Castex BR-1600 Operator And Parts Manual

ENGLISH - ESPAÑOL - FRANÇAIS

BR--1600

High Speed Floor Burnisher

PulidoradePisodeAltaVelocidad

Polisseuse de sols haute vitesse

Model No.:
9002792

Operator and Parts Manual

Manual del Operador y Piezas

Opérateur Manuel et Liste Des Piéces

1033090

Rev. 02 (04-2010)

*1033090*

OPERATION

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.

When ordering replacement parts, use the illustrated
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 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:

S The machine is operated with reasonable care.

MACHINE DATA

Please fill out at time of installation for future reference.

Model No.-

Install. Date -

Serial No.-

S The machine is maintained regularly - per the

machine maintenance instructions provided.

S The machine is maintained with manufacturer

supplied or equivalent parts.

PROTECT T HE ENVIRONMENT

Please dispose of packaging materials,
old machine components such as bat­teries, hazardous fluids such as anti­freeze and oil, in a safe environmental­ly way according to your local waste
disposal regulations.

Always remember to recycle.

TABLE OF CONTENTS

SAFETY PRECAUTIONS 3....................

WARNING LABEL 4..........................

MACHINE COMPONENTS 5...................

MACHINE SETUP 5..........................

MACHINE OPERATION 6.....................

MACHINE MAINTENANCE 7..................

STORING MACHINE 8........................

TRANSPORTING MACHINE 8.................

RECOMMENDED STOCK ITEMS 8.............

TROUBLE SHOOTING 9......................

SPECIFICATIONS 9..........................

ELECTRICAL DIAGRAM 26....................

HANDLE GROUP 28...........................

BASE GROUP 30..............................

Tennant Company

PO Box 1452
Minneapolis, MN 55440
Phone: [phone] or (763) 513--2850

www.tennantco.com

Specifications and parts are subject to change without notice.
Copyright E 2006, 2010 Tennant Company. All rights reserved.

Printed in U.S.A.

2

Castex BR--1600 (04--10)

SAFETY PRECAUTIONS

This machine is intended for commercial use only.
It is designed exclusively to burnish floors in an
indoor environment and is not constructed for any
other use. Use only recommended burnishing
pads and commercially available floor cleaners
and waxes 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, electrocution, electric shock, fire
or explosion:

WARNING: Do Not Use Flammable Liquids Or
Operate Machine In Or Near Flammable Liquids,
Vapors Or Combustible Dusts.

This machine is not equipped with an explosion
proof motor. The electric motor 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: Do Not Operate With Damaged
Power Cord. Do Not Modify Plug. Unplug Power
Cord Before Servicing Machine

If the supply cord is damaged or broken, it must
be replaced by the manufacturer or it’s service
agent or a similarly qualified person in order to
avoid a hazard.

WARNING: Do Not Use Outdoors. Do Not
Expose to Rain. Store Indoors.

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.

OPERATION

-- Unless trained and authorized.

-- Unless operator manual is read and
understood.

-- Unless cord is properly grounded.

-- With damaged cord or plug.

-- If not in proper operating condition.

-- In outdoor areas.

-- In standing water.

-- With the use of an extension cord.

2. Before operating machine:

-- Make sure all safety devices are in place
and operate properly.

-- Place wet floor signs as needed.

-- Remove loose objects on floor to prevent
dangerous projectiles if struck by spinning
pad.

3. When using machine:

-- Stay clear of spinning pad.

-- Do not run machine over cord.

-- Do not pull machine by plug or cord.

-- Do not pull cord around sharp edges or
corners.

-- Wear non-slip shoes.

-- Do not close doors on cord.

-- Do not unplug by pulling on cord.

-- Do not stretch cord.

-- Do not handle plug with wet hands.

-- Keep cord away from heated surfaces.

-- Never activate the power when the handle
is in the upright position.

-- Do not release handles until pad comes to
a complete stop.

-- Go slow on inclines and slippery surfaces.

-- Never allow children to play on or around.

-- Report machine damage or faulty
operation immediately.

-- Follow mixing and handling instructions
on chemical containers.

4. Before leaving machine:

-- Turn off machine.

-- Unplug cord from wall outlet.

5. When servicing machine:

-- Unplug cord from wall outlet.

-- Avoid moving parts. Do not wear loose
jackets, shirts, or sleeves.

-- Use manufacturer supplied or approved
replacement parts.

-- All repairs must be performed by a
qualified service person.

-- Do not modify the machine from it’s
original design.

Castex BR--1600 (10--02)

3

OPERATION

6. When transporting machine:

-- Get assistance when lifting machine.

-- Unplug cord from wall outlet.

-- Use tie--down straps to secure machine to
truck or trailer.

GROUNDING INSTRUCTIONS

Grounded
3HoleOutlet

Machine must b e 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 a cord 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.

WARNING LABEL

The warning label appears on the machine in the
location indicated. Replace label if it becomes
damaged or illegible.

Ground Pin

WARNING LABEL -- Located on backside
of machine handle.

4

Castex BR--1600 (12--06)

OPERATION

MACHINE COMPONENTS

1

4

6

5

3

2

7

MACHINE SETUP

Carefully check carton for signs of damage. Report
damages at once to carrier.

INSTALLING PAD
FOR SAFETY: Before leaving or servicing

machine, unplug cord from wall outlet.

1. The machine is shipped fully assembled. Pads are
sold separately. Select and install a recommended
pad that best meets your burnishing needs.

NOTE: Consult your authorized distributor for pad
recommendations. Use only manufacturer supplied or
approved pads.

2. Pull the handle release lever and raise the handle
to the upright position. Carefully tilt the machine
backwards and rest the handle on the floor
(Figure 1).

9

8

1. Power ON/OFF Twist Grips

2. Handle Release Lever

3. Safety Lock Button

4. Circuit Breaker Button

5. Power Cord Hook

6. 75 ft / 23 m Power Cord

7. Motor Cover

8. Transport Wheels

9. Burnish Head

10. Bumper
1 1. Burnishing Pad

10

11

FIG. 1

3. To install the pad, remove the plastic centerlock
ring from the pad driver by turning it clockwise.
Position the pad on the pad driver and replace
centerlock ring by turning it counter-clockwise.
Make sure the centerlock ring is fastened securely
(Figure 2).

Castex BR--1600 (12--06)

FIG. 2

4. Return machine to the upright position.

5

OPERATION

MACHINE OPERATION

FOR SAFETY: Do not operate machine unless
operator manual is read and understood.

1. Plug power supply cord to a grounded wall outlet
(Figure 3).

Grounded
3HoleOutlet

Ground Pin

3. Start machine by pressing the safety lock button
and turning the twist grips forward. Release thumb
from the safety lock button once machine starts
(Figure 5).

FIG. 5

A TTENTION: Use caution when starting out.
Machine will jolt when twist grips are turned.

FIG. 3

WARNING: Do Not Operate With Damaged
Power Cord. Do Not Modify Plug. Unplug Power
Cord Before Servicing Machine.

WARNING: Do Not Use Flammable Liquids Or
Operate Machine In Or Near Flammable Liquids,
Vapors Or Combustible Dusts.

This machine is not equipped with an explosion
proof motor. The electric motor 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.

2. Release the handle from the upright position by

lifting the handle release lever and lowering the
handle (Figure 4).

4. Begin burnishing by pushing the machine forward
or using a ”W” pattern motion.

FOR SAFETY: When using machine, stay clear of
spinning pad.

SPRAY BUFFING INFORMATION:

This machine should not be used for spray buffing;
circuit breaker may trip or machine overloading may
occur.

5. To prevent the possibility of motor overload and
causing circuit breaker to trip, periodically check
pad for excessive soil build-up. Turn pad over,
clean or replace when necessary.

NOTE: If circuit breaker should trip, unplug power
cord. Wait at least 15 seconds before resetting

breaker switch. While waiting determine reason why
circuit breaker tripped (Figure 6).

FIG. 4

NOTE: Handle does not lock while in lowered position.
It is designed to allow burnish head to float freely.

6

FIG. 6

Castex BR--1600 (12--06)

OPERATION

FOR SAFETY: Before leaving machine, unplug
cord from wall outlet.

6. To stop machine, rotate twist grips backward and
safety lock button will engage.

FOR SAFETY: When using machine, do not
release handles until pad comes to complete stop.

7. Do not operate the machine in the same spot for a
long period of time. Floor damage may result.

8. To maneuver over thresholds and floor grates,
stop the machine and tilt it back on the transport
wheels.

9. When machine is not in use, do not leave machine
standing on the pad. Pad damage may result.

10. When done burnishing perform the following
machine maintenance procedures.

FOR SAFETY: When transporting machine, get
assistance when lifting machine.

MACHINE MAINTENANCE

FOR SAFETY: Before servicing machine, unplug
cord from wall outlet.

1. Remove and clean the pad after each use.

2. Always store machine tilted back on rear wheels.

3. Clean the machine with an all purpose cleaner
after each use.

4. Inspect the power cord for damage after each use.
If worn or damaged, replace cord immediately.

5. Wipe the power cord with damp cloth and neatly
coil it around cord hook and handle after each use.

6. Gear system and motor are factory lubricated and
require no further attention.

7. Once a month, check the tension of the drive belt.
At mid--point of belt, the belt tension should have a
1/4 in / 6.4 mm deflection at 5 lb of force (Figure

7). To tighten belt, remove the pad driver and
loosen the (4) pad driver pulley bracket hex head
screws. Loosen the jam nut on the tension bolt
and turn bolt clockwise until belt is properly
adjusted, then retighten the pulley bracket screws
and jam nut (Figure 8).

NOTE: A belt that is too tight nor too loose can cause
early belt failure.

1/4in/6.4mm
Defection
5lbForce

FIG. 7

FIG. 8

8. Every 250 hours of operation, check the motor for
carbon brush wear. Replace brushes when worn
to a length of 3/8 in / 1 cm or less. Contact an
Authorized Service Center for carbon brush
inspection.

FOR SAFETY: When servicing machine, all repairs
must be performed by a qualified service person.

Castex BR--1600 (12--06)

7

OPERATION

STORING MACHINE

1. Unplug the power cord and remove the pad from
the machine. Neatly coil the cord around the cord
hook and handle to prevent cord damage
(Figure 9).

FIG. 9

2. Store the machine in a dry area in the upright
position with the handle positioned upward or
folded down.

TRANSPORTING MACHINE

1. Unplug the power cord and remove the pad from
the machine. Neatly coil the cord around the cord
hook and handle to prevent cord damage.

2. Load the machine using a recommended loading
ramp or carefully lift the machine with adequate
assistance.

FOR SAFETY: When transporting machine, get
assistance when lifting machine.

3. Secure machine with tie--down straps when
transporting by vehicle.

WARNING: Do Not Use Outdoors. Do Not

Expose to Rain. Store Indoors.

RECOMMENDED STOCK ITEMS

Refer to the Parts List section for recommended stock
items. Stock Items are clearly identified with a bullet
preceding the parts description as shown (Figure 10).

WARNING: Do Not Use Outdoors. Do Not

Expose to Rain. Store Indoors.

FIG. 10

8

Castex BR--1600 (12--06)

TROUBLE SHOOTING

PROBLEM CAUSE SOLUTION

Motor does not operate. Machine circuit breaker tripped.

(Spray buffing with the models is not
recommended).

Building circuit breaker tripped. Reset breaker and change to different

Faulty power cord. Contact Service Center.
Faulty wiring. Contact Service Center.
Faulty twist grip switch. Contact Service Center.
Faulty Rectifier. Contact Service Center.
Faulty Motor. Contact Service Center.

Machine circuit breaker trips
continuously.

Soiled Pad. Replace Pad.
Improper pad for application. Change to proper pad.
Defective circuit breaker. Contact Service Center.
Worn carbon brushes in motor. Contact Service Center.

Pad spins slowly or not at all. Loose drive belt. Tighten drive belt.

Broken drive belt. Replace drive belt.

Determine cause and reset breaker on
machine. Wait 15 seconds before
restarting machine.

circuit.

OPERATION

SPECIFICATIONS

MODEL

WIDTH 20.75 in / 530 mm
HEIGHT 49 in / 1,240 mm
LENGTH 29.75 in / 760mm
WEIGHT 68 lb / 31 kg
DRIVE MOTOR 120 V, 1.5 hp, 15 A, 60 HZ
PAD/BRUSH SPEED 2,000 rpm
POWERCORDLENGTH 75 ft / 23 m Gauge 3 X 1.5 mm
PAD DIAMETER 20 in / 510 mm
DECIBEL RATING AT

OPERATOR’S EAR, INDOORS ON TILE FLOOR

BR--1600

70 dBA

Castex BR--1600 (06--06)

9

OPERACIÓN

Este manual se incluye en todos los modelos nuevos.
Proporciona la información necesaria para su
utilización y mantenimiento.

Lea todo el manual detenidamente para
comprender la máquina antes de utilizarla o
revisarla.

Use la Lista de Piezas incluida en este manual al
ordenar piezas de repuesto. Antes de ordenar piezas
o suministros, asegúrese de tener el número de
modelo y el número de serie de su máquina. Las
piezas y los suministros pueden ordenarse por
teléfono o por correo de cualquier centro autorizado
de piezas y servicios, distribuidor de piezas o de
cualquier subsidiaria del fabricante.

Esta máquina proporcionará un servicio excelente. Sin
embargo, los mejores resultados se obtienen a un
costo mínimo si:

DATOS DE LA MÁQUINA

Por favor complete al momento de la instalación para
referencia futura.

No. de Modelo-

Fechadeinstalación-

No. de Serie-

ÍNDICE

S La máquina se opera con un cuidado razonable.
S La máquina se mantiene con regularidad, según las

instrucciones de mantenimiento provistas.

S La máquina se mantiene con las piezas provistas

por el fabricante o equivalentes.

PROTECCIÓN DEL MEDIO
AMBIENTE

Deseche el material de embalaje, los
componentes usados de la máquina
como las baterías y los líquidos
peligrosos como el anticongelante y el
aceite, de forma segura para el medio
ambiente, de acuerdo con las
normativas o disposiciones locales.

No olvide reciclar.

MEDIDAS DE SEGURIDAD 11..................

ETIQUETA DE ADVERTENCIA 12...............

COMPONENTES DE LA MÁQUINA 13...........

INSTALACIÓN DE LA MÁQUINA 13.............

FUNCIONAMIENTO DE LA MÁQUINA 14........

MANTENIMIENTO DE LA MÁQUINA 15.........

ALMACENAMIENTO DE LA MÁQUINA 16.......

TRANSPORTE DE LA MÁQUINA 16.............

STOCK RECOMENDADO DE REPUESTOS 16...

LOCALIZACIÓN DE AVERÍAS 17...............

ESPECIFICACIONES 17.......................

DIAGRAMA ELÉCTRICO 26....................

GRUPO DEL ASA 28..........................

GRUPO BASE 30..............................

Tennant Company

PO Box 1452
Minneapolis, MN 55440 EE.UU.
Teléfono: (800) 553--8033 o (763) 513--2850
www.tennantco.com

Las características técnicas y las piezas están sujetas a
modificaciones sin previo aviso.

Copyright E 2008, 2010 TENNANT Company.
Todos los derechos reservados. Impreso en USA.

10

Castex BR--1600 (04--10)