NSS 2300BP User manual

CHARGER 2300, 2500 BP
IMPORTANT SAFETY INSTRUCTIONS
READ AND UNDERSTAND ALL INSTRUCTIONS
BEFORE OPERATING OR SERVICING MACHINE
DANGER!Failure to Observe These Instructions Can Cause Personal Injury
to Machine Operator, By-standers or Possible Machine Damage.
ALWAYS wear eye protection and protective clothing when working with the batteries.
The batteries contain ACID Avoid contact with skin or clothing.
Antidote: EYES - Flush with water 15 minutes. Call Physician.
INTERNAL - Drink water or milk. Follow with Milk of Magnesia, beaten egg or vegetable oil.
Call physician.
Service should be don only by authorized, trained personnel.
Charge Batteries in a well ventilated area with Battery Compartment Open.
Batteries generate explosive gasses - keep sparks, flames, burning cigarettes or other ignition sources away at all
times.
Batteries are heavy - two (2) people are required for installation or removal.
Never lay anything on top of batteries to prevent arcing.
Turn off all switches during installation and service.
To maintain machine balance, always slide batteries back into position as shown on battery installation decal.
Connect batteries as shown on battery installation decal to avoid shorting out batteries and electrical system.
Disconnect battery leads before performing any service or repairs.
ALWAYS make sure battery charger is turned off when connecting/disconnecting to machine to prevent sparking.
ALWAYS operate this machine from the rear control panel, not from the side.
NEVER operate this machine in an explosive atmosphere (grain dust or gas vapor).
NEVER use flammable liquids (gas, kerosene, solvents or thinners) to clean floor.
ALWAYS turn OFF master switch when changing pads.
NEVER operate machine with skirts or covers removed.
NEVER leave this machine unattended.
PERSONAL INJURY AND PROPERTY DAMAGE FROM THIS MACHINE OVERTURNING, BATTERIES
FALLING OUT OF THE MACHINE OR BATTERIES LEAKING ACID CAN OCCUR IF YOU DO NOT
FOLLOW THESE PRECAUTIONS:
NEVER attempt to operate this machine unless you have been trained in its operation.
Follow these rules when working on or near loading docks and ramps:
ALWAYS be sure ramp is secured to vehicle before attempting to load/unload.
ALWAYS use extreme caution when operating this machine on a ramp or loading / unloading this
machine into or out of a truck. Use extreme caution if the ramp is wet, oily or covered with cleaning
chemicals.
NEVER turn this machine on an ramp or incline.
NEVER stop this machine on a ramp or incline.
NEVER attempt to climb a grade of more than 20 degrees.
NEVER park machine near a dock, or on ramps.
NEVER leave machine unattended.
WARNING: Failure to observe these instruction can cause machine damage and possible personal
injury to machine operator.
NEVER spray machine with water.
NEVER allow battery charging plugs to get wet. The battery charging plugs will short out if wet.
NEVER operate machine when charger is plugged in.
NEVER store machine near furnaces, boilers, ore flame which may damage machine.
NEVER store any items on this machine.
ALWAYS protect machine from freezing temperatures.
SAVE THESE INSTRUCTIONS

WARNING
READ THE SERVICE MANUAL BEFORE INSTALLING
BATTERIES OR USING CHARGER. FAILURE TO OBSERVE THE
FOLLOWING INSTRUCTIONS MAYRESULTIN DAMAGE TO THE
MACHINE, OR INJURYTO THE OPERATOR OR
BY-STANDERS.
BATTERYINSTALLATION INSTRUCTIONS
•ONLYTRAINED PERSONNEL SHOULD INSTALL BATTERIES.
•BATTERIES ARE HEAVY, USE TWO (2) PEOPLE TO INSTALL.
•WEAR EYE PROTECTION AND PROTECTIVE CLOTHING.
•TURN OFFALL MACHINE SWITCHES.
•CONNECT BATTERIES AS SHOWN ON THIS DECAL.
MACHINE WILL NOT TURN ON IF BATTERIES ARE
CONNECTEDIMPROPERLY.
•DO NOT LAYANYTHING ON TOP OF THE BATTERIES.
•DISCONNECT THE BATTERIES BEFORE PERFORMING ANY
SERVICE OR REPAIRS.
CHARGING INSTRUCTIONS
•READ INSTRUCTIONS ON THE CHARGER.
•ONLYUSE A36 VOLTCHARGER FOR THE CHARGER 2500 BP.
•ONLYUSE A24 VOLTCHARGER FOR THE CHARGER 2300 BP.
•BEFORE CHARGING CHECK TO INSURE THATTHE
BATTERYWATER LEVEL COVERS THE BATTERYPLATES.
•CHARGE IN WELL VENTILATED AREA.
•EXPLOSIVE GAS - DO NOT SMOKE - STRIKE AMATCH OR
CAUSE ASPARK DURING CHARGING.
•AFTER CHARGING - IF NEEDED - FILL THE BATTERYUP TO
THE BOTTOM OF THE FILL HOLE WITH DISTILLED WATER.
DO NOT OVER FILL. BATTERYAND MACHINE DAMAGE
MAYRESULT. WIPE ANY ACID FROM THE TOP OF THE
BATTERIES CLEAN USING ASOAP SOLUTION.
WET
STORAGE
BATTERY
* CONTAINSACID,AVOID CONTACT.
*ANTIDOTE:
* EYES - FLUSH WITH WATER
15 MINUTES.
* INTERNAL - DRINK WATER OR MILK.
FOLLOW WITH MILK OF
MAGNESIA, BEATEN EGG
OR VEGETABLE OIL.
*CALL PHYSICIAN.
POISON / DANGER
CAUSES SEVERE BURNS
BATTERY INSTALLATION INSTRUCTIONS
CORROSIVE
ACID

INSTRUCTIONS
Before operating and/or attaching/detaching the pads, you must read these instructions:
*The machine can be lowered in the back, which raises up the front for ease of transportation and pad
attachment/detachment.
*The machine arrives in Position No. 1 (the operating position). To lower the back of the machine to
Position No. 3 (the pad changing position), hold operator handle with one hand and move the Release
Knob up with other hand. Lower the machine slowly. Let go of Release Knob after machine begins to
lower. The machine will stop in Position No. 2. Move Release Knob up again and lower the machine
slowly to floor (Position No. 3). Pad can now be easily attached/detached.
*To raisemachine to Position No. 2 (the transport position), lift up on Operator handle with both hands.
The machine will stop in Position No. 2. The machine can now be transported.
*To raise the machine back to Position No. 1, lift up on Operator handle with one hand and move
Release Knob up with the other hand. Let go of Release Knob after machine starts to raise up. The
machine will stop in Position No. 1.
*After attaching a new pad and placing machine in Operating position, adjust Pad Pressure Knob until
the arrow (Below Left) points to the Release Knob.
*Push machine forward when starting to avoid possible damage to the floor.
*Increase or decrease Pad Pressure as needed, after machine starts.
Pad Installation
Remove the pad that is supplied in the battery compartment of the machine. Remove the center hole of
the pad and step on the center of the pad to compress the edges around the center hole. This will allow
easier installation of the pad holding cup.
With the machine in the pad changing position, #3, carefully center the pad on the driver. Place pad
grabber in the center hole of the pad. Holding the pad grabber, turn the pad driver clockwise until the pad
cup is tight and stops turning.
Caution: Pads must be installed concentric (evenly aligned) with the outside edge of the pad driver.
Failure to follow these precautions will cause excessive machine vibration, a reduction in pad life and
produce unsatisfactory burnishing results. Failure to install the pad grabber tightly may allow the
pad to be thrown from the driver. Never operate the machine without a Flexiwall Shield in
position over the pad.
Setting Pad Pressure
Pad pressure relates to buffing performance. Too much pad pressure will give uneven results and may
cause circuit breaker to blow. Too light pad pressure will also give poor results and no contact with the
floor. New pads are manufactured in different thicknesses; however, ALL pads will thin down during use
and require periodic adjustment of pad. Therefore, follow procedure below:
ALWAYS start with ALL pad pressure OFF the floor. Increase pad pressure on the floor in
small increments to prevent damage to the floor.
CAUTION: Too Much pad pressure may permanently damage floor.
The adjustment knob is a simple method of setting the pad pressure based on the thickness of
the pad.
To increase pad pressure, turn the knob counter clockwise.
To decrease pad pressure, turn the knob clockwise.
If the circuit breaker blows on the machine, immediately reduce pad pressure by one full turn or
more on the adjustment knob clockwise. Reset circuit breaker and try machine.
NEW PADS - Alwaysdecrease pad pressure three turns after installing a new pad. Move
machine forward while starting machine and fine tune operating amps. Failure to decrease pad
pressure can cause an amp overload, blowing machine circuit breaker.

OPERATION
What Floor System Works Best With The Charger 2300BP/2500BP.
Dry polishing or burnishing works best with the Charger 2300BP/2500BP. Use mop on restorers rather
than spray buff systems to restore the shine.
Spray buffing is time consuming, uses more pads because they become loaded with floor finish, and
can cause overloading of the machine’s circuit breaker.
HOW THE CHARGER 2300BP/2500BP WORKS
•The Charger 2000BP/2500BP utilizes a 2.5 HP permanent magnet motor to drive the 20" pad.
The pad pressure is adjustable by turning a knob on the top of the machine, which will either
increase or decrease the pad pressure.
•The level of pad pressure is indicated on the dial on the right-hand side of the control panel. The
pad is adjusted properly when the arrow on average stays in or on the green arrow indicating
proper amps.
•Due to imperfections in the floor, the amps will change slightly. Periodic adjustment may be
necessary to keep the dial running in the green. Too much pad pressure (dial pointing in the
red) may cause the circuit breaker to disconnect the circuit to the motor. If this happens, reduce
the pad pressure, push the black button that says “70” and continue running the machine.
To Begin Operation
Make sure that the correct pad (7/8" to 1") x 20" has been properly installed on the pad driver with pad
grabber and ring in place.
You are now ready to run the machine.
WARNING: MACHINE MUST BE MOVING AT ALL TIMES WHEN PAD IS ROTATING OR
FLOOR MAY BE DAMAGED.
•Turn the master switch to “I”, check the level of battery work range (put machine on “charge” if
not in the high range).
•Push the machine forward slightly and squeeze the deadman switch lever to activate pad driving
motor. (on VS Model, set knob to desired speed setting prior to operation)
•With the machine moving forward, watch the amp meter for the average needle position on the
meter. Adjust the black knob in the center of the control panel counter clockwise to increase the
pad pressure. It will move the amp indicator needle more toward the right, or the red area.
•Adjust the knob clockwise to decrease the pad pressure, decreasing the amps which moves the
needle to the left. Adjust until the amp meter needle averages in the area of the green arrow,
indicating proper amps.
WARNING: NEVER OPERATE MACHINE WITH THE NEEDLE IN THE RED AREA OF THE GAUGE,
OR DAMAGE TO THE MACHINE FROM OVERLOAD MAY RESULT.
Floors that have high or low spots will cause the amp meter to enter into the red area occasionally. This
is to be expected and will cause no harm to the machine. If you operate the machine continuously in the
red area, the circuit breaker in the rear panel can, and will blow, indicating too much pad pressure or
load. Push the button to reset, decrease pad pressure by 2 or 3 turns or more on the adjustment knob,
change or turn the pad; otherwise, damage to the machine will result.
Operating the machine with higher than recommended pad pressure in the red area will shorten the
operating time per battery charge. Maximum operating time can be achieved by adjusting pad pressure
throughout the buffing cycle.
Battery Meter Gauge
Turn the switch to the “I” position. Check to see that the indicator light is on. With master switch on ,
check battery meter for charge indication. If needle is in the red area on the left side, marked “recharge”,
the batteries are too low to operate and should be recharged. The middle, green area, indicates
whether or not the batteries are in the high or low range. The right side of the gauge indicates (when the
battery charger is connected and charging and switch is on) the level of the charge in the batteries,
whether high, low or in between. When needle is in the far right, red area, shown as high, and the
automatic charger has shut off, charging of the batteries is complete.

MAINTENANCE
MOTOR - The motors used on the Charger 2300BP/2500BP. require very little service. Using
compressed air, blow the entire motor every 60 days. Pay close attention to the carbon brush
area. Accumulated dirt will cause excessive carbon brush arcing, reduced brush life, poor
machine performance and possible damage.
CARBON BRUSHES - Inspect every 1000 hours of use for uneven wear and pitting. Replace carbon
brushes when they have worn to a length of 3/8". Failure to replace carbon brushes will cause
poor machine performance and possible motor damage.
WHEELS/CASTER - Every 30 days, lubricate the wheels/caster with an industrial grade bearing grease.
Failure to lubricate wheels/caster will cause the machine to maneuver with difficulty and
premature failure of the wheels/caster and bearing.
PAD PRESSURE/PIVOT LINKAGE - Every 60 days, inspect ALL connections in the pad pressure
adjustment and pivot linkage assembly. All linkage must move freely and smoothly to ensure
proper machine operation. Lubricate each part as required with small amount of grease such as
Lubricate. Failure to lubricate these components may make it impossible to adjust the pad
pressure or place machine into all three positions.
DUST CONTROL SYSTEM - Weekly, check vac hose for connection to Flexiwall Shield and filter bag.
When filter bag is more than one-half (1/2) full, dispose of old bag and replace with new bag.
Inspect flexiwall Shield for dents, cracks and wear. A damaged Flexiwall Shield will greatly
reduce the burnishing and dust control capabilities. Dirt build up on the brush should be
removed.
POLYETHYLENE BODY - Weekly, clean with “Armorall” type protector or wipe with a damp cloth.
Never Spray machine with water.

BASE ASSEMBLY
ITEM PART NO. DESCRIPTION QTY.
101 64-9-111-3 CONTROL FRAME WELDMENT 1
102 91-2-139-0 11/32 I.D. X 11/16 O.D. X .051/.080 THICK SAE FLAT WASHER (5/16) 2
103 91-2-145-0 5/16-18 HEX NUT WITH NY-LOK INSERT 2
104 64-9-078-3 BASEASSEMBLY 1
105 91-2-139-0 11/32 I.D. X 11/16 O.D. X .051/.080 THICK SAE FLAT WASHER (5/16) 2
106 91-2-152-0 5/16 SPLIT LOCK WASHER 2
107 91-2-164-0 5/16-18 X 3/4 HEX BOLT 2
108 91-2-100-0 1/4-20 X 5/8 TRUSS HEAD PHILLIPS MACHINE SCREW 2
109 91-2-097-0 1/4 EXTERNAL STAR LOCK WASHER 2
110 48-9-085-1 CABLE CLAMP 2
111 64-9-070-1 CATCHASSEMBLY 1
112 91-2-164-0 5/16-18 X 3/4 HEX BOLT 4
113 91-2-152-0 5/16 SPLIT LOCK WASHER 4
114 91-2-139-0 11/32 I.D. X 11/16 O.D. X .051/.080 THICK SAE FLAT WASHER (5/16) 4
115 44-9-534-3 LEFT SUPPORT BRACKET 1
116 44-9-533-3 RIGHT SUPPORT BRACKET 1
117 44-9-050-1 CASTER 1
44-9-039-1 CASTER WHEEL WITH BEARING 1
118 91-2-218-0 13/32 I.D. X 13/16 O.D. X .051/.080 THICK SAE FLAT WASHER (3/8) 4
119 91-2-226-0 3/8-16 X 1 HEX BOLT 4
120 44-9-520-3 FRAMEASSEMBLY 1
121 64-9-020-1 SHAFT COLLAR LEG SUPPORT 2
122 91-2-254-0 1/2-13 X 1 1/4 HEX BOLT 2
123 91-2-242-0 1/2 SPLIT LOCK WASHER 2
124 91-2-245-0 17/32 I.D. X 1 1/16 O.D. X .074/.121 THICK SAE FLAT WASHER (1/2) 2
125 64-9-069-1 LIFTARM 2
126 44-9-514-6 LIFT ARM SPACER 2
127 91-2-245-0 17/32 I.D. X 1 1/16 O.D. X .074/.121 THICK SAE FLAT WASHER (1/2) 2
128 91-2-242-0 1/2 SPLIT LOCK WASHER 2
129 91-2-254-0 1/2-13 X 1 1/4 HEX BOLT 2
130 44-9-279-6 BUSHING, PIVOT 2
131 91-2-226-0 3/8-16 X 1 HEX BOLT 2
132 91-2-210-0 3/8 SPLIT LOCK WASHER 2
133 91-2-218-0 13/32 I.D. X 13/16 O.D. X .051/.080 THICK SAE FLAT WASHER (3/8) 2
134 44-9-051-1 WHEEL - 8" 2
44-9-048-1 WHEELBEARING 1
135 44-9-292-6 WHEEL SPACER 2
136 44-9-254-6 AXLE 1
137 91-2-249-5 1/2-13 THIN HEX NUT WITH NY-LOK INSERT 2
138 44-9-279-6 BUSHING, PIVOT 2
139 44-9-516-3 PIVOT WELDMENT 1
140 91-2-254-0 1/2-13 X 1 1/4 HEX BOLT 2
141 91-2-245-0 17/32 I.D. X 1 1/16 O.D. X .074/.121 THICK SAE FLAT WASHER (1/2) 2
142 91-2-147-0 5/16-18 X 1 FLAT HEAD PHILLIPS MACHINE SCREW 2
143 91-2-145-0 5/16-18 HEX NUT WITH NY-LOK INSERT 2
144 91-2-139-0 11/32 I.D. X 11/16 O.D. X .051/.080 THICK SAE FLAT WASHER (5/16) 2
145 91-2-147-0 5/16-18 X 1 FLAT HEAD PHILLIPS MACHINE SCREW 2

BASE ASSEMBLY

SHIELD AND PAD DRIVER ASSEMBLY
ITEM PART NO. DESCRIPTION QTY.
201 44-9-158-1 RUBBER BOOT, MOTOR 2
202 64-9-068-1 MOTOR 36 VOLT - 2500 BP 1
64-9-148-1 MOTOR 24 VOLT - 2300 BP 1
203 52-9-341-1 1 1/4 X .770 X .082 WASHER 2
204 44-9-266-3 MOTOR MOUNT 1
205 44-9-261-3 FORK 1
206 91-2-139-0 11/32 I.D. X 11/16 O.D. X .051/.080 THICK SAE FLAT WASHER (5/16) 3
207 91-2-152-0 5/16 SPLIT LOCK WASHER 3
208 91-2-164-0 5/16-18 X 3/4 HEX BOLT 3
209 44-9-516-3 PIVOT WELDMENT 1
210 64-9-073-2 BUMPER STRAP 1
211 91-2-035-0 10-24 HEX NUT WITH NY-LOK INSERT 1
212 44-9-553-1 END CUFF - 2" 1
213 44-9-554-1 HOSE, 2" DIA. X 3 FT. LONG 1
214 44-9-544-1 HOSE CLAMP, 1 9/16"- 2 1/2" DIA. 1
215 91-2-045-0 10-24 X 1 ROUND HEAD PHILLIPS MACHINE SCREW 1
216 64-9-019-1 BUMPER/BRUSH 1
217 64-9-072-9 CW-FLEXIWALL SHIELD ASSEMBLY 1
218 44-9-289-1 MOTOR KEY 1
219 64-9-100-9 FLEXIBLE DRIVER ASSEMBLY 1
220 52-9-354-1 MOTOR WASHER, 1" O.D., STAINLESS 1
221 91-2-152-0 5/16 SPLIT LOCK WASHER 1
222 91-2-149-0 5/16-24 X 7/8 HEX BOLT 1
223 91-2-081-0 10 X 1/2 PAN HEAD PHILLIPS SHEET METAL SCREW 3
224 65-9-128-1 PAD HOLDER RING 1
225 59-9-061-1 BIG MOUTH PAD GRABBER LOCK RING 1
226 64-9-200-1 20" LUSTER LITE BURNISH PAD (BULK) 1
227 59-9-060-1 BIG MOUTH PAD GRABBER ASSEMBLY 1
228 91-2-098-0 1/4-20 X 1 SOCKET HEAD CAP SCREW 3
229 91-2-088-0 1/4 SPLIT LOCK WASHER 3
230 91-2-095-0 1/4 X 1 1/4 FENDER WASHER 3
231 57-9-609-9 PAPER BAG - 6 PACK 1
232 91-2-164-0 5/16-18 X 3/4 HEX BOLT 6
233 91-2-152-0 5/16 SPLIT LOCK WASHER 6
234 91-2-139-0 11/32 I.D. X 11/16 O.D. X .051/.080 THICK SAE FLAT WASHER (5/16) 6

SHIELD AND PAD DRIVER ASSEMBLY

CONTROL FRAME ASSEMBLY
ITEM PART NO. DESCRIPTION QTY.
301 44-9-052-1 LOAD ADJUST KNOB (INCLUDES SET SCREW) 1
302 91-2-245-0 17/32 I.D. X 1 1/16 O.D. X .074/.121 THICK SAE FLAT WASHER (1/2) 2
303 52-9-457-1 1/2" BOWED WASHER 1
304 64-9-061-1 ADJUSTMENT ROD 1
305 64-9-062-1 ADJUSTMENT ROD COLLAR 1
306 91-2-218-0 13/32 I.D. X 13/16 O.D. X .051/.080 THICK SAE FLAT WASHER (3/8) 1
307 44-9-056-1 INSULATED STANDOFF 1
308 91-2-097-1 1/4 EXTERNAL STAR LOCK WASHER 1
309 91-2-121-0 1/4-20 X 5/8 HEX BOLT 1
310 44-9-101-1 SOLENOID, 36 VOLT - 2500 BP 1
64-9-147-1 SOLENOID, 24 VOLT - 2300 BP 1
311 91-2-093-0 9/32 I.D. X 5/8 O.D. X .051/.080 THICK SAE FLAT WASHER (1/4) 2
312 91-2-088-0 1/4 SPLIT LOCK WASHER 2
313 91-2-117-0 1/4-20 X 1/2 HEX BOLT 2
314 44-9-092-1 1/4-20 X 2 1/2 HEX BOLT GR.8 1
315 27-9-128-6 BUSHING SPACER 2
316 27-9-128-6 BUSHING SPACER 2
317 91-2-093-0 9/32 I.D. X 5/8 O.D. X .051/.080 THICK SAE FLAT WASHER (1/4) 2
318 91-2-090-0 1/4-20 HEX NUT WITH NY-LOK INSERT 2
319 64-9-060-1 ADJUSTMENT BRACKET WELDMENT 1
320 44-9-532-6 SWITCH BRACKET 1
321 91-2-037-0 7/32 I.D. X 1/2 O.D. X .032/.065 THICK SAE FLAT WASHER (10) 2
322 91-2-032-0 10 SPLIT LOCK WASHER 2
323 91-2-046-0 10-24 X 1 1/4 ROUND HEAD PHILLIPS MACHINE SCREW 2
324 44-9-107-1 SNAP SWITCH 1
325 91-2-013-0 6 EXTERNAL STAR LOCK WASHER 2
326 91-2-009-0 6-32 X 7/8 PAN HEAD PHILLIPS MACHINE SCREW 2
327 91-2-090-0 1/4-20 HEX NUT WITH NY-LOK INSERT 2
328 44-9-060-1 KNOB, RAISE/LOWER ROD 1
329 64-9-010-1 LATCH HANDLE 1
330 64-9-009-3 LATCHASSEMBLY 1
331 44-9-063-1 COMPRESSION SPRING 1
332 91-2-245-0 17/32 I.D. X 1 1/16 O.D. X .074/.121 THICK SAE FLAT WASHER (1/2) 2
333 91-2-127-0 1/4-20 X 1 HEX BOLT 4
334 91-2-088-0 1/4 SPLIT LOCK WASHER 4
335 44-9-535-6 SPACER GUIDE 4
336 91-2-032-0 10 SPLIT LOCK WASHER 2
337 91-2-041-0 10-24 X 1/2 ROUND HEAD PHILLIPS MACHINE SCREW 2
338 64-9-070-1 CATCHASSEMBLY 1
339 64-9-078-3 BASEASSEMBLY 1
340 91-2-152-0 5/16 SPLIT LOCK WASHER 2
341 91-2-164-0 5/16-18 X 3/4 HEX BOLT 2
342 91-2-139-0 11/32 I.D. X 11/16 O.D. X .051/.080 THICK SAE FLAT WASHER (5/16) 2
343 44-9-103-1 SHUNT 1
344 91-2-097-1 1/4 EXTERNAL STAR LOCK WASHER 2
345 91-2-092-0 1/4-20 HEX NUT 2
346 27-9-267-1 WIRE TIE 5 1/2" LONG 4
347 64-9-111-3 CONTROL FRAME WELDMENT 1
348 91-2-097-1 1/4 EXTERNAL STAR LOCK WASHER 2
349 91-2-127-0 1/4-20 X 1 HEX BOLT 2
350 44-9-280-3 TOP SUPPORT BRACKET 1
351 91-2-164-0 5/16-18 X 3/4 HEX BOLT 2
352 91-2-152-0 5/16 SPLIT LOCK WASHER 2
353 91-2-139-0 11/32 I.D. X 11/16 O.D. X .051/.080 THICK SAE FLAT WASHER (5/16) 2
354 91-2-140-0 3/8 I.D. X 7/8 O.D. X .064/.104 THICK WROUGHT WASHER (5/16) 2
355 91-2-148-0 5/16-18 X 1 ROUND HEAD PHILLIPS MACHINE SCREW 2
356 91-2-116-0 1/4-20 X 3/8 HEX BOLT 1
357 91-2-088-0 1/4 SPLIT LOCK WASHER 4
358 52-9-479-1 COTTER PIN 1/8 X 3/4 2
359 ———————- 10-32 X 1/2 SET SCREW 1

CONTROL FRAME ASSEMBLY

HOUSING ASSEMBLY
ITEM PART NO DESCRIPTION QTY
401 64-9-176-1 BATTERY WARNING LABEL 1
402 64-9-034-1 SIDE DECAL - 2500 BP 2
64-9-103-1 SIDE DECAL - 2300 BP 2
403 64-9-117-1 SOFT DRAW LATCH WITH CONCEALED KEEPER 1
404 91-2-140-0 3/8 I.D. X 7/8 O.D. X .064/.104 THICK WROUGHT WASHER (5/16) 2
405 91-2-148-0 5/16-18 X 1 ROUND HEAD PHILLIPS MACHINE SCREW 2
406 ——————- 10-32 X 1/2 SET SCREW 1
407 44-9-052-1 LOAD ADJUST KNOB (INCLUDES SET SCREW) 1
408 44-9-104-1 AMP METER 1
409 44-9-109-1 INDICATOR LIGHT - RED LENS / 48 VDC - 2500 BP 1
24-9-048-1 INDICATOR LIGHT - GREEN LENS / 24 VDC - 2300 BP 1
410 44-9-110-1 TOGGLE SWITCH, MOTOR 1
411 10-9-987-1 STAINLESS FLAT WASHER 1
412 06-9-185-1 LOCK WASHER 1
413 07-9-882-1 5/8 HEX NUT 1
414 64-9-029-1 DASH PANEL DECAL 1
415 44-9-290-1 SWITCH PLATE - RIGHT 1
416 91-2-127-0 1/4-20 X 1 HEX BOLT 2
417 44-9-288-1 SWITCH PLATE - LEFT 1
418 91-2-218-0 13/32 I.D. X 13/16 O.D. X .051/.080 THICK SAE FLAT WASHER (3/8) 2
419 44-9-105-1 BATTERY METER 36 V - 2500 BP 1
23-9-139-1 BATTERY METER 24 V - 2300 BP 1
420 44-9-107-1 SNAP SWITCH 1
421 91-2-004-0 6 INTERNAL STAR LOCK WASHER 2
422 91-2-009-0 6-32 X 7/8 PAN HEAD PHILLIPS MACHINE SCREW 2
423 27-9-128-6 BUSHING SPACER 2
424 44-9-062-1 3/8 SPRING WASHER 4
425 91-2-090-0 1/4-20 HEX NUT WITH NY-LOK INSERT 2
426 91-2-093-0 9/32 I.D. X 5/8 O.D. X .051/.080 THICK SAE FLAT WASHER (1/4) 2
427 91-2-051-0 10-24 X 1/2 TRUSS HEAD PHILLIPS MACHINE SCREW 4
428 44-9-304-6 HANDLE 1
429 91-2-036-0 10-24 HEX NUT WITH STAR LOCK WASHER 1
430 91-2-037-0 7/32 I.D. X 1/2 O.D. X .032/.065 THICK SAE FLAT WASHER (10) 1
431 91-2-048-0 10-24 X 1 3/4 ROUND HEAD PHILLIPS MACHINE SCREW 1
432 91-2-009-0 6-32 X 7/8 PAN HEAD PHILLIPS MACHINE SCREW 2
433 44-9-190-1 CHARGER PLUG ONLY - GRAY 36 V - 2500 BP 1
64-9-082-1 WIRE ASSEMBLY, ANDERSON TO SOL./STANDOFF 36 V 1
23-9-209-1 CHARGER PLUG ONLY - RED 24 V - 2300 BP 1
64-9-102-1 WIRE ASSEMBLY, ANDERSON TO SOL./STANDOFF - 24 V 1
434 91-2-079-0 10 X 5/8 PAN HEAD PHILLIPS SHEET METAL SCREW 8
435 64-9-109-1 LABEL PAD POSITION 1
436 91-2-090-1 1/4-20 HEX NUT WITH NY-LOK INSERT 1
437 48-9-085-1 CABLE CLAMP 1
438 64-9-153-3 REAR COVER PANEL 1
439 91-2-117-0 1/4-20 X 1/2 HEX BOLT 1
440 91-2-156-1 5/16-18 X 1/2 HEX BOLT 1
441 23-9-576-1 CLAMP 1
442 91-2-145-0 5/16-18 HEX NUT WITH NY-LOK INSERT 1
443 64-9-095-1 1/4 MIPT PLUG 2
444 64-9-189-1 WIRING DIAGRAM DECAL 1
445 91-2-002-0 6-32 HEX NUT WITH STAR LOCK WASHER 2
446 44-9-070-1 CIRCUIT BREAKER - 70 AMP/ETA - 2500 BP 1
64-9-126-1 CIRCUIT BREAKER - 90 AMP - 2300 BP 1
447 91-2-035-0 10-24 HEX NUT WITH NY-LOK INSERT 1
448 44-9-064-1 EXTENSION SPRING 1
449 64-9-001-1 HOUSING WITH SLIDE RAILS 1
450 64-9-101-1 SIDE DECAL - LONG 2
451 91-2-103-7 1/4-20 X 5/8 FLAT HEAD PHILLIPS HEAD PHILLIPS MACHINE SCREW 6
452 64-9-121-1 TAPPING PLATE 2
453 64-9-119-3 HOOD STOP / SUPPORT BRACKET 2
454 91-2-093-0 9/32 I.D. X 5/8 O.D. X .051/.080 THICK SAE FLAT WASHER (1/4) 4
455 91-2-127-0 1/4-20 X 1 HEX BOLT 4
456 91-2-088-0 1/4 SPLIT LOCK WASHER 4
457 44-9-554-1 HOSE 2" DIA. X 3 FT. LONG 1
458 44-9-553-1 END CUFF - 2" 1
459 64-9-117-1 SOFT DRAW LATCH WITH CONCEALED KEEPER 1
460 64-9-079-1 PLUG, 3" 1
461 64-9-113-1 SLIDE RAIL, RIGHT 1
462 91-2-093-0 9/32 I.D. X 5/8 O.D. X .051/.080 THICK SAE FLAT WASHER (1/4) 6
463 91-2-090-0 1/4-20 HEX NUT WITH NY-LOK INSERT 6
464 57-9-609-9 PAPER BAG - 6 PACK 1
465 59-9-032-1 WASHER, 5/32 I.D. STEEL 4
466 59-9-031-1 POP RIVET, 5/32 I.D. 4
467 64-9-035-1 HOOD DECAL 1
468 59-9-031-1 POP RIVET, 5/32 I.D. 4
469 59-9-032-1 WASHER, 5/32 I.D. STEEL 4
470 64-9-074-1 HOUSING, HOOD ONLY 1
471 64-9-114-1 SLIDE RAIL, LEFT 1
472 91-2-092-0 1/4-20 HEX NUT 4
473 91-2-103-9 1/4-20 X 1 1/2 ELEVATOR BOLT - ZINC PLATED 4

HOUSING ASSEMBLY

WEIGHT ASSEMBLY - CHARGER 2300
ITEM PART NO. DESCRIPTION QTY
501 64-9-130-1 BATTERY BOX 1
502 99-9-755-0 VELCRO HOOK, P.S. 13"
503 99-9-756-0 VELCRO LOOP, P.S. 13"
504 23-9-196-3 WEIGHT 1

MOTOR
ITEM PART NO. DESCRIPTION QTY
144-9-161-1 THRU BOLT - 2500 BP 2
64-9-195-1 1/4-20 X 7 3/4 HEX HEAD BOLT - 2300 BP 2
291-2-088-0 1/4 SPLIT LOCK WASHER 2
3————— PLUG (NOT AVAILABLE) 1
444-9-158-1 RUBBER BOOT 2
544-9-162-1 5/16-18 THIN HEX NUT, BRASS 2
644-9-163-1 5/16-18 HEX NUT, BRASS 2
791-2-152-0 5/16 SPLIT LOCK WASHER 2
891-2-139-0 11/32 I.D. X 11/16 O.D. X .051/.080 THICK SAE FLAT WASHER (5/16) 2
944-9-164-1 INSULATION WASHER 2
10 44-9-165-1 INSULATION SPACER 2
11 44-9-166-1 TOP END BELL 1
12 44-9-164-1 INSULATION WASHER 2
13 91-2-139-0 11/32 I.D. X 11/16 O.D. X .051/.080 THICK SAE FLAT WASHER (5/16) 2
14 ————— LEAD HARNESS ASSEMBLY 2
15 44-9-167-1 5/16-18 X 1 3/4 HEX BOLT, BRASS 2
16 ————— 10-32 X 3/8 SCREW, BRASS BINDING HEAD 4
17 44-9-169-1 CARBON BRUSH - 2500 BP 4
64-9-197-1 CARBON BRUSH - 2300 BP 4
18 44-9-168-1 BRUSH RING ASSEMBLY - 2500 BP 1
64-9-196-1 BRUSH RING ASSEMBLY - 2300 BP 1
19 44-9-170-1 BRUSH SPRING 4
20 ————— 10-32 X 3/8 HEX HEAD SCREW 2
21 44-9-171-1 FRAME WITH MAGNETS - 2500 BP 1
64-9-198-1 FRAME WITH MAGNETS -2300 BP 1
22 53-9-344-1 THRUST WASHER 1
23 50-9-204-1 TOP BEARING 1
24 64-9-194-1 COMPLETE ARMATURE ASSEMBLY - 2500 BP 1
64-9-199-1 COMPLETE ARMATURE ASSEMBLY - 2300 BP 1
25 44-9-173-1 VENT FAN 1
26 44-9-289-1 KEY 1
27 44-9-175-1 RETAINING RING 1
28 44-9-084-1 BOTTOM BEARING 1
29 44-9-174-1 BOTTOM END BELL 1

WIRING DIAGRAM
ITEM PART NO. DESCRIPTION QTY
64-9-080-1 WIRE ASSEMBLY, BREAKER TO SHUNT 1
264-9-081-1 WIRE ASSEMBLY, SOLENOID TO BREAKER 1
364-9-082-1 WIRE ASSEMBLY, ANDERSON TO SOLENOID / STANDOFF 36 V 1
64-9-102-1 WIRE ASSEMBLY, ANDERSON TO SOLENOID / STANDOFF 24 V 1
464-9-083-1 WIRE ASSEMBLY, SHUNT TO MOTOR 1
564-9-084-1 WIRE ASSEMBLY, MOTOR TO STANDOFF 1
664-9-085-1 WIRE ASSEMBLY, SOLENOID TO MAIN SWITCH 1
764-9-086-1 WIRE ASSEMBLY, SOLENOID/LIGHT/VOLT METER TO STANDOFF 1
864-9-087-1 WIRE ASSEMBLY, SAFETY SWITCH TO VOLT METER / MAIN SWITCH TO LIGHT 1
964-9-088-1 WIRE ASSEMBLY, HANDLE SWITCH TO SAFETY SWITCH 1
10 64-9-089-1 WIRE ASSEMBLY, SOLENOID TO HANDLE SWITCH 1
11 64-9-182-1 WIRE ASSEMBLY, ANDERSON TO POS./NEG. BATTERY 36 V 1
64-9-177-1 WIRE ASSEMBLY, ANDERSON TO POS./NEG. BATTERY 24 V 1
17 64-9-183-1 WIRE ASSEMBLY, ANDERSON TO SOLENOID/STANDOFF 36 V 1
64-9-178-1 WIRE ASSEMBLY, ANDERSON TO SOLENOID/STANDOFF 24 V 1
97 23-9-198-1 BATTERY JUMPER 3/8" RING #97 (3 REQUIRED FOR 24 V - 2300) 2
-27-9-267-1 WIRE TIE, 5 1/2" LONG 6
-27-9-573-1 HOUR METER 1
-44-9-056-1 INSULATED STANDOFF 1
-44-9-070-1 CIRCUIT BREAKER - 70 AMP/ETA - 2500 BP 1
-64-9-126-1 CIRCUIT BREAKER - 90 AMP/ETA - 2300 BP 1
-44-9-101-1 SOLENOID, 36 VOLT - 2500 BP 1
-64-9-147-1 SOLENOID, 24 VOLT - 2300 BP 1
-44-9-103-1 SHUNT 1
-44-9-104-1 AMP METER 1
-44-9-105-1 BATTERY METER 36 V - 2500 BP 1
-23-9-139-1 BATTERY METER 24 V - 2300 BP 1
-44-9-106-1 BATTERY, 185 AMP/HR, 12 VOLT - 2500 BP 3
-33-9-036-1 BATTERY, 220 AMP/HR, 6 VOLT - 2300 BP 4
-44-9-107-1 SNAP SWITCH 2
-44-9-109-1 INDICATOR LIGHT - RED LENS / 48 VDC - 2500 BP 1
-24-9-048-1 INDICATOR LIGHT - GREEN LENS / 24 VDC - 2300 BP 1
-44-9-110-1 TOGGLE SWITCH, MOTOR 1
-44-9-190-1 CHARGER PLUG ONLY - GRAY 36 V - 2500 BP 1
-23-9-209-1 CHARGER PLUG ONLY - RED 24 V - 2300 BP 1
-64-9-068-1 MOTOR 36 VOLT - 2500 BP 1
-64-9-148-1 MOTOR 24 VOLT - 2300 BP 1
-64-9-184-1 175 AMP ANDERSON W/CONTACTS GRAY 36 V 2
-64-9-188-1 175 AMP ANDERSON W/CONTACTS RED 24 V 2

WIRING DIAGRAM

NSS ® Enterprises, Inc.
3115 Frenchmens Road, Toledo, Ohio 43607
PHONE [phone] FAX [phone]
NSS ® Enterprises, Inc. European Distribution Centre
Unit II, Pinfold Trading Estate * 55 Nottingham Road
STAPLEFORD, NOTTINGHAM NG9 8AD ENGLAND U.K.
PHONE: [phone] * FAX: [phone]
CHARGER 2300, 2500 BP ORIG. 05-98 REV. B 06-99 9096401 WHW
PROBLEM CAUSE SOLUTION
Pad Does Not Turn Low Battery Charge. Recharge Batteries.
Loose Battery Cable. Tighten & Clamp battery Cables.
Circuit Breaker Has Tripped. Reduce Pad Pressure/Change Pad
Reset Breaker.
Worn Motor Carbon Brushes. Change Carbon Brushes.
Pad Load Adjustment Knob. Adjust Knob Until Motor Will
Out Of Adjustment. Turn On.
Microswitch Not Engaged. Adjust Mounting Bracket.
Machine Pushes Hard Worn Wheel Or Caster. Grease Wheels Or Replace.
Uneven Floor Buffing Worn Pad. Change pad.
Motor out of Alignment. Call NSS Service Center For Repair.
Machine Vibrates Pad Is Torn Or Not Centered. Center pad.
Change Pad. Use Correct Pad.
Check Pad Driver For Damage &
Replace If Necessary.
Circuit Breaker Trips Pad Pressure Too Heavy. Reduce Pad Pressure. Run Machine
In Green Area of AMP Meter.
Spray Buffing. Do Not Spray With Charger
2300BP/2500BP.
Pad Rubbing On Flexiwall Realign Pad On Driver Or Replace
Shield with new pad. Check Pad size.
Short Running Time Dead Cell In Battery Test Batteries And Replace.
On Battery Charge Excessive Pad Pressure. Reduce Pad Pressure.
Incorrect Pad. Use NSS Pads Or Recommended
Equivalent.
Battery Charger Does Connection Not Made Between Check Anderson Connectors For
Not Turn On Battery Charger And Machine Proper Contact On Both Charger
And Machine.
Improper Charger Sequence. Read Instructions On Battery
Charger Or In Instruction Manual.
WIRING DIAGRAM