 08013A, 08014A CONTENTS OF KIT ITEM PART NO. QTY DESCRIPTION Washer, Lock 1/4 [20] Harness-Wiring PBU Hose-Lpg Hose-Vac A 1 Plug Manifold Sensor [24] 98471A 12 H038 1/8 X 7 1/2 Nylon Tie S Cable-Throttle NOTE Cable-Throttle NOTE Gasket-Exhaust Washer LK 5/16 Regpltd 29# Adapter-.25MPT X.25FPT-Brass [ ] NA 1 Service Manual [ ] = Not Shown # = Revised or new since last update NOTE 1: Only used on models 08012B, 08989B, 08945B, 08987B, 08947B. NOTE 2: Only used on models 08013A, 08014A, 08767B, 08988B Nilfisk-Advance, Inc. (page 1 of 11)

2 INSTALLATION INSTRUCTIONS WARNING! DISCONNECT BATTERY BEFORE SERVICING. DISCONNECT AND REMOVE EXISTING WIRING HARNESS MAKE NOTE OF ALL CONNECTIONS FOR REASSEMBLY 1 2 FIGURE 1 See Figure 1. Disconnect Harness Connector (A) from the engine oil pressure switch. Disconnect Harness Connector (B) from the LPG lock off valve. B A FIGURE See Figure 2. Disconnect Harness Connector (C) from the key switch. Disconnect Harness Connectors (D) from the hour meter. C D 2014 Nilfisk-Advance, Inc. (page 2 of 11)

3 DISCONNECT AND REMOVE EXISTING WIRING HARNESS MAKE NOTE OF ALL CONNECTIONS FOR REASSEMBLY FIGURE 3 See Figure 3. Cut Cable Ties (E) and disconnect Harness Connectors (F & G). Disconnect Harness Connector (H) from the engine starter. Disconnect all harness connectors from the Starter Solenoid (I). F H E G I FIGURE Tip the machine over onto its right side to gain access to the battery. See Figure 4. Disconnect Harness Connector (J) from the battery and Connector (K) from the grounding point. K J 2014 Nilfisk-Advance, Inc. (page 3 of 11)

4 DISCONNECT AND REMOVE EXISTING WIRING HARNESS MAKE NOTE OF ALL CONNECTIONS FOR REASSEMBLY 10 FIGURE 5 See Figure 5. Cut all Cable Ties (L) securing the machine Harness (M) and remove the old harness from the machine. L M DISCONNECT FUEL LINES AND REMOVE REGULATOR FIGURE 6 See Figure 6. Disconnect Hoses (N & O). Remove Hose (P) and Fitting (Q) and save for re-use. Remove the two mounting screws securing the LPG Regulator (R) and remove the regulator from the machine. NOTE: Save the screws and washers for reuse. R O N Q P 2014 Nilfisk-Advance, Inc. (page 4 of 11)

5 DISCONNECT THROTTLE CABLE-NON CLUTCH MODELS 14 See Figure 7. Cut all Cable Ties (S) securing the Throttle Cable (T) to the handle. 15 Remove Hardware (U) and separate the Throttle Cable (T) from the handle. There is no need to completely remove the cable from the machine since it is mounted to the engine which is also being removed. NOTE: Save the hardware for reuse. FIGURE 7 U S T FIGURE 8 DISCONNECT THROTTLE CABLE-CLUTCH MODELS 16 See Figure 8. Cut all Cable Ties (S) securing the Throttle Cable (T) to the handle. 17 Remove Hardware (U) and separate the Throttle Cable (T) from the handle. There is no need to completely remove the cable from the machine since it is mounted to the engine which is also being removed. NOTE: Save the hardware for reuse. U T S 2014 Nilfisk-Advance, Inc. (page 5 of 11)

6 REMOVE DRIVE BELT AND ENGINE PULLEY-NON CLUTCH MODELS 18 See Figure 9. Tip the machine over onto its right side. 19 Push down on the Belt Tensioner (V) to relieve tension on the Belt (W) enough to remove the belt from the Engine Pulley (X). 20 Remove the set screw securing the Pulley (X) and remove the pulley from the engine shaft. NOTE: A gear puller may be needed to remove the pulley from the engine shaft. V FIGURE 9 PUSH DOWN X W FIGURE 10 REMOVE DRIVE BELT AND CLUTCH-CLUTCH MODELS 21 See Figure 10. Tip the machine over onto its right side. 22 Push down on the Belt Tensioner (V) to relieve tension on the Belt (W) enough to remove the belt from the Clutch (X). 23 Remove the bolt securing the V Clutch (X) and remove the clutch from the engine shaft. NOTE: Use of an impact wrench is recommended to remove the bolt. A gear puller may be needed to remove the clutch from the engine shaft. PUSH DOWN X W 2014 Nilfisk-Advance, Inc. (page 6 of 11)

7 REMOVE ENGINE MOUNTING BOLTS AND REMOVE OLD ENGINE FROM MACHINE 24 See Figure 11. Tip the machine over onto its right side. 25 Remove the bottom two engine mounting Bolts (Y). NOTE: DO NOT remove the third engine mounting Bolt (Z) yet or the engine will fall off of the machine. Each mounting bolt has a nut on the top side of the machine. 26 Tip the machine back upright and then remove the third Bolt (Z). 27 The engine can now be carefully lifted from the base housing. FIGURE 11 Z Y MODIFY BASE HOUSING 28 See Figure 12. Drill out the three engine mounting Holes (AA) shown using a 13/32 drill bit. FIGURE Inch Base Housing 21 Inch Base Housing AA AA 2014 Nilfisk-Advance, Inc. (page 7 of 11)

8 MOUNT NEW ENGINE TO THE MACHINE 29 See Figure 13. Carefully lift the new engine assembly (BB) and sit it on the base housing. NOTE: The engine ships with the following items mounted on (connected to) the engine: exhaust pipe, fuel lines, regulator assembly and wiring harness. 30 Mount the engine to the base using the three Screws (5) and Washers (17) as shown through the three holes drilled out in step Mount the regulator assembly to the handle reusing the two original mounting Screws. NOTE: Mount using the same two holes as the original regulator was mounted with. 32 Install the original Hose (P) and Fitting (Q) removed in step 12 earlier. NOTE: Use pipe dope on Fitting (Q). FIGURE 13 Reuse mounting screws P Q BB Nilfisk-Advance, Inc. (page 8 of 11)

9 MOUNT MUFFLER / CATALYTIC CONVERTOR TO ENGINE MOUNT THROTTLE CABLE-NON CLUTCH MODELS ONLY 33 See Figure 14. Mount the Muffler / Catalyst (16) to the engine using Exhaust Clamp (18), Screws (6) and Washers (28). 34 Mount Throttle Cable (25) to the handle as shown if you have one of the following models (08012B, 08989B, 08945B, 08987B, 08947B). Reuse the original mounting hardware. The mounting hole is pre-drilled. NOTE: Since Throttle Cable (25) is used on the majority of models it comes pre-mounted to the engine. If you have one of the following models (08013A, 08014A, 08767B, 08988B) you will need to remove Cable (25) and install Cable (26) according to the instructions on the next page. NOTE: After all assembly is complete refer to the service manual (included in kit) for throttle cable adjustment procedure. FIGURE Nilfisk-Advance, Inc. (page 9 of 11)

10 MOUNT THROTTLE CABLE-CLUTCH MODELS ONLY 35 See Figure 15. Mount Throttle Cable (26) to the handle as shown reusing the mounting hardware. 36 Route the cable behind the engine as shown and through the same P-Clamp (CC) on the left side of the engine as Cable (25) is routed through on the other models. 37 The end of the cable is connected to the engine exactly the same as Cable (25) was. See Throttle Cable Connection inset. NOTE: After all assembly is complete refer to the service manual (included in kit) for throttle cable adjustment procedure. FIGURE 15 CC 26 Throttle Cable Connection 38 Follow steps 1 through 9 in reverse order to connect the new Wire Harness to the machine. Secure where needed using Cable Ties (24). 39 Follow steps 18 through 20 in reverse order to reinstall the Engine Pulley (X) and Belt (W) for the following models (08012B, 08989B, 08945B, 08987B, 08947B). Follow steps 21 through 23 in reverse order to reinstall the Clutch (X) and Belt (W) for models (08013A, 08014A, 08767B, 08988B). Refer to the last page for final steps and old vs new model cross reference chart Nilfisk-Advance, Inc. (page 10 of 11)

11 FINAL STEPS 40 Check engine oil. 41 Connect Fuel Line (P) to the LPG tank. Spray soapy water on the fitting connections and open the tank valve. Check for signs of leaks and seal as needed. 42 Refer to service manual (included in kit) for throttle cable adjustment procedure. After installing the engine retro kit you will have basically converted your PBU machine into one of the new production models. Refer to the chart below for a list of the old models and the new equivalent models after engine replacement. If needed you can order the new model equivalent lit pack after installing the retro kit to support your machine for operating instructions and replacement parts. OLD PBU MODEL ENGINE RETRO KIT NEW PBU MODEL EQUIVALENT NEW PBU LIT PACK 08987B (2717B) (27KB) B (2117B) (21KB) B (2113BCAT) (21KBCAT) B (2117BCAT) (21KBCAT) B (2717BCAT) (27KBCAT) B (2717BCLU) (27KBCL) B (2717BCATCLU) NO EQUIVALENT A (21) (MPS-1721) A (27) (MPS-1727) Nilfisk-Advance, Inc. (page 11 of 11)