Castex TS-2700 Product manual

Operator and Parts Manual
Automatic Floor Scrubber
Model No.:
607257 -TS-3300
607258 -TS-2700
TS-2700/TS-3300
607578
Rev. 01 (03-04)
CASTEX CUSTOMER SERVICE:
1--800--365--6625
FAX: [phone]
TECHNICAL SUPPORT:
1--800--522--7839 EXT. 5356
TENNANT COMPANY
701 NORTH LILAC DRIVE
MINNEAPOLIS, MN 55422
MAILING ADDRESS:
TENNANT COMPANY
P.O. BOX 1452
MINNEAPOLIS, MN 55440--1452

OPERATION
TS--2700/TS--3300 (05--04)
2
This manual is furnished with each new model.
It provides necessary operation and maintenance
instructions and an illustrated parts list.
Read this manual completely and understand the
machine before operating or servicing it.
Use the illustrated Parts Lists to order parts. Before
ordering parts or supplies, be sure to have your
machine model number and serial number handy.
Parts and supplies may be ordered by phone or mail
from any authorized parts and service center,
distributor or from any of the manufacturer’s
subsidiaries.
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 care instructions provided.
SThe machine is maintained with manufacturer
supplied or equivalent parts.
MACHINE DATA
Please fill out at time of installation for future reference.
Model No.-
Install. Date -
Serial No.-
E1999, 2004 Tennant Company Printed in U.S.A.
Castex is a registered United States trademark of Tennant Company
TABLE OF CONTENTS
SAFETY PRECAUTIONS 3....................
SAFETY LABEL 4............................
MACHINE COMPONENTS 5...................
CONTROL PANEL SYMBOLS 5...............
MACHINE INSTALLATION 6...................
UNCRATING MACHINE 6..................
ATTACHING SQUEEGEE ASSEMBLY 6.....
INSTALLING BATTERIES 6................
MACHINE SETUP 7..........................
PRE--OPERATION CHECKS 7..............
INSTALLING BRUSH OR PAD DRIVERS 7...
FILLING SOLUTION TANK 8...............
MACHINE OPERATION 8.....................
WHILE OPERATING MACHINE 9...........
CIRCUIT BREAKERS 10....................
DRAINING TANKS 10..........................
DRAINING RECOVERY TANK 10............
DRAINING SOLUTION TANK 10.............
CHARGING BATTERIES 11....................
MACHINE MAINTENANCE 12..................
DAILY MAINTENANCE 12...................
WEEKLY MAINTENANCE 12................
MONTHLY MAINTENANCE 12...............
QUARTERLY MAINTENANCE 12............
BATTERY MAINTENANCE 13...............
DRIVE CHAIN MAINTENANCE 14...........
TRANSPORTING MACHINE 14.................
STORING MACHINE 14........................
RECOMMENDED STOCK ITEMS 14.............
TROUBLE SHOOTING 15......................
SPECIFICATIONS 17..........................
MACHINE DIMENSIONS 17....................
ELECTRICAL DIAGRAMS 18...................
PARTS LIST 20...............................
REPLACEMENT BRUSHES AND
PAD DRIVER GROUP 20...................
RECOVERY TANK GROUP 22...............
CHASSIS GROUP 24.......................
DRIVE WHEEL GROUP 26..................
CONTROL PANEL GROUP 28...............
CONTROL CONSOLE GROUP 30...........
PAD DRIVER GROUP 32...................
BRUSH LIFT GROUP 34....................
SOLUTION CONTROL GROUP 36...........
ELECTRICAL GROUP 38...................
SKIRT GROUP 40..........................
SQUEEGEE CONTROL GROUP 42..........
SQUEEGEE GROUP 44....................

OPERATION
TS--2700/TS--3300 (05--04) 3
SAFETY PRECAUTIONS
This machine is intended for commercial use. It is
designed exclusively to scrub hard floors in an
indoor environment and is not constructed for any
other use. Use only recommended pads, brushes
and commercially available floor cleaners
intended for machine application.
All operators must read, understand and practice
the following safety precautions.
The following warning alert symbol and the “FOR
SAFETY” heading 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.
Failure to follow these warnings may result in:
personal injury, electrical shock, fire or explosion.
WARNING: Fire Or Explosion Hazard. Never
Use Flammable Liquids Or Operate Machine In Or
Near Flammable Liquids, Vapors Or Combustible
Dusts.
This machine is not equipped with explosion
proof motors. The electric motors will spark upon
start up and during operation which could cause a
flash fire or explosion if machine is used in an
area where flammable vapors/liquids or
combustible dusts are present.
WARNING: Fire Or Explosion Hazard. Do Not
Pick Up Flammable Materials Or Reactive Metals.
WARNING: Fire Or Explosion Hazard.
Batteries Emit Hydrogen Gas. Keep Sparks And
Open Flame Away. Keep Battery Compartment
Open When Charging.
WARNING: Electrical Hazard. Disconnect
Battery Cables Before Servicing Machine.
The following information signals potentially
dangerous conditions to the operator or
equipment:
FOR SAFETY:
1. Do not operate machine:
-- With flammable liquids or near flammable
vapors as an explosion or flash fire may
occur.
-- Unless trained and authorized.
-- Unless operation manual is read and
understood.
-- If not in proper operating condition.
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.
-- Wear no--slip shoes.
-- Use care when reversing machine.
-- Report machine damage or faulty
operation immediately.
-- Never allow children to play on or around.
-- Follow mixing and handling instructions
on chemical containers.
4. Before leaving or servicing machine:
-- Stop on level surface.
-- Turn off machine.
5. When servicing machine:
-- Avoid moving parts. Do not wear loose
jackets, shirts, or sleeves.
-- Block machine tires before jacking up.
-- Use hoist or jack that will support the
weight of the machine.
-- Wear eye and ear protection when using
pressurized air or water.
-- Disconnect battery connections before
working on machine.
-- Wear protective gloves and safety glasses
when handling batteries or battery cables.
-- Avoid contact with battery acid.
-- Use manufacturer supplied or approved
replacement parts.
-- All repairs must be performed by a
qualified service person.
-- Do not modify the machine from its
original design.

OPERATION
TS--2700/TS--3300 (05--04)
4
6. When transporting machine:
-- Turn machine off.
-- Get assistance when lifting machine.
-- Do not lift machine when batteries are
installed.
-- Use a recommended ramp when
loading/unloading into/off truck or trailer.
-- Use tie--down straps to secure machine to
truck or trailer.
SAFETY LABEL
The safety label appears on the machine in the
location indicated. Replace label if it becomes
damaged or illegible.
WARNING LABEL -- LOCATED ON THE RECOVERY TANK LID.
FOR SAFETY LABEL --
LOCATEDONTHE
SWITCH PANEL.
READ MANUAL BEFORE
OPERATING.

OPERATION
TS--2700/TS--3300 (05--04) 5
MACHINE COMPONENTS
4
10
15
7
3
13
9
12
14
5
6
16 17
20
1
8
20
2
1918
212223
11
1. Squeegee Lift Lever
2. Recovery Tank Drain Hose
3. Brush Pressure Lever
4. Circuit Breakers
5. Squeegee Assembly
6. Brush Lift Foot Pedal
7. Solution Tank Drain Hose
8. Solution Tank Fill Ports
9. Recovery Tank Lid
10. Recovery Tank
11. Battery Charger Receptacle
(inside Battery Compartment)
12. Wall Rollers
13. Scrub Head Skirt
14. Rear Casters
15. Battery Compartment
16. Vacuum On/Off Switch
17. Battery Meter
18. Brush/Solution On/Off Switch
19 Solution Flow Control Knob
20. Trigger Switch
21. Transport/Fast Scrub Switch
22. Main Power/Slow Scrub Switch
23. Reverse Switch
CONTROL PANEL SYMBOLS
Main Power/
Slow Scrub
Switch
Vacuum
Switch
Transport/
Fast Scrub
Switch
Battery
Meter
Solution
Flow
Brush/
Solution
Switch
Reverse
Switch
Squeegee
Lift Lever
Brush Lift
Foot Pedal

OPERATION
TS--2700/TS--3300 (05--04)
6
MACHINE INSTALLATION
UNCRATING MACHINE
Carefully check carton for signs of damage. Report
damages to carrier at once. Check carton contents to
ensure all accessories are included. Squeegee is
packaged with machine. Batteries, battery charger and
pad drivers are packaged separately.
To uncrate your machine, remove shipping straps and
raise scrub head. To raise scrub head, step down
firmly on the bottom brush lift foot pedal until pedal
locks into the raised position. Carefully lift or use a
ramp to remove machine from pallet.
ATTENTION: Battery installation must be
accomplished after removing machine from
shipping crate.
ATTENTION: Do not roll machine off pallet,
machine damage may occur.
ATTACHING SQUEEGEE ASSEMBLY
1. Slide squeegee lift lever to the right to raise
squeegee mount bracket (Figure 1).
FIG. 1
2. Loosen two thumb knobs on squeegee and slide
squeegee into slots at rear of squeegee mount
bracket. Be certain that squeegee roller wheels
are toward the rear (Figure 2).
FIG. 2
3. Tighten thumb knobs securely.
INSTALLING BATTERIES
WARNING: Fire Or Explosion Hazard.
Batteries Emit Hydrogen Gas. Keep Sparks And
Open Flame Away. Keep Battery Compartment
Open When Charging.
FOR SAFETY: When servicing machine, wear
protective gloves and safety glasses when
handling batteries or battery cables. Avoid contact
with battery acid.
Recommended Battery Specifications:
Four 6 volt, deep cycle, 305 amp hour batteries. Part
Number 606991. Maximum battery dimensions are
178mm (7 in.) W x 308mm (12.13 in.) L x 356mm
(14in.) H.
1. Turn all switches to the off (O) position.
2. Carefully hinge open recovery tank to access
battery compartment. Remove loose battery
cables from compartment (Figure 3).
FIG. 3

OPERATION
TS--2700/TS--3300 (05--04) 7
3. Carefully install batteries into compartment and
arrange battery posts as shown (Figure 4).
Machine
Front
12
3
4
5
FIG. 4
ATTENTION: Do not drop batteries into
compartment, battery and machine housing
damage may result. This damage in not covered
by warranty.
4. Connect terminals to battery posts in numerical
order as labeled, RED TO POSITIVE & BLACK
TO NEGATIVE (Figure 4).
5. Double check cable connections before closing up
battery compartment.
6. Turn main power switch on (I) and check battery
meter charge level to ensure batteries are fully
charged. If batteries need charging, see
CHARGING BATTERIES.
MACHINE SETUP
PRE--OPERATION CHECKS
1. Sweep and dust-mop floor to remove particles and
other debris.
2. Check battery meter charge level to ensure
batteries are fully charged (See CHARGING
BATTERIES).
3. Check that pads or brushes are installed.
4. Check that squeegee is installed.
INSTALLING BRUSH OR PAD DRIVERS
1. Turn main power switch to the off (O) position.
FOR SAFETY: Before leaving or servicing
machine, stop on level surface and turn off
machine.
2. Raise scrub head. Step down firmly on bottom
brush lift foot pedal to raise (Figure 5).
FIG. 5
3. Unfasten black latch at front of machine and hinge
open skirt housing to access motor hub (Figure 6).
FIG. 6
4. Select recommended pad or brush that best
meets your cleaning needs.
NOTE: Consult your authorized distributor for
pad/brush recommendations.
5. (For Pad Installation) Attach pads to pad drivers
before connecting drivers to motor hub. To attach
pad to driver, remove plastic centerlock ring from
pad driver. Position pad on pad driver and replace
centerlock ring (Figure 7).
FIG. 7

OPERATION
TS--2700/TS--3300 (05--04)
8
6. Attach brush/pad drivers to motor hubs. Align (3)
mounting studs with slots in motor hub. Give driver
a quick turn toward spring clip located on motor
hub. Be certain pad driver is securely fastened
and spring clip locks into one of the studs before
operating machine (Figure 8).
FIG. 8
NOTE: Always make sure pad driver and motor hub
surfaces are clean before installing drivers. Keeping
surfaces clean will make it easier when removing pad
drivers.
7. Close skirt housing and refasten latch.
FILLING SOLUTION TANK
1. Transport machine to filling station. Raise
squeegee and scrub head when transporting.
2. Turn off machine.
FOR SAFETY: Before leaving or servicing
machine, stop on level surface and turn off
machine.
3. Open solution fill door on side of machine and fill
solution tank with clean water, 60°C (140°F)
maximum temperature. Or you can fill solution
tank using hose fill port at rear of machine. Pull off
plug and insert hose to fill. The clear tube below
the fill port has 19L (5 gallon) increment markers
to indicate amount of water in tank (Figure 9).
FIG. 9
NOTE: The water must not be hotter than 60_C
(140_F) or tank damage may occur.
NOTE: If filling with a bucket be certain that bucket is
clean. This will prevent possible solution line clogs.
4. Add cleaning chemical. See proper dilution ratio
instructions on bottle.
FOR SAFETY: When using machine, follow mixing
and handling instructions on chemical containers.
ATTENTION: Use only recommended detergents.
Machine damage due to improper detergent usage
will void the manufacturer’s warranty. Contact
your sales representative for detergent
recommendations.
WARNING: Fire Or Explosion Hazard. Never
Use Flammable Liquids.
MACHINE OPERATION
FOR SAFETY: Do not operate machine unless
operator manual is read and understood.
1. Slide squeegee lever to the left to lower squeegee
assembly (Figure 10).
FIG. 10
2. Push top foot pedal forward to lower scrub head
(Figure 11).
FIG. 11

OPERATION
TS--2700/TS--3300 (05--04) 9
3. Turn on main power, vacuum and brush/solution
switches.
NOTE: The brush motors will start when triggers are
activated.
4. Pull triggers to begin scrubbing.
WARNING: Fire Or Explosion Hazard. Do Not
Pick Up Flammable Materials Or Reactive Metals.
5. Turn solution flow control knob to maximum for 30
seconds, then adjust to desired flow (Figure 12).
FIG. 12
6. To operate in reverse, push and hold reverse
switch while pulling triggers (Figure 13).
FIG. 13
7. If additional scrubbing speed is desired, activate
the transport/fast scrub switch.
WHILE OPERATING MACHINE
WARNING: Fire Or Explosion Hazard. Never
Operate Machine In Or Near Flammable Liquids,
Vapors Or Combustible Dusts.
FOR SAFETY: When using machine, go slow on
inclines and slippery surfaces.
1. Observe amount of solution on floor and adjust
solution flow knob accordingly.
2. Periodically observe recovery tank for excessive
foam (look through clear lid). If excessive foam
appears, pour a recommended foam control
solution into recovery tank.
ATTENTION: Do not allow foam or water to enter
recovery tank float shut--off screen, vacuum motor
damage will result. The float shut--off screen will
not keep foam out. Vacuum damage due to foam
or water is not covered by warranty.
3. Change or turn pads over when worn.
4. If squeegee leaves streaks, raise and wipe blades
with a cloth. Pre-sweep area to prevent streaking.
5. During brief stops, it’s not required to turn brush
switch off, the brush will automatically stop when
triggers are released.
6. Observe battery meter needle. When needle
drops into the red zone, recharge batteries.
ATTENTION: Do not continue to run machine
when battery meter needle is in the red zone,
battery damage will result.
7. If additional scrubbing pressure is needed for
small, heavily soiled areas, perform the following:
a. Lower scrub head.
b. Lift pad pressure lever to the locked position
(Figure 14).
NOTE: Scrub head must be lowered to allow pad
pressure lever to be lifted to the locked position. Lower
lever before raising scrub head.
FIG. 14
8. Periodically observe clear tube for remaining
cleaning solution.
9. When solution tank runs dry, transport machine to
draining area (See DRAINING TANKS).

OPERATION
TS--2700/TS--3300 (05--04)
10
CIRCUIT BREAKERS
The machine is equipped with (4) circuit breakers to
protect motors from damage. If circuit breakers should
trip, they cannot be reset immediately. Determine
cause, allow motor to cool and then reset. The brush
motor circuit breakers (35A), located near charger
plug, will trip due to excessive overload on pad. Turn
over or change pads if breakers should trip. The main
circuit breaker (10A) and vacuum/drive motor circuit
breaker (35A) are located at rear of machine
(Figure 15).
FIG. 15
DRAINING TANKS
FOR SAFETY: Before leaving or servicing
machine, stop on level surface and turn off
machine.
DRAINING RECOVERY TANK
Recovery tank must be emptied prior to refilling
solution tank. To drain recovery tank, perform the
following steps:
ATTENTION: If recovery tank is not emptied
between fill--ups, foam or water will enter float
shut--off screen located in the recovery tank and
damage vacuum motor. Float shut--off screen will
not keep foam out. Vacuum damage due to foam
or water is not covered by warranty.
1. Remove recovery tank drain hose from holder,
position hose over floor drain and twist off cap.
To completely drain recovery tank, hinge open
tank sideways and flip up tank support stand to
rest tank on (Figure 16).
NOTE: If using a bucket to drain machine, do not use
same bucket for filling solution tank. This will prevent
possible solution line clogs.
FIG. 16
2. Rinse out recovery tank after each use. This will
prevent foul odor buildup. Use a hose to rinse out
the recovery tank. Be careful not to spray water
into shut--off float screen.
3. Replace drain hose cap tightly after draining.
DRAINING SOLUTION TANK
1. Pull solution tank drain hose (clear hose) off hose
barb at rear of machine and drain solution into
floor drain or bucket (Figure 17).
FIG. 17
2. Rinse out solution tank with clean water after each
use and flush out solution flow system. This will
prevent clogging due to chemical buildup. Use
clear hose to drain solution tank.
3. Reconnect clear hose to hose barb. Be certain
hose is completely pushed onto hose barb.