Castex FP-1600 Product manual

609638
Rev. 00 (01-00)
Model No.:
609539
FP-1600
Operator and Parts Manual
FAX: [phone]
CUSTOMER SERVICE: 1–800-964–9644
CASTEX
12875 RANSOM STREET
HOLLAND MI 49424 U.S.A.
Water Transfer Machine
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OPERATION
2FP-1600 (12–99)
This manual is furnished with each new model. It
provides necessary operating and preventative
maintenance instructions and an illustrated parts list.
Read this manual completely and understand the
machine before operating or servicing it.
When ordering replacement parts, use the parts lists
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:
The machine is operated with reasonable care.
The machine is maintained regularly - per the
machine maintenance instructions provided.
The machine is maintained with manufacturer
supplied or equivalent parts.
MACHINE DATA
Please fill out at time of installation for future reference.
ModelNo.-
Install. Date -
Serial No.-
1999 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. . . . . . . . . . . . . . . . . . . . .
SETUP AND OPERATION 4. . . . . . . . . . . . . . . . . . . . . .
MACHINE MAINTENANCE 5. . . . . . . . . . . . . . . . . . . . .
STORING MACHINE 5. . . . . . . . . . . . . . . . . . . . . . . . . . .
RECOMMENDED STOCK ITEMS 5. . . . . . . . . . . . . . .
TROUBLESHOOTING 6. . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL DIAGRAM 7. . . . . . . . . . . . . . . . . . . . . . .
PARTS LIST 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECOVERY TANK GROUP 8. . . . . . . . . . . . . . . . . . . .
VACUUM MOTOR / MACHINE BASE GROUP 10. . .
DISCHARGE PUMP GROUP 12. . . . . . . . . . . . . . . . . .
HANDLE GROUP 14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
FLOOR TOOL, HOSES AND
SQUEEGEE GROUP 15. . . . . . . . . . . . . . . . . . . . . . . . .
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OPERATION
FP-1600 (11–99) 3
SAFETY PRECAUTIONS
This machine is intended for commercial use. It is
designed to vacuum water in an indoor environment
and is not constructed for any other use. Use only
recommended accessories.
The following safety alert symbols are used throughout
this manual as indicated in their description.
WARNING: To warn of hazards or unsafe
practices which could result in severe personal
injury or death.
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 operator manual is read and
understood.
– In flammable or explosive areas unless
designed for use in those areas.
– Unless cords are properly grounded.
– With damaged cord or plug.
– With the use of additional extension cords.
Only use manufacturer’s extension cord
equipped with machine which has proper
capacity and is grounded.
– If not in proper operating condition.
– In outdoor areas.
– In standing water.
– Without bag and filter in place.
2. Before operating machine:
– Make sure all safety devices are in place
and operate properly.
3. When using machine:
– Do not run machine over cords.
– Do not pull machine by plug or cords.
– Do not pull cords around sharp edges or
corners.
– Do not unplug by pulling on cords.
– Do not stretch cords.
– Do not handle plug with wet hands.
– Keep cords away from heated surfaces.
– Do not pick up burning or smoking debris,
such as cigarettes, matches or hot ashes.
– Report machine damage or faulty
operation immediately.
4. Before leaving or servicing machine:
– Turn off machine.
– Unplug cords from wall outlet.
5. When servicing machine:
– Unplug cords from wall outlet.
– Use manufacturer supplied or approved
replacement parts.
WARNING: Hazardous Voltage. Shock or
electrocution can result. Unplug machine before
servicing.
WARNING: Flammable materials or reactive
metals can cause an explosion or fire. Do not pick
up.
GROUNDING INSTRUCTIONS
Machine must be grounded. If it should
malfunction or breakdown, grounding provides a
path of least resistance for electrical current to
reduce the risk of electrical shock. This machine
is equipped with cords having an
equipment–grounding conductor and grounding
plug. The plug must be plugged into an
appropriate outlet that is properly installed in
accordance with all local codes and ordinances.
Do not remove ground pin; if missing, replace
plug before use.
GROUNDED OUTLET
(3 HOLE)
GROUNDING PIN
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OPERATION
4FP-1600 (12–99)
MACHINE COMPONENTS
6
3
4
5
9
8
7
1
2
1. ON/OFF Switch
2. Drain Hose
3. Intake Hose Connector
4. Discharge Hose Connector
5. 76L (20 Gal) Recovery Tank
6. Recovery Tank Cover
7. Cover Latches
8. 254 mm (10 in) Stair Climbing Wheels
9. Swivel Casters
13. (50 ft) Extension Cord (not shown)
NOTE: See Parts List section for standard
accessories.
SETUP AND OPERATION
FOR SAFETY: Do not operate machine unless
operator manual is read and understood.
1. Carefully check carton for signs of damage.
Report damages at once to carrier. Machine is
fully assembled and ready for use.
2. Check that float shutoff screen and filter bag are
installed in recovery tank (Figure 1).
FIG. 1
ATTENTION: Do not operate machine without
screen and filter bag in place, vacuum motor and
pump damage will result.
3. Connect 5 M (15 ft) hose to intake connector and
8 M (25 ft) hose to discharge connector (Figure 2).
Place opposite end of discharge hose outside or to
drain that will handle large volume of water.
Intake Hose
Discharge Hose
FIG. 2
NOTE: Do not exceed 31 M (100 ft) of intake hose.
For best performance, length of 8 M (25 ft) is
recommended. Discharge hose can be any horizontal
length, do not raise discharge hose beyond 2 M (8 ft).
4. Attach accessory tool to intake hose if desired.
5. Connect equipped extension cords to pig tails on
machine and plug each cord into a separate
grounded circuit (Figure 3).
ATTENTION: Be certain to use a separate circuit
for each power cord to prevent circuit overload
(machine draws 17 amps).
FOR SAFETY: Do not operate machine with the
use of additional extension cords. Only use
manufacturer’s extension cord equipped with
machine which has proper capacity and is
grounded.
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OPERATION
FP-1600 (11–99) 5
Circuit 1 Circuit 2
FIG. 3
4. Turn ON/OFF switch to the on position.
5. Begin vacuuming water. When water level reaches
a certain height, the pump will automatically
discharge water.
WARNING: Flammable materials or reactive
metals can cause an explosion or fire. Do not pick
up.
6. Observe recovery tank for excessive foam while
operating. Foam will not activate float shut-off
screen, located in recovery tank.
ATTENTION: Do not allow foam or water to enter
float shut-off screen, vacuum motor damage will
result.
7. After operating machine, turn machine off and
drain excess water from recovery tank using drain
hose.
MACHINE MAINTENANCE
To keep machine in good working condition, simply
follow maintenance procedures below:
FOR SAFETY: When servicing machine, unplug
cords from wall outlet.
1. Drain and flush recovery tank with clean water
after each use (Figure 4).
FIG. 4
2. Clean the float shut-off screen and filter bag
located in recovery tank after each use (Figure 5).
FIG. 5
3. Inspect power cords for damage, replace
immediately if damaged. Coil cords neatly after
each use.
4. Inspect vacuum hoses for holes and loose cuffs.
5. Clean machine housing with an all purpose
cleaner and damp cloth.
6. Inspect machine for leaks and loose hardware.
7. Lubricate wheels and casters with a water
resistant oil.
8. Every 250 hours of use check vacuum motor for
carbon brush wear. Replace brushes when worn
to a length of 10mm (0.38 in) or less.
STORING MACHINE
1. Before storing machine, be certain to flush tank
and drain machine of all water.
2. Store machine in a dry area in the upright position.
3. Open recovery tank cover to promote air
circulation.
ATTENTION: Do not expose to rain. Store indoors.
ATTENTION: If storing machine in freezing
temperatures, be sure that machine and pump are
completely drained and dry.
RECOMMENDED STOCK ITEMS
Refer to Parts List section for recommended stock
items. Stock Items are clearly identified with a bullet
preceding the parts description. See example below:
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OPERATION
6FP-1600 (12–99)
TROUBLESHOOTING
PROBLEM CAUSE SOLUTION
Poor pick up. Float shut-off screen is clogged. Clean screen inside recovery tank.
Loose drain hose knob. Close drain valve.
Loose recovery tank cover. Tighten down cover with latches.
Damaged hose. Replace hose.
Vacuum motor does not
t
Unplugged cord. Plug cords into separate grounded circuits.
operate. Faulty switch or loose wiring. Contact Service Center.
Tripped building circuit breaker. Reset circuit breaker.
Defective vacuum motor. Contact Service Center.
Discharge pump does not
t
Unplugged cord. Plug cords into separate grounded circuits.
g
operate. Faulty pump float switch. Contact Service Center.
Tripped building circuit breaker. Reset circuit breaker.
Defective vacuum motor. Contact Service Center.
Discharge pump operates
continuously. Airlock has formed in discharge pump
inlet. Connect open end of discharge hose to vacuum intake hose connector and turn on
machine.
Faulty pump float switch. Contact Service Center.
SPECIFICATIONS
Model FP-1600
LENGTH 762 mm(30 in)
WIDTH 508 mm (20 in)
HEIGHT 889 mm(35 in)
WEIGHT 41 Kg (90 lbs)
RECOVERY TANK CAPACITY 60.5 L(16 gal)
VACUUM HOSE 4.5 m (15 ft) x 38 mm (1.5 in)
DISCHARGE HOSE 7.6 m (25 ft) x 38 mm (1.5 in)
FLOOR WAND WIDTH 330 mm (13 in)
DISCHARGE PUMP 120 volt, 100 psi/6.9 bar, 4.8 amp
DISCHARGE PUMP FLOW RATE 151 L (40 gal) per minute
VACUUM MOTOR 120 volt, 3–stage, 1.6 hp, 10.7 amp,1242 watts
SEALED WATER LIFT 3048 mm (120 in)
POWER CORD LENGTH 15 m (50 ft)
TOTAL POWER CONSUMPTION 120V, 17 A, 2040 W (Use Separate Circuits)
DECIBEL RATING AT OPERATOR’S EAR, INDOORS ON CARPET 80dB(A)
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ELECTRICAL DIAGRAM
FP-1600 (11–99) 7
VAC.
MOTOR
VACUUM
SWITCH
BLACK
WHITE
POWER
CORDS
GREEN
GROUND
TO PLATE
BLACK
WHITE
GREEN
12AMP
CIRCUIT
BREAKER
POWER
CORDS
BLACK
WHITE
GREEN
FLOAT
SWITCH
DISCHARGE
PUMP
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PARTS LIST
FP-1600 (11–99)
8
RECOVERY TANK GROUP
1
23
4
5
6
7
8
910
11
12
13 14
15
14
16
17
18
19
20
21
22
23
24
25
26
27
28
32
31
33
34
35
36
37
38
39
29 30
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PARTS LIST
FP-1600 (12–99) 9
RECOVERY TANK GROUP
REF PART # DESCRIPTION QTY.
1 140801 SCREW, 8–32X3/8 4
2140023 WASHER. #8 INT 4
3140932 LATCH, HOOD RUBBER W/ KEEPER 2
4607373 COVER. 16G RM–BLUE 1
5230905 TUBE, INLET 1
6100097 GASKET, 16 GALLON COVER 1
7230497 BRACKET. AIR DEFLECTOR 1
8140197 SCREW. 10–24X3/8 2
9230482.BK BRACKET. SUPPORT 16 GAL TANK 1
10 140824 SCREW. 1/4–20X5/8 2
11 140003 WASHER. 1/4X1 2
12 900222 BAG, 16 GALLON 1
13 230318 HINGE. COVER 16 GALLON 1
14 140195 SCREW, 1/4–20X1/2 2
15 140000 WASHER, 1/4 FLT 1
16 130181 CORD, GRIP 1
17 609639 DECAL, FP-1600 2
18 140223 SCREW, 5/16–18X3/4 8
19 231034 PLATE, CASTER MOUNT 1
20 103065 CASTER, SWIVEL 4” 2
∇ASSEMBLY
INCLUDED IN ASSEMBLY
RECOMMENDED STOCK ITEMS
REF PART # DESCRIPTION QTY.
21 140546 NUT, 5/16–18 NYLK 2
22 140223 SCREW, 5/16–18X3/4 4
23 140015 WASHER, 5/16 SPLTLCK 4
24 607349 TANK, 16G RM–BLUE 1
25 120101 DECAL, CASTEX 1
26 140932 LATCH, HOOD RUBBER W/ KEEPER 2
27 140802 SCREW, 8–32X5/8 4
28 140288 NUT, NYLOCK M4 X 0.7 4
29 140307 CLAMP, HOSE 1
30 130041 WIRE TIE, NYLON 1
∇31 701058 ASM., DRAINHOSE 1
32 160457 HOSE, DRAIN 25” 1
33 140072 CLAMP, 1–9/16 2
34 140921 SLEEVE, DRAIN HOSE 1
∇35 701061 ASM., DRAINHOSE STOPPER 1
36 140955 PLUG, DRAIN HOSE W/RIBS 1
37 140056 WASHER, 3/8IDX1.50OD 1
38 230882 STRAP, DRAIN STOPPER 1
39 230831 KNOB, DRAIN HOSE 1
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PARTS LIST
FP-1600 (11–99)
10
VACUUM MOTOR / MACHINE BASE GROUP
1
10
2
345
6
7
8
9
7
12
13
14
15
16
17
18
19
20
21
22 23
24
25
26
27
28
29
30
31
32 33
34
35
36
37
38
39
40
41
42 43
11
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PARTS LIST
FP-1600 (11–99) 11
VACUUM MOTOR / MACHINE BASE GROUP
REF PART # DESCRIPTION QTY.
1 180613 FLOAT, SHUT–OFF 1
2100381 ELBOW, VAC TUBE 1
3100096 GASKET, VAC TUBE ELBOW 1
4140824 SCREW, 1/4–20X5/8 2
5700435 ASM., PVC ELBOW 1
6140308 CLAMP, HOSE 1
7160482 HOSE, VACUUM 2” X 13” 1
8600272 BRUSHES CARBON (2 PACK) 2
9100038 GASKET, VAC MOTOR 1
10 130417 MOTOR, VAC 5.7 3 STG 120V 1
11 230486.BK COVER PLATE 1
12 140308 CLAMP, HOSE 1
13 140199 SCREW, 1/4–20X4–1/2 4
14 140003 WASHER, 1/4X1 4
15 100380 HOUSING, VACUUM MOTOR 1
16 100143 GASKET, VAC MOTOR 5.7 1
17 100095 GASKET, VAC MOTOR END 1
18 140900 SCREW, 10–24X3/4 1
19 140519 NUT, 10–24 KEP 3
20 230522 PLATE, MOTOR MOUNT 1
21 140340 SCREW, #10–24X5/8 4
22 140501 NUT, 1/4–20 NYLK 4
RECOMMENDED STOCK ITEMS
REF PART # DESCRIPTION QTY.
23 130110 BUSHING, STRAIN–RELIEF 1
24 130267 CORD, 16/3X30” YELLOW 1
25 130181 CORD GRIP 1
26 140195 SCREW, 1/4–20X1/2 4
27 140824 SCREW, 1/4–20X5/8 2
28 230496.BK SUPPORT, DRAIN HOSE 1
29 140063 WASHER 1
30 140201 SCREW, 3/8–16X3/4 4
31 140017 WASHER, 3/8 SPLTLCK 4
32 140028 WASHER, 3/8 FLT 1
33 140900 SCREW, 10–24X3/4 1
34 140553 SCREW, 1/4–20X1/2 4
35 140016 WASHER, 1/4 LCK 4
36 230746 BRACKET, AXLE OFFSET 2
37 140504 NUT, CONDUIT LOCK 1/2” 1
38 230317 AXLE 1
39 140195 SCREW, 1/4–20X1/2 2
40 140003 WASHER, 1/4X1 2
41 103068 WHEEL, 10”X1.75 GRAY 2
42 130670 BREAKER CIRCUIT 12A 1
43 140022 WASHER, 3/8 INT 1
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PARTS LIST
FP-1600 (11–99)
12
DISCHARGE PUMP GROUP
1
10
2
3
4
5
6
7
8
9
11
12
13 14
15
16
17
18
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PARTS LIST
FP-1600 (11–99) 13
DISCHARGE PUMP GROUP
REF PART # DESCRIPTION QTY.
1 150500 FITTING, 1–1/2MX1–1/2H 1
2608517 DECAL, DISCHARGE 1
3150301 FITTING, INLET 1
4608467 ASM., 45 DEGREE ELBOW 1
5140308 CLAMP, HOSE 1
6608488 HOSE, 1.62 ID 6” 1
7140308 CLAMP, HOSE 1
8210007 VALVE, CHECK 1
9230183 FITTING, 1–1/2 1
RECOMMENDED STOCK ITEMS
REF PART # DESCRIPTION QTY.
10 608885 PUMP, DISCHARGE 1
11 130041 WIRE TIE, NYLON 1
12 140553 SCREW, 1/4–20X1/2 2
13 608884 BRACKET, PUMP 2
14 608883 PLATE, PUMP BLACK 1
15 100029 GASKET, TANK CONNECTOR 2
16 140027 WASHER, 5/16 FLT 2
17 140015 WASHER, 5/16 SPLTLCK 2
18 140223 SCREW, 5/16–18X3/4 2
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PARTS LIST
FP-1600 (12–99)
14
HANDLE GROUP
1
11
2
3
45
6
7
8
9
10
12
13
REF PART # DESCRIPTION QTY.
1 578729 DECAL, ”READ MANUAL” 1
219417 SWITCH, W/ ON/OFF 1
3100376 HANDLE, 12/16 RM–BLUE 1
4230696.BK BRACKET, DRAIN HOSE 1
5140825 SCREW, #6X1/2 2
6602596 DECAL, WARNING WET/DRY VAC 1
7130201 CORD, 16/3X28” YELLOW 2
RECOMMENDED STOCK ITEMS
REF PART # DESCRIPTION QTY.
8 140231 SCREW, 3/8X1–1/2 4
9140017 WASHER, 3/8 SPLTLCK 4
10 140028 WASHER, 3/8 FLT 4
11 130267 CORD, 16/3X30” YELLOW 1
12 140504 NUT, CONDUIT LOCK 1/2” 1
13 130250 CORD, 16/3X50’ EXT SJT YELLOW 2
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PARTS LIST
FP-1600 (02–00) 15
FLOOR TOOL, HOSES AND SQUEEGEE GROUP
1
5
6
78
9
10
11
12
3
4
2
REF PART # DESCRIPTION QTY.
∇200125 TOOL, FLOOR (COMPLETE) 1
1200426.BK TOOL, FLOOR 1
2200939 SHOE, 13” FLOOR TOOL 2
∇600341 KIT, HOSE/SQUEEGEE 1
3160466 HOSE, VAC 1.5X25 1
4160465 HOSE, VAC 1.5X15’ 1
∇200170 SQUEEGEE ASSEMBLY 1
5240200 KNOB, SQUEEGEE 2
∇ASSEMBLY
INCLUDED IN ASSEMBLY
RECOMMENDED STOCK ITEMS
REF PART # DESCRIPTION QTY.
6 240054.BK PLATE, NUT 15” SQUEEGEE 1
7240060 BACKING BLADE, 15” SQUEEGEE 1
8140011 WASHER, 3/16 FLT 5
9240055.BK PLATE, NUT 13” SQUEEGEE 1
10 240056.BK CHANNEL, 15” SQUEEGEE 1
11 240059 WIPING BLADE, 15” SQUEEGEE 1
12 140887 SCREW, 10–24X3/8 10
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