Castex BR-2250 Product manual

Operator and Parts Manual
Burnisher
607357
Rev. 02 (11–01)
BR–2250/BR–2500
FAX: [phone]
CUSTOMER SERVICE: 1–800-964–9644
CASTEX
12875 RANSOM STREET
HOLLAND MI 49424 U.S.A.
Model No.:
608192 – BR-2250
608193 – BR-2250 Pac
607358 – BR-2500
607359 – BR-2500 Pac
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OPERATION
2BR–2250/BR–2500(11–01)
This manual is furnished with each new model. It
provides necessary operation and maintenance
instructions.
Read this manual completely and understand the
machine before operating or servicing it.
When ordering replacement parts use the parts list
section in this manual. Before ordering parts or
supplies, be sure to have your machine model number
and serial number available. Parts and supplies may
be ordered by phone or mail from any authorized
Service Center or Distributor.
This machine will provide excellent service. However,
the best results will be obtained at minimum costs if:
SThe machine is operated with reasonable care.
SThe machine is maintained regularly - per the
machine maintenance instructions provided.
SThe machine is maintained with manufacturer
supplied or equivalent parts.
MACHINE DATA
Pleasefill out at time of installation for future reference.
Model No.-
Install. Date -
Serial No.-
E2001 Tennant Company Printed in U.S.A.
Castex is a registered United States trademark of Tennant Company.
Specifications and parts are subject to change without notice.
TABLE OF CONTENTS
SAFETY PRECAUTIONS 3. . . . . . . . . . . . . . . . . . .
MACHINE COMPONENTS 4. . . . . . . . . . . . . . . . . .
CONTROL PANEL SYMBOLS 4. . . . . . . . . . . . . .
MACHINE SETUP 5. . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING BATTERIES 5. . . . . . . . . . . . . . .
INSTALLING PAD 5. . . . . . . . . . . . . . . . . . . . . .
MACHINE OPERATION 6. . . . . . . . . . . . . . . . . . . .
PRE–OPERATION 6. . . . . . . . . . . . . . . . . . . . . .
BURNISHING WITH BR–2250 MODEL 6. . . .
BURNISHING WITH BR–2500 MODEL 6. . . .
ADJUSTING PAD PRESSURE 7. . . . . . . . . . .
BATTERY LEVEL METER 8. . . . . . . . . . . . . . .
HOUR METER 8. . . . . . . . . . . . . . . . . . . . . . . . .
CARBON BRUSH INDICATOR LAMP 8. . . . .
CHARGING BATTERIES 9. . . . . . . . . . . . . . . . . . .
MACHINE MAINTENANCE 10. . . . . . . . . . . . . . . .
DAILY MAINTENANCE: 10. . . . . . . . . . . . . . . .
WEEKLY MAINTENANCE: 11. . . . . . . . . . . . . .
MONTHLY MAINTENANCE: 11. . . . . . . . . . . .
QUARTERLY MAINTENANCE: 11. . . . . . . . . .
BATTERY MAINTENANCE: 11. . . . . . . . . . . . .
TRANSPORTING MACHINE 12. . . . . . . . . . . . . . .
STORING MACHINE 12. . . . . . . . . . . . . . . . . . . . . .
RECOMMENDED STOCK ITEMS 12. . . . . . . . . . .
SPECIFICATIONS 12. . . . . . . . . . . . . . . . . . . . . . . .
TROUBLE SHOOTING 13. . . . . . . . . . . . . . . . . . . .
ELECTRICAL DIAGRAMS 14. . . . . . . . . . . . . . . . .
PARTS LIST 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRAME GROUP 16. . . . . . . . . . . . . . . . . . . . . . .
DRIVE GROUP 18. . . . . . . . . . . . . . . . . . . . . . .
COVER GROUP 20. . . . . . . . . . . . . . . . . . . . . .
COMPONENT PANEL GROUP 22. . . . . . . . . .
INSTRUMENT PANEL GROUP (BR–2250) 24
INSTRUMENT PANEL & SPEED CONTROL
GROUP (BR–2500) 26. . . . . . . . . . . . . . . . . . . .
PAD SHROUD LINKAGE GROUP 28. . . . . . .
PAD DRIVER GROUP 30. . . . . . . . . . . . . . . . .
PAD MOTOR BREAKDOWN 32. . . . . . . . . . . .
DRIVE MOTOR BREAKDOWN 33. . . . . . . . . .
BATTERY GROUP 34. . . . . . . . . . . . . . . . . . . .
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OPERATION
BR–2250/BR–2500 (11–01) 3
SAFETY PRECAUTIONS
This machine is suited to burnish smooth floor
surfaces in an indoor environment and is not
constructed for any other use. The pick up of any
liquid or hazardous type of dust is prohibited.
Use only recommended burnishing pads and
non–flammable floor cleaners and waxes intended for
machine application.
The following safety alert symbols are used throughout
this manual as indicated in their descriptions.
WARNING: To warn of hazards or unsafe
practices which could result in severe personal
injury or death.
CAUTION: To warn of hazards or unsafe
practices which could result in minor personal
injury.
FOR SAFETY: To identify actions which must be
followed for safe operation of equipment.
The following information signals potentially dangerous
conditions to the operator or equipment:
FOR SAFETY
1. Do not operate machine:
–Unless trained and authorized.
–Unless operation manual is read and
understood.
–In flammable or explosive areas.
–Without dust bag in place.
2. Before starting machine:
–Make sure all safety devices are in place
and operate properly.
3. When using machine:
–Go slow on inclines and slippery surfaces.
–Use care when reversing machine.
–Report machine damage or faulty
operation immediately.
4. Before leaving or servicing machine:
–Stop on level surface.
–Turn off machine.
–Remove key.
5. When servicing machine:
–Avoid moving parts. Do not wear loose
jackets, shirts, or sleeves.
–Block machine tires before jacking
machine up.
–Use hoist or jack of adequate capacity to
lift machine.
–Disconnect battery connections before
working on machine.
–Wear protective gloves when handling
batteries or battery cables.
–Avoid contact with battery acid.
–Use manufacturer supplied or approved
replacement parts.
WARNING: Batteries emit hydrogen gas.
Explosion or fire can result. Keep sparks and
open flame away. Keep battery compartment open
when charging.
WARNING: Flammable materials or reactive
metals can cause explosion or fire. Do not pick
up.
WARNING: Moving parts. Turn off power
before working on machine.
CAUTION: Pad head must be in full up (pad
load) position before making pad pressure
adjustment.
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OPERATION
4BR–2250/BR–2500(11–01)
MACHINE COMPONENTS
5
6
7
9
8
4
10
2
3
118 17 11
12
13
14
15
16
1. Control Console
2. Dust Control Hose
3. Dust Bag Access Door
4. Dust Control Skirt
5. Battery Cover
6. Frame
7. Wall Rollers
8. Pad Driver
9. Main Wheels
10. Circuit Breakers
11. Pad Pressure Meter
12. Key ON Light
13. Travel Speed Selection Switch
14. Key Switch
15. Fuse Holder
16. Control Grips
17. Battery Level Meter
18. Carbon Brush Indicator Lamp
CONTROL PANEL SYMBOLS
Main Power Read Manual
Before Operating
Battery
Charge Meter Fast
Speed Slow Speed
Pad
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OPERATION
BR–2250/BR–2500(11–01) 5
MACHINE SETUP
Carefully check carton for signs of damage. Report
damages at once to the carrier.
Unpack the machine and check machine for
completeness according to the packing list.
INSTALLING BATTERIES
Battery installation must be accomplished after
removing the machine from the pallet. Carefully follow
the battery installation diagram below.
+
–
+
+
+
+
+
1
2
FRONT
OF
MACHINE
457mm 305mm
CABLE CABLE
––
–––
FIG. 1
WARNING: Batteries emit hydrogen gas.
Explosion or fire can result. Keep sparks and
open flame away. Keep battery compartment open
when charging.
FOR SAFETY: When servicing machine, wear
protective gloves when handling batteries or
battery cables. Avoid contact with battery acid.
INSTALLING PAD
1. Select a burnishing pad that is designed to
operate over 2000 RPM. The pad should be a
maximum of 25.4 mm (1 inch) thick,
483 mm (19 inch) in diameter with a standard
89 mm (3.5 inch) center hole.
FOR SAFETY: Before leaving or servicing
machine, stop on level surface and turn off
machine.
2. Tap the right front side of the pad shroud with your
toe. The head will rise to the pad mounting
position (Figure 2).
FIG. 2
3. Remove the plastic centerlock from the pad driver
by turning it clockwise. Position the pad accurately
centered on the pad driver, and screw the
centerlock in place counter-clockwise until it is
tight (Figure 3).
Close Open
FIG. 3
NOTE: This machine is equipped with a pad
centerlock with a left hand thread.
NOTE: Make sure centerlock does not cross thread or
floor damage may occur.
ATTENTION: Do not operate machine without a
pad and centerlock in place.
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OPERATION
6BR–2250/BR–2500(11–01)
MACHINE OPERATION
FOR SAFETY: Do not operate machine unless
operator manual is read and understood.
PRE–OPERATION
1. Check battery meter charge level to ensure
batteries are fully charged. See CHARGING
BATTERIES.
2. Sweep or dust mop the floor to remove debris.
Then damp mop or scrub the floor to assure that
dirt is not burnished into the finish.
3. Check that a pad is installed.
4. Check that a dust bag is installed.
5. Make sure floor to be burnished is dry.
BURNISHING WITH BR–2250 MODEL
1. Turn key switch to the ”ON”position (Figure 4).
The key ON light on the panel will light green.
FIG. 4
2. With the control grips released, step down on the
rear of the pad shroud until the head locks in the
down position (Figure 5).
FIG. 5
3. Remove foot from the pad shroud.
4. Twist the control grips forward (Figure 6). The pad
motor will start and suction will draw the moving
pad to the floor. Immediately push or pull the
machine in the desired direction.
FIG. 6
FOR SAFETY: When using machine, go slow on
inclines and slippery surfaces.
ATTENTION: Keep machine moving at all times to
prevent floor damage.
5. To stop, release the control grips. The pad will
automatically lift from the floor until the grips are
activated again.
BURNISHING WITH BR–2500 MODEL
1. Turn the key switch to the ”ON”position
(Figure 4). The key ON light on the panel will light
green.
2. With the control grips released, step down on the
rear of the pad shroud until the head locks in the
down position (Figure 5).
3. Remove foot from the pad shroud.
4. Select a speed with the travel speed selection
switch (Figure 7):
UP position provides both slow and fast forward
speeds.
DOWN position provides slow forward speed only.
Use this position for maneuvering in tight areas.
FIG. 7
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OPERATION
BR–2250/BR–2500(11–01) 7
5. Twist control grips forward until the pad motor
starts (Figure 6). The machine will transport
forward and suction will draw the moving pad to
the floor.
6. To reverse, twist the control grips backward. The
pad motor will start and the machine will transport
backwards.
7. To stop, release the control grips.
FOR SAFETY: When using machine, go slow on
inclines and slippery surfaces.
ATTENTION: Keep machine moving at all times to
prevent floor damage.
8. To increase travel speed (mode switch in ”UP”
position), twist the control grips all the way forward
to select the second (high) travel speed.
9. To stop, release the control grips and hold back on
the machine until it stops moving. The reverse
direction may be used as a stopping brake if
desired.
NOTE: The drive circuit is equipped with a circuit
breaker located on the lower left rear frame. If the
driver system is overloaded during use the breaker will
trip. Allow it to cool for a few moments and reset the
breaker by pushing on the black button (Figure 8).
FIG. 8
ADJUSTING PAD PRESSURE
CAUTION: The pad head must be in the full
up (pad load) position before making the pad
pressure adjustment. DO NOT ADJUST in the
down position as the head could release and
pinch arm or fingers in the mechanism.
1. Your machine has a pad pressure meter located
on top of the control console. This meter has one
green bar and 2 red bars (Figure 9):
GREEN BAR: The operating zone within which the
needle must read.
RED BAR TO THE RIGHT: Indicates too much
pressure or pad resistance.
RED BAR TO THE LEFT: Indicates too low pressure
or that the battery charge is low.
FIG. 9
2. Operate the machine on the actual floor with the
finish and pad you will be using. Notice the needle
position on the meter. For most jobs the needle
should be in the center of the green bar.
3. If the needle is not in the center of the green bar,
raise the pad head into the full up position and
locate the pad pressure knob under the rear frame
(Figure 10).
FIG. 10
4. If the needle indicates too much pressure turn the
knob counterclockwise and repeat testing until the
needle is in the center.
5. If the needle indicates too little pressure turn the
knob clockwise and repeat testing until the needle
is in the center.
NOTE: Increasing pad pressure will improve shine but
it will also reduce battery run time.
ATTENTION: Do not adjust the pressure so the
needle runs in the right red bar. This will cause
the circuit breaker to trip.
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OPERATION
8BR–2250/BR–2500(11–01)
6. If high performance is needed and run time is not
a consideration, adjust the pressure so the needle
runs in the higher (right side) of the green bar.
7. If long run time is needed, adjust the pressure so
the needle runs in the lower (left side) of the green
bar.
Once initial pad pressure has been set:
8. If during use the needle moves into the right red
bar, it will cause the circuit breaker to trip. Allow
the pad motor to cool down and then press the
pad motor circuit breaker red reset button.
9. If the needle moves again into the right red bar
and the circuit breaker trips, the pad may have
become dirty and filled with finish. Turn the pad
over to a clean side or replace the pad. Then reset
the circuit breaker. To remove/change pads see
INSTALLING PAD .
NOTE: The operator should watch the pad meter
during operation and change the pad before the circuit
breaker trips.
10. If the needle drops into the left red bar, this
indicates the battery charge is low and recharging
is required. See CHARGING BATTERIES section.
BATTERY LEVEL METER
1. Your machine has a battery level meter located on
top of the control console. This meter has one
green bar and one red bar (Figure 11).
GREEN BAR: The operating zone within which the
needle must read.
RED BAR: Indicates the batteries need to be
recharged. See CHARGING BATTERIES section.
FIG. 11
HOUR METER
1. Your machine has an hour meter located inside
the battery compartment next to the machine
connector (Figure 12).
FIG. 12
2. To gain access to this meter remove the battery
cover.
3. This meter keeps a running total of the hours of
operation of your machine.
4. Use this meter to determine when your machine
should to be maintained.
CARBON BRUSH INDICATOR LAMP
1. Your machine has an amber carbon brush
indicator lamp which will light when the carbon
brushes in the pad drive motor need to be
replaced (Figure 13). See QUARTERLY
MAINTENANCE section.
FIG. 13
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OPERATION
BR–2250/BR–2500(11–01) 9
CHARGING BATTERIES
NOTE: Recharge batteries ONLY after a total of 30
minutes of use or more. This will prolong battery life.
The following charging instructions are intended
for supplied 36V chargers only. Only use a
charger with the following specifications to
prevent battery damage.
CHARGER SPECIFICATIONS:
SOUTPUT VOLTAGE - 36 VOLTS
SOUTPUT CURRENT - 25 AMPS MAXIMUM
SAUTOMATIC SHUTOFF CIRCUIT
SFOR DEEP CYCLE BATTERY CHARGING
NOTE: For optimum machine operation, keep
batteries charged at all times. Never let batteries set in
a discharge condition for lengthy periods.
WARNING: Batteries emit hydrogen gas.
Explosion or fire can result. Keep sparks and
open flame away. Keep battery compartment open
when charging.
FOR SAFETY: When servicing machine, wear
protective gloves when handling batteries or
battery cables. Avoid contact with battery acid.
1. Transport machine to a flat, dry surface in a well–
ventilated area for charging.
2. Turn off all switches and key.
FOR SAFETY: Before leaving or servicing
machine, stop on level surface and turn off
machine.
3. Slide the battery cover from the machine
(Figure 14).
FIG. 14
4. Before charging batteries, check electrolyte level
(A) in each battery cell. Do not charge batteries
unless electrolyte is slightly covering battery plates
(B). If battery plates (B) are exposed, add just
enough distilled water to slightly cover plates, level
(A). Never add acid to batteries. DO NOT overfill.
Batteries can overflow during charging due to
expansion. Replace cell caps before charging
(Figure 15).
A
B
FIG. 15
NOTE: For machines with 305 amp batteries, to gain
access to the 2 top rear battery cells, remove the
2 acorn nuts holding the console to the frame
(Figure 16). Tip the console back on the hinge to
access these cells.
FIG. 16
5. Disconnect the battery plug from the machine
(Figure17). With charger’s power supply cord
unplugged, connect battery charger into battery
plug.
Connect battery
charger to this plug
FIG. 17
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OPERATION
10 BR–2250/BR–2500(11–01)
NOTE: Do not connect the charger into the machine
plug, or damage to the machine may occur.
6. Then plug charger’s power supply cord into a
grounded wall outlet (Figure 18).
FOR SAFETY: Do not operate charger unless cord
is properly grounded.
Grounded Outlet
Grounding
Edge/hole
Grounded
3 Hole Outlet
Ground Pin
(120V) (230V)
FIG. 18
7. Charger will automatically begin charging and
automatically shut off when fully charged.
8. After charger has turned off, unplug charger from
wall outlet first then disconnect charger from
machine.
9. Recheck battery electrolyte level (A) after
charging. Add distilled water to bring level 1cm
from bottom of sight tubes (B). Replace cell caps
securely and wipe off the top of batteries with a
clean cloth (Figure 19).
A
B
FIG. 19
MACHINE MAINTENANCE
To keep machine in good working condition, simply
follow daily, weekly and monthly maintenance
procedures.
FOR SAFETY: Before leaving or servicing
machine, stop on level surface and turn off
machine.
FOR SAFETY: When servicing machine,
disconnect battery connections before working on
machine.
ATTENTION: Contact an Authorized Service
Center for machine repairs. Machine repairs
performed by other than an authorized person will
void your warranty.
DAILY MAINTENANCE
(Every 4 Hours of Use)
1. Remove burnishing pad. Clean and replace or
install a new pad (Figure 20).
Close Open
FIG. 20
2. Dust bag maintenance:
Open the dust bag access door to gain access to
the dust bag (Figure 21).
Paper Bag: Grasp the bag to check the contents.
Remove and discard the bag if it is full. Install a
new bag on the fitting and close the dust bag
access door.
Cloth Bag (Option): Remove the bag. Unzip,
invert and shake the contents from the bag. Close
the zipper and reinstall on the fitting. Close the
dust bag access door.
NOTE: If the bag is extremely soiled, launder the
bag before reuse.
FIG. 21
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