NSS CHAMP ZS 35 User manual

CHAMP ZS 35
OPERATION MANUAL
IMPORTANT SAFETY INSTRUCTIONS
WARNING: Failure to observe these instructions can cause
personal injury to machine operator or by-standers.
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 or use such
materials in tanks.
ALL REPAIR SERVICE MUST BE PERFORMED BY AN NSS AUTHORIZED DISTRIBUTOR/
SERVICE STATION USING ONLY NSS ORIGINAL EQUIPMENT PARTS.
SAVE THESE INSTRUCTIONS
INTENDED USE
This machine is intended for commercial use, scrubbing
floors in an indoor environment. NSS does not
recommend using this machine 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.
•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 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 this machine with the side skirt
removed.
•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 become extremely slippery
when wet.
•ALWAYS keep face, fingers, hair or any other body
part or loose clothing away from any machine opening
or moving part (revolving brush, pad driver, or vacuum
motor).
•ALWAYS turn the machine off when attaching pads or
brushes.
•ALWAYS remove keys when this machine is left
unattended.
•NEVER turn on machine unless sitting in the operators
seat.
•NEVER climb on machine when it is turned on.
•NEVER use machine to transport passengers other than
the operator.
•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 8 degrees.
•NEVER park or store the machine near a dock, on
ramps, near a furnace, boiler, open flame, or other high
heat source.
•NEVER allow this machine to freeze.
•NEVER expose the machine to rain, snow, or extreme
temperatures.
•NEVER store any items on this machine.
•ALWAYS store this machine indoors in a dry, cool area.

IMPORTANT SAFETY INSTRUCTIONS
BATTERY POWERED EQUIPMENT
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 hydrogenwhich 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.
WARNING: Failure to observe these instructions can cause
personal injury to machine operator or by-standers.
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.
•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

MACHINE INSPECTION
•Carefully unpack the CHAMP ZS 35 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.
•Inspect squeegee assembly for concealed damage.
MACHINE UNPACKING INSTRUCTIONS
•Remove staples and lift off carton.
•Disconnect pallet anchors.
•Remove skirts, squeegee and pad drivers.
•Plug in battery connector (under seat).
•Put ramp in place.
•Slowly back machine off of pallet.
MACHINE COMPONENTS
BATTERY PACKAGE
The CHAMP ZS 35 is a 36 volt system.
•Six (6) volt batteries.
Consult your local NSS authorized distributor for application recommendations.
CONTROL PANEL
The operator control panel is located to the left of the operator’s seat. This panel has components that
control various machine functions. See diagram below.
Push Button
Toggles between display screens.
Defaults to screen 1 when turned
on. Brush Switch
3 positions, 3 functions:
Up is on, lowering brushes to light
pressure.
Middle is off, raising brushes.
Down is on, lowering brushes to heavy
pressure.
Brushes only come on when machine
is moving in forward or reverse.
Vacuum Switch
2 positions; 2 functions:
Up is on, lowering squeegee.
Down is off, raising squeegee.
Squeegee automatically raises in
reverse.
Traction Speed Switch
3 Positions:
Down is high speed.
Center is medium speed.
Up is low speed.
LCD Display Screen
Brightly lit to work in all lighting
situations.
Emergency Stop Button
Push for off.
Turn for on.
Key Switch
Key must be turned to the right to
activate machine.
Brush Speed
2 Positions:
Up rotates the brushes at 220 RPM.
Down rotates the brushes at 300
RPM.

THE DISPLAY SCREENS
•There are many symbols that can be displayed on the LCD. Therefore, the LCD Mode switch
can be used to toggle between pre-defined screens (see Control Panel for Details).
Controller Hours
Battery Lockout
System Inhibit
Brush Motor Hours
Drive Motor Hours
Diagnostic Fault code
Battery Discharge
Indicator
Diagnostic Fault Code
System Inhibit
High Pedal Disable
Throttle Displaced

MACHINE OPERATION
General Information
The CHAMP ZS 35 is very maneuverable and is designed to clean as you drive the machine. Follow
these steps to prepare the machine for daily operation.
Always sweep or dust mop the floor of debris before scrubbing. You may also need to preclean some
types of spills or stains before scrubbing. Plan your work so that you make long, straight paths with the
fewest amount of turns as possible. Remove as many obstacles as possible from the area to be
cleaned. Consult your local NSS distributor for more complete procedures and chemical advice.
DAILY USE
To Prepare the Solution Tank:
•Never use water over 140° F (60° C).
•Pour all liquids through the mesh filter at the left side of the solution tank.
•Fill with clean water, up to 29 gallons.
•Add the cleaning chemicals to the solution tank.
To Prepare the Recovery Tank:
•Always use a defoamer to protect the vacuum motor of this machine, we recommend that you add
at least 4 to 6 ounces of defoamer chemical. Vacuum the defoamer into the recovery tank through
the vac hose.
•Make sure that the drain plug of the recovery tank hose is closed tightly.
To Install a Pad Driver and Pad:
•Pull pin and open skirt.
•There are a wide range of pads or brushes available for the many cleaning applications of this
machine. See the “Accessories” page in the Parts List manual.
•Turn the pad driver upside down on the floor and remove the pad holding cup.
•Remove the center cutout of the 18” pad and place the pad on the face of the pad driver.
•The pad must be centered on the driver to prevent wobbling or bouncing.
•Install and secure the pad holding cup to the pad driver. Turn the pad driver over so that the pad
faces the floor.
•Raise the brush motor into the transport position (center position of switch).
•Align the lugs of the pad driver with notches of the drive casting.
•Turn the pad driver to lock onto the drive casting.
•Close the locking latch.
•Close the skirt.
To Install a Brush:
•Pull pin and open skirt.
•Raise the brush motor into the transport position.
•Align the lugs of the brush with the notches of the drive casting.
•Turn the brush to lock onto the drive casting.
•Close the locking latch.
•Close the skirt.

SQUEEGEE ASSEMBLY
To Install the Squeegee Assembly:
•Loosen the two mounting knobs and slide the squeegee assembly onto the mounting plate.
•Hand tighten the mounting knobs. Do not use pliers to tighten the knobs as this will defeat the
“breakaway” design.
•As the machine is used, the squeegee blades wear out, and need to be replaced due to damage.
•Squeegee blades should lay over (like a window squeegee) whenever the machine is moving
forward.
•Do not add any weights or other pressure to the squeegee mechanism, it will not improve the
performance or service life.
•The squeegee rises automatically when the machine is in reverse.
•Squeegee springs add pressure to floor. There are 3 adjustments available by moving the end at the
frame from hole to hole. Always move both sides the same.
MACHINE MAINTENANCE
Daily Maintenance
•Recharge the batteries when indicated by the Battery Discharge Indicator.
•Empty and rinse clean the recovery tank.
•Remove and rinse clean the squeegee assembly.
•Remove and rinse clean the pad driver and / or brush.
•Inspect the machine components for wear or damage. Call authorized service center for repairs.
•Wipe machine down, NEVER spray this machine with water or any liquids.
Weekly Maintenance
•Verify that all daily maintenance has been performed.
•Refill the batteries using the Auto Fill System provided with the batteries.
•Check all battery terminal and cable connections. Tighten as deemed necessary.
•Clean any corrosion from the battery terminals and cables.
•Check the solution flow to the pad driver and/or brush. Flush clean the solution tank and hose with
a mixture of 8 oz. (250ml.) of white vinegar to 1 gallon (4 liter) of warm water.
•Inspect filters.
Monthly Maintenance
•Verify that all daily and weekly maintenance has been performed.
•Clean filters by rinsing with cool, clear water.
After every 750 Hours of Operation:
•Inspect the drive motor carbon brushes for wear.
Replace the brushes when they are 3/8 in. (9mm.) in length.
•Inspect the brush drive motor carbon brushes for wear.
Replace the brushes when they are 1/2 in. (13mm.) in length.
•Inspect the vacuum motor carbon brushes for wear.
Replace the brushes when they are 7/16 in. (11mm.) in length.

The Xafter the first 3 numbers will appear as a number. If a code appears, make a note of the
code #. Turn machine off, wait 10 seconds. Turn machine on, controller will automatically reset.
If code appears again, call your authorized service center reference the code # for service / repair.
NSS X-IQ ELECTRONIC CONTROL DIAGNOSTIC CODES
CODE # Description of Code Possible Cause/Solution
O7OXSwitch Reference Codes. Check for incorrectly wired input switches.
O81
X
Throttle codes.
Check for incorrectly wired or faulty potentiometer.
OAO1 Power down error. Power down error.
131O Supply over current. Check Motors and Batteries for Excessive Current.
16OO High battery voltage. Check for Proper Battery Voltage and Installation.
18OXWatchdog Tripped. Internal control fault-reset controller/consult factory.
1DO2 Throttle Specification Modified. Happens when throttle program is changed.
1EO3 Inhibit Active. Inhibit Active/Reset Controller.
2COXLow Battery Voltage. Check Batteries/Charge as necessary.
2FO1 Throttle Input Displaced. Check for incorrectly wired or faulty potentiometer.
31OXLow Bridge Fault. May indicate problem with motor connections.
75O
X
LCD Module Communications Out.
Check Wiring From Controller to LCD Module.
76OO Brush Motor Disconnected. Check Brush Motor Wiring for Proper Connections.
76O1 Brush Motor Running at Current Limit. Check Brush Motor for Obstructions / Reset Controller.
76O2 Brush Motor Current Overload. Check Brush Motor for Obstructions / Reset Controller.
76O3 Possible Short Circuit on Brush Output. Check Brush Motor Wiring for Frayed or Faulty Condition.
77OO Vacuum Motor Disconnected. Check Vacuum Motor Wiring for Proper Connections.
77O1 Vacuum Motor at Current Limit. Check Vacuum Motor for Obstructions.
77O2 Vacuum Current Overload. Check Vacuum Motor for Obstructions.
77O3 Possible Short Circuit on Vacuum Output. Check Vacuum Motor Wiring for Frayed or Faulty Condition.
78OO Drive Motor Disconnected. Check Drive Motor Wiring for Proper Connections.
78O1 Drive Motor Overcurrent Error. Check Drive Motor / Brake System for Damage.
78O2 Drive Current Overload. Check Drive Motor / Brake System for Damage.
790
X
Emergency Stop.
Check "STOP" switch and wires.

CHAMP ZS 35 ORIG. 02-02 REV. C 02-03 9097607
PROBLEM CAUSE SOLUTION
No Solution Flow. The solution valve is closed. Open the solution valve.
Water solenoid valve not open. Charge the battery.
Obstruction in the solution hose. Remove the obstruction.
Solution valve or cable damaged. Repair / replace the valve cable.
Solution tank is empty. Fill the tank.
Solution valve is dirty. Clean the solution valve.
Damaged seat and washer in valve. Replace valve.
Will Not Pick Up Any Water Squeegee is up. Lower squeegee.
From The Floor. Vac motor switch is “off”. Turn vac motor switch “on”.
Recovery tank is full. Empty tank.
Vacuum shut-off float is stuck. Remove obstruction.
Hole in squeegee hose. Replace hose.
Vac motor is not running. Have an authorized serviceman repair.
Drain plug not in tight. Tighten drain plug.
Port-hole cover is missing. Replace port-hole cover.
Squeegee blade is worn / damaged. Reverse / replace squeegee blade.
Obstruction / damage in the squeegee, Remove obstruction / repair damage.
squeegee hose or standpipe.
Batteries Do Not Seem To Tops of batteries are dirty / wet. Clean / dry, charge batteries.
Run Long Enough. Battery terminals are dirty / damaged. Clean terminals and connectors,
replace damaged cables.
Electrolyte level is too low. Add water and charge.
Batteries are not fully charged. Charge batteries for 8 hours.
Charger is damaged. Have an authorized serviceman repair.
Battery is defective. Check cell voltage while discharging.
Wrong size battery. Replace with larger batteries.
Batteries have memory — recharging Don’t recharge batteries until “Battery
prematurely will result in a loss of Recharger” indicator is displayed.
battery capacity.
Battery tray full. Drain battery tray.
Cleaning Is Not Even. Brush / pads are worn. Replace.
Damage to brush assembly or Have an authorized serviceman repair.
solution valve.
Motor is not running. Check circuit breakers, reset if necessary,
replace carbon brushes, repair wiring,
replace switch.
Not enough or uneven water. Check solution hose for blockage.
Machine Does Not Run. Check circuit breaker. Reset circuit breaker. Check battery
connections.
Code on control panel. Contact authorized repair servide center.
NSS®Enterprises, Inc.
3115 Frenchmens Road, Toledo, Ohio 43607
PHONE [phone] FAX [phone]
NSS®Enterprises,Inc.EuropeanDistributionCentre
Unit II, Pinfold Trading Estate * 55 Nottingham Road
STAPLEFORD, NOTTINGHAM NG9 8AD ENGLAND U.K.
PHONE: [phone] * FAX: [phone]
TROUBLESHOOTING
NOTE: If problems remain after taking the above steps, contact your local authorized service station for further
evaluation and repair.