NSS charger 2000 User manual

OPERATION MANUAL
NSS HIGH-SPEED BATTERY BURNISHERS
IMPORTANT SAFETY INSTRUCTIONS
WARNING: Failure to observe these instructions can cause
personal injury to machine operator or bystanders.
WARNING: Fire or explosion hazard.
NEVER operate this machine in an
explosive atmosphere (grain dust,
flammable liquids or fumes, etc.).
WARNING: Fire or explosion hazard.
NEVER attempt to pick up flammable or
combustible materials.
INTENDED USE
NSS Burnishers are intended for commercial use,
buffing and burnishing floors in an indoor environment.
It is not intended for spray burnishing. NSS does not
recommend using these machines for any other
purpose.
FOR SAFETY
•ALWAYS read and understand all instructions before
operating or servicing machine.
•ALWAYS use this machine ONLY as described in
this manual.
•NEVER attempt to operate this machine unless you
have been trained in its operation.
•NEVER allow an untrained person to operate this
machine.
•ALWAYS operate this machine from the rear control
panel, not from the side.
•ALWAYS turn off master switch when attaching or
changing pads.
•NEVER attempt to operate this machine if it is not
working properly or has been damaged in any
manner.
•NEVER disconnect or modify any switches or safety
devices (circuit breaker).
•NEVER drop or insert any object into any machine
opening.
•NEVER operate this machine with any air opening
blocked. Keep all air openings free of dust, lint, hair,
etc.
•NEVER pick up anything that is burning or smoking,
such as cigarettes, matches or hot ashes.
•NEVER use flammable liquids (gas, kerosene,
solvents, or thinners) to clean or burnish floor.
•NEVER allow this machine to be used as a toy. Close
attention is necessary when used by or near children.
•ALWAYS wear clean tennis shoes or “non-slip” shoes.
Leather soled shoes will be extremely slippery.
•ALWAYS keep face, fingers, hair or any other body
part or loose clothing away from any machine opening
or moving part (revolving pad driver).
•ALWAYS be sure that the ramp is secured to the
vehicle before attempting to load / unload.
•ALWAYS use extreme caution when operating the
machine on a ramp or loading / unloading this machine
into or out of a truck / trailer. Use extreme caution if
the ramp is wet, oily, or covered with cleaning
chemicals.
•NEVER stop or turn the machine on a ramp or incline.
•NEVER attempt to climb a grade or operate this
machine on a ramp or incline of more than 20 degrees.
•ALWAYS store this machine indoors in a dry, cool
area.
•NEVER park or store the machine near a dock, on
ramps, near a furnace, boiler, open flame, or other
high heat source.
•NEVER spray this machine with water or any liquids.
•NEVER allow the vacuum motor or battery charging
plug to get wet or a short may occur.
•NEVER operate this machine when the battery
charger is plugged in.
•NEVER operate the machine outdoors or allow
machine to freeze.
•NEVER expose the machine to rain, snow, or extreme
temperatures.
•NEVER store any items on the machine.
ALL REPAIR SERVICE MUST BE PERFORMED BY AN NSS AUTHORIZED DISTRIBUTOR /
SERVICE STATION USING ONLY NSS ORIGINAL EQUIPMENT PARTS.
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IMPORTANT SAFETY INSTRUCTIONS
BATTERY POWERED EQUIPMENT
WARNING: Failure to observe these instructions can cause personal
injury to machine operator or bystanders.
Read and understand all
instructions before installing
or charging batteries.
No smoking, open
flames, or sparks while
working with batteries.
Contains acid.
Avoid contact.
Poison. Causes
severe burns. Avoid
contact.
WARNING: Batteries emit hydrogen, which can cause fire or explosion.
NEVER smoke, light a match, or cause a spark during operation or charging.
ALWAYS charge in a well-ventilated area away from open flame.
GENERAL
•ALWAYS read and understand all
instructions before installing or charging
batteries.
•NEVER attempt to install or charge
batteries unless you have been trained to
do so.
•NEVER allow an untrained person to install or
charge batteries.
•ALWAYS remove all jewelry when working on
or near the batteries.
•ALWAYS turn off all switches during
installation and service.
•ALWAYS disconnect the battery leads before
performing any service or repair.
•ALWAYS wear eye protection and protective
clothing to avoid contact with battery acid.
•NEVER lay anything on top of batteries as
arcing may occur.
•IF CONTACT WITH BATTERY ACID
OCCURS, follow these instructions:
•SKIN –rinse area with water.
•EYES –Flush with water for 15 minutes.
•INTERNAL –Drink water or milk. Follow
with Milk of Magnesia, beaten egg or
vegetable oil. Call a physician
immediately.
BATTERY INSTALLATION
• ALWAYS use two people to install, as batteries are heavy.
•ALWAYS turn off all machine switches.
•ALWAYS position batteries as shown on the machine
installation decal to maintain machine balance.
•ALWAYS connect batteries as shown on the machine
installation decal to avoid shorting out the batteries and
the electrical system.
BATTERY CHARGING
•ALWAYS read instructions on charger carefully.
•ALWAYS use the NSS supplied charger with proper
voltage rating.
For lead acid batteries only, (does not apply to gel cell
or maintenance free batteries).
•ALWAYS check to ensure the battery water level covers
the battery plates before charging.
•ALWAYS check water level after charging and add water
if necessary to bring level to the bottom of the fill hole.
•NEVER overfill batteries as battery
and machine damage may result.
•ALWAYS wipe any acid from the top
of batteries using a soap solution.
•ALWAYS reattach caps to batteries. Do not charge with
caps loose or removed.
•ADD only distilled or treated city water. Not well water.
ALL REPAIR SERVICE MUST BE PERFORMED BY AN NSS AUTHORIZED DISTRIBUTOR/
SERVICE STATION USING ONLY NSS ORIGINAL EQUIPMENT PARTS.
SAVE THESE INSTRUCTIONS
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Flexiwall Shield
Master
Switch
Circuit
Breaker(s)
Release
Knob
Battery Meter
Charging
Plug
Battery Compartment
Drain Plug
Indicator
Light
Handle
HousingAmp Meter
Deadman
Lever
Speed Control
Knob
VS MODELS
Pad Pressure Knob
NON -VS MODELS
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PAD PRESSURE ADJUSTMENT KNOB
CLOCKWISE –LESS PRESSURE
COUNTERCLOCKWISE –MORE PRESSURE
Battery Meter
Switch
(ON-OFF)
Speed Adjustment Knob
VS Models Only
Indicator Lig
ht
(ON –OFF)
Amp Meter
OPERATING POSITION
ADJUSTKNOBUNTILMETER
READSIN GREEN
TRANSPORT POSITION PAD CHANGING POSITION
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MACHINE INSPECTION
•Carefully, unpack the machine and recycle all
packing materials.
•Inspect the machine for damage or missing
components. If damage is found, contact the local
freight company to file a freight claim.
UNPACKING INSTRUCTIONS
•Remove staples and lift off carton.
•Disconnect pallet anchors.
•Remove the foam from under pad drivers.
•Put ramp in place.
•Slowly, back machine off pallet.
MACHINE COMPONENTS
Housing
The housing protects both the batteries and the
internal components. It is made of durable
Polyethylene.
Pad Pressure Knob
Located in the middle of the control panel at the upper
most point. Turning this knob controls the pressure
the pad exerts on the floor.
Operator Control Panel
The operator control panel is located at the upper rear
area of the machine. This panel has components that
control various machine functions.
•The toggle switch on the left side of the panel turns
the unit on and off.
•The light in the center, when lit up, indicates the
unit is turned on.
•The knob on the right; only if this is a variable
speed (VS) machine, adjusts the speed of the
machine.
Battery Meter
The battery meter is located on the left side of the
operator control panel and shows the state of charge
of batteries during operation and recharge.
•Work Range -This is the green area in the middle
of the meter. It shows the approximate amount of
“power” available in the batteries. Observe this
reading when operating this machine.
•Recharge Range -This is the red area on the left of
the meter. It shows when the batteries need to be
recharged. Continued machine operation in this
area will cause battery damage and potential
machine damage.
Amp Meter
•The amp meter is located on the right side of the
control panel and is a visual indication of the
amount of pad pressure. The pad is adjusted
properly when the needle on the amp meter, on
average stays in the green area indicating proper
amps.
Dead Man Lever
This bar is located just under the handle. When
squeezed it activates the pad driving motor, on VS
Models, it also turns on the wheel drive motor to propel
the machine. It is not functional in the pad changing
position.
Battery Charging Plug
•This plug is located on the left side of the rear panel.
•To recharge the batteries, insert the battery charger
plug into the charging plug.
•This plug is gray on 36-volt machines.
See charging instructions for more details.
Release Knob
Located in the center of the back panel, this knob is
used to adjust the positions of the machine.
•The machine is in the operating position when the
handle is at its highest level.
•The machine is in the transport position when the
handle is in the center position.
•The machine is in the pad changing position when
the handle is at its lowest level.
•See diagram on page 4.
Circuit Breaker (s)
Located on the right side of the rear panel is the circuit
breaker. If this is a VS model there will be two circuit
breakers.
•Too much pad pressure may cause the circuit
breaker(s) to disconnect the circuit to the motor.
If this happens, reduce the pad pressure, push the
black button, and continue running the machine.
Battery Compartment Drain Plug
This plug is located on the left and right side of the
machine inside the rear panel. Spilled liquids from the
battery compartment area are collected here. Remove
the plug to drain, disposed of all liquids according to
your local EPA regulations.
Flexiwall Shield
The Flexiwall shield creates a seal with the floor to
contain and collect any dust created by the burnishing
operation.
Speed Control Knob (VS Models only)
The Speed Control Knob gives the user the ability to
adjust the forward travel speed of the machine, by
positioning the dial in the green area. Turning the knob
counterclockwise to position it in the red dotted area,
will essentially put the machine in neutral and allow the
machine to be easily pulled in reverse.
Brush Gear Motor
This machine has a 36-volt brush motor located at the
front of the machine.
•The Charger 2000BP / 2500BP utilizes a 2.5 HP (1.8
KW.) permanent magnet motor to drive the 20"
(51cm.) pad.
•The Ultra Maxx utilizes a 3 HP (2.2 KW.) permanent
magnet motor to drive the 27” (69cm) pad.
•These motors have carbon brushes that must be
serviced on a regular basis.
Refer to the maintenance section later in this book.
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Wheel Drive Motor
•VS machines are powered by a 36-volt drive motor.
•The speed is electronically controlled for smooth
increase and decrease of speed.
•The motor moves the drive wheels through a chain
and sprocket system.
•This motor has carbon brushes that must be
serviced on a regular basis.
Refer to the maintenance section later in this book.
Battery Packages
•These machines utilize a 36-volt system, and are
available with three (3) 12-volt, 210-Amp Hour
Batteries.
•Consult your local NSS authorized distributor for
application recommendations.
•Do not substitute smaller batteries, as the balance
of the machine will be affected.
MACHINE OPERATION
General Information
This machine works best with dry polishing or
burnishing. 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.
Preparing the Machine for use
Install the batteries:
•Always wear protective glasses and clothing when
handling batteries.
See Battery Warnings on page 2.
•Turn off all switches, unlatch the clasps and slide
the housing forward to expose the battery
compartment.
•Batteries are heavy -use two people to install.
•Refer to wiring diagram inside the battery
compartment. Align batteries in compartment as
shown on diagram.
•Install battery cables as shown on wiring diagram.
•Tighten bolts and hex nuts with a wrench.
Caution: Do not short across two terminals with a
wrench.
Caution: Loose or improper battery connections
will cause battery or machine damage and possible
personal injury.
•Install terminal boots over terminals to complete
installation.
Check the Battery Charge
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.
•When the needle is in the red area on the left side,
marked “recharge”, the batteries are too low to
operate and should be recharged.
•When the needle is in the green area, the batteries
are within the high to low working range.
•When the needle is in the red area on the right side
of the gauge it indicates the level of battery charge
while connected to the charger.
•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.
Pad Installation / Changing
Lower the back of the machine to Position 3 (see
bottom figure on page 4), by lifting up on the release
knob with one hand, and with your other hand on the
operator handle, gently lower the back of the machine
until it rest on the floor.
•Make sure that the correct pad (7/8" to 1") X 20" is
being installed.
•Place the pad flat on the floor, and remove the
center hole of the pad, 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,
carefully center the pad on the driver.
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.
•Place the pad grabber in the center hole of the pad.
•Holding the pad driver and pad, push upward on the
pad grabber until the spring clip has clicked twice.
Caution: Failure to install the pad grabber tightly
may allow the pad to be thrown from the driver.
There is a wide range of pads and brushes available
for the many burnishing applications of this machine.
Consult your local NSS authorized distributor for
application recommendations
Transporting the Machine to the work site
From the pad changing position raise the back of the
machine up by lifting up on the operator’s handle with
both hands, until you hear the adjustment knob “click”
into position. The machine is now ready for transport.
See bottom figure on page 4.
•On pad assist machines, push the machine to the
work site turn the master switch to “I”, and pull up on
the dead man lever.
•On VS models, adjust the speed control knob to an
appropriate speed, turn the master switch to “I”, and
pull up on the dead man lever.
Operating the Machine
From the transport position raise the back of the
machine up by lifting up on the operator’s handle with
both hands. The machine will automatically stop in
position 1, see bottom figure on page 4.
•Turn the master switch to “I”; check the level of
battery work range (put machine on “charge” if not in
the high range).
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•Push the machine forward slightly and squeeze the
deadman switch lever to activate the pad driving
motor.
•The machine will tilt forward slightly as the pad
sucks to the floor.
CAUTION: This Machine must be moving at all
times when the pad is rotating or the floor may be
damaged. Never operate this machine with the
needle in the red area of the amp meter, or damage
to the machine from overload may result.
See Setting / Adjusting Pad pressure.
Setting / Adjusting Pad Pressure
•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.
•With the machine moving forward, watch the amp
meter for the average needle position on the meter.
Pad pressure relates to buffing performance.
Too much pad pressure, (operating the machine
continuously in the red area), may damage the floor,
give uneven results, and / or cause the circuit breaker
to blow. Push the button to reset, then, adjust the
pad pressure. See Setting / Adjusting Pad pressure.
Operating the machine with higher than
recommended pad pressure in the red area will also
shorten the operating time per battery charge.
Maximum operating time can be achieved by
adjusting pad pressure throughout the buffing cycle.
Too light pad pressure will also give poor results and
no contact with the floor. The thickness of a new pad
varies during the manufacturing process; however,
ALL pads will thin down during use and require
periodic adjustment of pad. 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.
Maintenance
Daily Maintenance
•Recharge the batteries when indicated by the
Battery Meter.
•Check water level.
•Inspect the machine components for wear, loose
fasteners, or damage.
•Call authorized service center for repairs.
•Wipe machine down with a damp cloth.
•NEVER spray this machine with water or any liquids.
Weekly Maintenance
•Verify all daily maintenance has been performed.
•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 a 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.
•Clean the polyethylene body with an “Armorall” type
protector or wipe with a damp cloth.
•Never Spray machine with water.
•Check the Battery Compartment for liquid level on a
weekly basis.
•Dispose of liquids according to your local EPA
regulations.
Monthly Maintenance
•Verify all weekly maintenance has been performed.
•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.
•Tighten and Lube the drive motor chain.
Every 60 days
•Verify all monthly maintenance has been performed.
•The motors require very little service. Using
compressed air, blow the entire motor. 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.
•Inspect ALL pad pressure / pivot linkage
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.
Every 6 Months
•Inspect the carbon brushes 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.
Repairs performed by an unauthorized company will void the machine warranty. If you require assistancefinding
an authorized service center, contact NSS Enterprises.
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TROUBLE SHOOTING
PROBLEM CAUSE SOLUTION
Pad Does Not Turn. Low battery charge. Recharge batteries.
Loose battery cable. Tighten and 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 out of
adjustment. Adjust knob until motor will turn on.
Micro switch not engaged. Adjust mounting bracket.
Machine Pushes Hard. Worn wheel or caster. Grease wheels or replace.
Motor out of alignment. Call NSS Service Center for repair.
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.
Check pad driver for damage and 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 buff.
Pad rubbing on flexiwall shield. Realign pad on driver or replace with new
pad.
Check pad size.
Short Running Time on Battery
Charge. Dead cell in battery. Test batteries and replace.
Excessive pad pressure. Reduce pad pressure.
Incorrect pad. Use NSS pads or recommended
equivalent.
Battery Charger Does Not Turn
On Connection not made between battery charger and machine. Check Anderson connecters for proper contact on both charger and machine.
Improper charger sequence. Read instructions on battery charger or in
instruction manual.
Overly discharged batteries. Contact NSS Service Center for repair.
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]
NSS High Speed Battery Burnishers, 9096451 Orig. 02-02 Rev A 02-03
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