NSS 2717DB, 2022DB User Manual

OPERATION MANUAL

CHARGER 2717 DB & CHARGER 2022 DB

Original Instructions

Instructions D'origine

Instrucciones Originales

OPERATION MANUAL

CHARGER 2717 DB & CHARGER 2022 DB

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: This product contains a chemical known to the state of California to cause
cancer and birth defects or other reproductive harm.

WARNING: Fire or explosion hazard.
NEVER use flammable liquids (gas,

kerosene, solvents, or thinners) to
clean or burnish floor.

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 Burnishers are Twister Approved.
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 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 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.

SAVE THESE INSTRUCTIONS

IMPORTANT SAFETY INSTRUCTIONS

BATTERY POWERED EQUIPMENT WITH ON BOARD CHARGERS

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.

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.

No smoking, open
flames, or sparks while
working with batteries.

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, rubber gloves 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.

ALL REPAIR SERVICE MUST BE PERFORMED BY AN NSS AUTHORIZED DISTRIBUTOR/
SERVICE STATION USING ONLY NSS ORIGINAL EQUIPMENT PARTS

Contains acid.
Avoid contact

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

distilled water if necessary to bring level to the bottom
of the fill hole.

 NEVER

battery
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 water.
For All Types of Batteries

 ALWAYS study battery manufacturers’ specific

precautions such as recommended rates of charge.

 NEVER charge a frozen battery.
 ALWAYS plug the charger into an earthed socket-

outlet.

 NEVER touch uninsulated portion of output connector

or uninsulated battery terminal.

 ALWAYS disconnect the AC supply before making or

breaking the connections to the battery while
charging.

 NEVER open or disassemble charger.
 NEVER operate charger if the AC supply cord is

damaged or if the charger has received a sharp blow,
been dropped, or otherwise damaged in any way.

Poison. Causes
severe burns. Avoid
contact.

overfill batteries as

and machine damage may

(

(

NOISE AND VIBRATION

Lower Brush/Pad to Operating Position

NOISE
Sound pressure level at Operator
position
VIBRATION
Weighted RMS acceleration value

ISO 5349)

ISO 11201)

68 dB(A)

.269 m/s

2

MACHINE INSPECTION

 Now that the machine is unpacked remember to

recycle all packing materials.

 Inspect the machine for damage or missing

components. If damage is found, contact the
freight company to file a freight claim.

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 and uses more pads
because they become loaded with floor finish, which
can cause overloading of the machine’s control
system.

Quick Start

Connecting Battery Pack to Machine

 Move the front of the machine from/to pad

changing position or operating position by grasping
the handle and moving it to the desired position.

 Turn on master switch (and key switch if so

equipped). Wait until you hear a click, the machine
is now on. See Machine Components for more
information.

 Check that the battery meter is reading in the high

or green range. The machine should be put on
charge if not in the high range. See Charging
Instructions later in this manual.

 Turn on brush switch. See Machine Components

for more information.

 Twist the handle grips forward (away from you) to

activate the Pad and Drive Motors. To move
backward twist the handle grips backward (toward
you). See Machine Components for more
information.

CAUTION: This Machine must be moving at all
times when the pad is rotating or the floor may be
damaged.

Transporting the Machine to Work Site

When the machine is shipped with batteries, the
machine will arrive with the battery pack
disconnected from the machine.
 Lift up on the handle on the top cover to expose the

battery pack.

 Connect the cable with the Anderson connector

into the Anderson connector mounted to the
machine at the rear of the battery compartment in
front of the control column.

For machines shipped without batteries

 See Battery Installation in the Maintenance Section

later in this manual.

NSS recommends transporting the machine to the
work site with the front of the machine in the
operating position and the brush switch in the off
position. This will reduce the potential of damage to
the Flexiwall Shield and Pad Driver when moving
through stock/storage rooms and double swinging
doors.

For questions and all information pertaining to
this machine read the rest of this manual.

MACHINE COMPONENTS

Operator Control Column

The operator control column is located at the rear of
the machine. This column has components that
control various machine functions.

Drive System Control

 At the top on both sides of the control column are

two (2) rubber twist grips. These grips rotate
forward and backward to control the direction and
speed of the machine.

 They also activate the Brush Motor so it is only on

when the machine is moving. The farther the grips
are rotated, the faster the machine will move.

 These twist grips have a safety feature that returns

the machine to the neutral position when the
handles are released.

Battery Meter
The battery meter is located in the back of the control
column cover and has two uses. It shows the state of
charge of batteries during operation and flashes fault
codes when there is a problem with the machine.
 The rate of charge is indicated by numbers. The

higher the number the greater the charge in the
battery pack.

 When there is a fault with the machine, the Battery

Meter will flash an “F” followed by a number.

 See Trouble Shooting Chart for more

information.

Battery Charger

Master Switch

 The master switch is located on the top right side

of the control column and it turns the machine on
and off.

 If the brush switch is on and the brush head is

down or the twist grips are not in the neutral
position the machine will not turn on. A flashing
fault code will appear on the battery meter. See the
bottom of the decal on control column cover and
correct the problem.

 The control system will automatically turn the

machine off if it sets idle for 10 minutes. Turned off
the master and brush switch and then turn the
master switch back on to restart.

Hour Meter

 The hour meter is located under the Master Switch

and counts the hours the brush motor is on. The
hour meter is used for indicating maintenance
intervals. The hour meter cannot be reset.

 See maintenance section for maintenance

intervals.

Fuse Holder

 The fuse holder is located under the Hour Meter. It

houses a 2 AMP fuse.

The battery charger is located on top of the battery
box cover.
 This high efficiency battery charger is designed for

onboard operation.

Key Switch

 A Key Switch is Optional and will be located above

the hour meter when installed. The key switch and
master switch will both need to be used to turn the
machine on and off.

MAINTENANCE

ALWAYS turn OFF all machine switches
before performing any maintenance or
repairs to any equipment.

Check the tension of the Drive Chain after the
first 100 hrs of use and then every 90 days or 300
hours as needed. For the chain tightening
instructions see the maintenance section called
90 Day Maintenance (300 Hours).

Daily Maintenance

Never leave the machine sit with a used pad
installed. This can cause the pad driver to warp.

Pad Installation / Changing

Brush Switch

 The brush switch is located on the left side of the

control column and it turns the brush on and off.

 There is also a tilt switch in this circuit located

under the brush head that only allows the brush to
be turned on when the brush head is in the
operating position.

Circuit Breaker

 There is one master circuit breaker located below

the brush switch on the control column.

Brush Head

 The brush motor, Filter Bag and Flexiwall shield

are located at the front of the machine.

 The bag connects directly to the Flexiwall shield

and has a snap that retains the rear of the bag.

There is a wide range of pads available for many
different burnishing applications. Consult your local
NSS authorized distributor for application
recommendations.
 Lift the front of the machine up to the 90-degree

position to view the pad driver and pad.

 Make sure that the correct pad (7/8" to 1" [22mm to

25.4mm]) X 27" [68.6 cm] 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 allows for easier installation of the pad
centering 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 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.

Daily Maintenance (continued)

 Empty the filter bag daily or when it is

approximately one-half (1/2) full.

Charging Batteries

 Recharge the batteries when indicated by the

Battery Meter.

 Never let the batteries sit overnight after the

machine has been run for 1hr or more since last
recharge.

 NEVER let the electrolyte level fall below the tops

of the plates. This will damage the batteries
immediately, and void the warranty.

 Check charger cord for exposed wires and

damaged plugs before using.

 To recharge the batteries plug the charger cord into

the charger located on top of the machine and then
into an electrical outlet.

 When the cord is plugged into an outlet the

machine will automatically become disabled.

 Charge the batteries with the cover open when

possible to reduce heat build up in the batteries.

 See charging instructions for more details.

 ALWAYS wear eye protection, rubber gloves and

protective clothing to avoid contact with battery
acid when working around batteries.

 After charging batteries check the water level of

each battery cell and add distilled water as
required to level specified by battery manufacturer.

 Check and verify that all battery connections are

clean and tight.

 Wipe machine down with a damp cloth.
 NEVER spray this machine with water or any

liquids.

 ALWAYS Check the tilt switch for proper

operation. With the master switch turned off, put
the brush head into the pad change position. Turn
the brush switch on then the master switch on, the
machine should turn on.

 If the machine does not turn on and the battery

meter is flashing a one, the tilt switch has failed.
DO NOT use the machine until the tilt switch has
been replaced.

Opportunity Charging

Opportunity charging is charging the batteries when
an opportunity presents itself, such as during breaks,
and is done in addition to a full charge cycle.
Opportunity charging is recommended, as this extra
charging time will help raise the operating voltage of
the batteries, and will help ensure maximum runtime
and cycle life.

See Monthly Maintenance and Operating Battery
Charger Instructions for equalizing your batteries
especially if you have been opportunity charging
your machine.

Weekly Maintenance (Every 25 Hrs)

Verify all daily maintenance has been performed.

 Inspect the Flexiwall Shield for dents around the

outside edge and cracks in the plastic.

 Check that the Brush and Retaining Band are

properly installed.

 Remove dirt build up on the brush along the

bottom of the Flexiwall Shield.

 A damaged Flexiwall Shield Assembly will greatly

reduce dust control capabilities of the machine.

Monthly Maintenance
(Every 100 Hrs)

Verify that all daily and weekly maintenance has
been performed.

Equalize your batteries (Flooded only).

The batteries should be equalized once every 30
days for maximum battery runtime and life.

To equalize the batteries:

 Plug in the charger, and fully charge the batteries

(until the green 100% LED is on continuously).

 Unplug the charger from the wall outlet, then plug it

back in.

 The charger will run for 2hrs, holding the batteries

at a constant voltage, and equalizing each cell.

THIS STEP IS ESPECIALLY IMPORTANT IF YOU
PRACTICE OPPORTUNITY CHARGING.

90 Day Maintenance
(Every 300 Hrs)

Verify that all daily, weekly and monthly
maintenance has been performed.

Tighten Chain

 Check the tension on the drive motor chain. If the

chain has more than ½” [12.7mm] deflection,
tighten as needed.

 Access to the bolts for the drive motor are on the

left side of the machine. There are two bolts on top
which are accessed through the holes as shown in
the picture above. There are also two bolts located
below the frame. A total of four bolts.

Lubrication

 Check the Battery Tray Drain Hose for liquid level

on a monthly basis.

 Spilled liquids from the battery compartment area

are collected in a tray under the batteries. The tray
can be drained using the hose at the right rear of
the machine as shown above.

 IMPORTANT: Drain all liquids into an approved

container and dispose of according to your local
and federal regulations.

 Inspect the machine components for wear, loose

fasteners, or damage. Pay special attention to all
pivot points and moving parts.

 Call an authorized NSS service center for repairs.

 Lubricate the casters with an industrial grade

bearing grease. Failure to lubricate casters will
cause the machine to maneuver with difficulty and
premature failure of the caster will result.

 Lubricate the drive wheel bearings with an

industrial grade bearing grease. The zerk fittings

y

on the bearings can be accessed from the front of
the machine.

 Failure to lubricate drive wheel bearings will cause

the machine to maneuver with difficulty and
premature failure of the bearings will result.

Every 6 Months (Every 600 Hours)

Call your Authorized NSS Distributor / Service
Station to have the following services performed.

Verify that all daily, weekly, monthly and quarterly
maintenance has been performed.

Inspect Brush Motor carbon brushes for wear.

 Lube the drive motor chain with a small amount of

grease using a brush. A chain spray can also be
used.

 NEVER use your fingers to put the lube on the

chain. Serious injury may occur.

 Lubricate all moving parts as required with a small

amount of grease.

 DO NOT lubricate the Gas Spring shaft, it does not

require lubrication as it is self lubricating.

 Using compressed air, blow the accumulated

carbon brush dust out of the motor.

 Replace carbon brush when they measure ½”

[12.7mm] or less in length.

 Failure to replace carbon brushes will cause poor

machine performance and possible motor damage.

Check the condition of the batteries.

 A battery may be checked using a Hydrometer to

check the specific gravity (strength) of the acid in
each cell. Variations in readings occur due to the
chemical reaction taking place during use.

 Always check the specific gravity when the battery

is fully charged.

 Replace batteries as needed.

Battery Installation:

 Turn off all switches. Disconnect battery pack from

the machine.

 ALWAYS wear eye protection, rubber gloves and

protective clothing to avoid contact with battery
acid when installing batteries. See Battery
Warnings on page 3.

Repairs performed by an unauthorized company will void the machine warranty.
If

ou require assistance finding an authorized service center, contact NSS Enterprises.

Every 12 Months
(Every 1200 Hours)

Call your Authorized NSS distributor / Service
Station to have the following services performed.
Verify that all daily, weekly, monthly and quarterly
maintenance has been performed.

Inspect Drive Motor carbon brushes for wear.

 Remove the side panel and top cover. There are

two bolts (one in each corner) on top of the side
panel and two nuts (one in each corner) at the
bottom of the cover. Note that the nuts at the
bottom are not visible from the side.

 The cover will still be attached to the side panel.

Move them out of the way to install the Batteries.

 Batteries are heavy – ALWAYS use two people to

install batteries into machine.

 Refer to wiring diagram located on the under side

of the cover. Align batteries in compartment the
same as the old batteries or as shown on diagram.

 Install battery cables the same as they were on the

old batteries or as shown on wiring diagram
located on the under side of the cover.

 NSS recommends replacing the battery cables

when replacing batteries.

 Tighten bolts and hex nuts with a wrench.
 Install terminal boots over terminals to complete

installation.

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.

 This will require removing the drive motor from the

machine and should only be done by an authorized
NSS Service Station.

 Using compressed air, blow the accumulated

carbon brush dust out of the motor.

 Replace carbon brush when they measure ½”

[12.7mm] or less in length.

 Failure to replace carbon brushes will cause poor

machine performance and possible motor damage.

Gas Spring Service

ALWAYS secure Brush Head in the pad change
position using the strap provided before
attempting any maintenance or repairs to the gas
spring or coil spring assemblies.

 Remove the spring clip that secures the gas spring

to the machine. Then pull the gas spring off of the
ball stud. There is a clip and ball stud at each end.

 Place one end of the gas spring against a hard

surface and push on it. If you can compress it, it
must be replaced. If you can not compress it, it is
most likely OK.

Pad Pressure Adjustment

The NSS Charger 2717 DB and Charger 2022 DB
is preset at the factory for medium duty
applications. It can be tuned to your specific
application for optimum performance.

ONLY an authorized NSS Service Station should
perform this adjustment.

Tools required for Pad pressure adjustment

1) ¾ open end wrench

2) Clamp on Amp Meter

Checking the Pad Motor Amperage

 First install a new pad on the pad driver. Caution:

Checking the Amps with a used pad will cause the
machine to have high amps when a new pad is
installed.

 Lower the Pad Motor into the operating position

and open the cover over the battery compartment.

 Put the clamp on AMP Meter around the red

(positive) wire coming from the battery pack to the
machine as shown.

 While running the machine read the amp meter.

The amp meter should be reading between 70-80
amps for the Charger 2717 DB & 50-70 amps for
the Charger 2022 DB.

Pad Pressure Adjustment

 It is necessary to use a clamp on AMP Meter when

adjusting the pad pressure.

 There are many different manufactures and

models of AMP Meters to choose from. Two AMP
Meters are shown above. The one on the left is
AMPROBE Model ACDC-610 and the one on the
left is AMPROBE Model ACDC-400.

If adjustment is required, follow these
instructions.

 It will be easier to access the lock nut and spring

guide rod assembly with the machine in the pad
change position.

 First loosen the lock nut on the spring guide. With

the lock nut loose, the spring guide rod assembly
will be easily turned by grasping the set collar on
the spring guide rod.

 Turn the spring rod guide assembly ½ to 1 turn at a

time. A little adjustment goes a long way.

 Thread the spring guide rod assembly out of the

ball joint to decrease the pad pressure. Thread the
spring guide rod assembly into the ball joint to
increase the pad pressure.

 Every time an adjustment is made check the amps.

This may require a few tries to get it were it should
be.

 After the adjustment is made tighten the lock nut

and redo the amp test. If it has not changed the
process is complete.

Fall back setting 

If your machine has come totally out of adjustment, or
you need to replace the Spring Rod Guide Assembly
you may need to start from the beginning.

 The factory starting setting for the pad pressure on

the Charger 2717 DB is 3/4 of an inch [19mm] from
the set collar to the lock nut.

 The factory starting setting for the pad pressure on

the Charger 2022 DB is 1/2 of an inch [12.7mm]
from the set collar to the lock nut.

 From this setting, proceed with the Pad Pressure

Adjusted.

Battery Replacement Notes

 Entire Pack.

oIt is always recommended to replace all batteries

in the pack at the same time.

 One or more batteries out of the pack. This is not

recommended. Replacing just one or two batteries
out of the pack can lead to the following:

 Overcharging the new, or the remaining

original, batteries.

 Undercharging the new, or remaining

original, batteries.

 Over discharging either the new or the

remaining original batteries.

o If you wish to only replace some of the batteries

in the pack, follow these steps for best results:

 Replacement batteries must always be of the

same battery manufacturer, model and amp­hour rating, as the remaining batteries in the
pack.

 Never mix batteries from different

manufacturers in the same pack.

 Fully charge both the new battery, and the

remaining original batteries. (specific gravity
= 1.265 minimum, use a hydrometer)

 Use a replacement battery that is close to the

same age as the remaining original ones.

 Do not run the machine as long for about 20

cycles. For example, if you used to get 4 hrs
runtime, only run it for 2.5 hrs, and then
charge the batteries completely.

 Opportunity charge whenever possible.
 Equalize after 30 days (Flooded only).
 The above steps will provide the best

opportunity for the new battery(s) to join the
pack.

Battery Do’s and Don’ts:

a. You do not have to fully discharge the batteries

before charging. They do not have a “memory”.

b. Plug the charger in anytime the machine is not in

use.

c. NEVER let the electrolyte level fall below the tops

of the plates (flooded cell batteries). This will
damage your batteries almost immediately, and
void the battery warranty. They can tell if this
happened.

d. NEVER refill the batteries with well or tap water

(flooded cell batteries).

e. NEVER overfill the batteries (flooded cell

batteries).

f. NEVER let the batteries sit discharged overnight

(or between shifts).

g. ALWAYS check the electrolyte level about every 3

or 4 charge/discharge cycles BEFORE
CHARGING.

h. ALWAYS refill the batteries with distilled water (if

needed) AFTER CHARGING.

i. ALWAYS fully recharge the batteries after use

(until the green LED comes on).

j. ALWAYS equalize the batteries (Flooded only)

every 30 days.

k. NEVER OVER DISCHARGE!
l. NEVER charge GEL batteries with the charger set

to FLOODED/AGM.

m. NEVER charge FLOODED/AGM batteries with the

charger set to GEL. EXCEPTION-CROWN AND

TROJAN AGM’S TO BE CHARGED WITH GEL
SETTING.

Battery charger

The onboard battery charger supplied with this
machine is capable of charging lead acid batteries
from 185 to 350ah capacity. There is no need to
change algorithms or settings based on battery
manufacturer, or battery size.

The charger can also be set to charge flooded (wet)
cell, AGM, or Gel batteries. LED’s on the charger
indicate which type of battery the charger is set to
charge. One setting is for Flooded and (most) AGM
batteries, the other setting is only for Crown and
Trojan AGM and GEL batteries.

Depending on the battery charger model, the charger
can operate on 100/115/230 VAC 1ph 50/60 HZ
power, and will automatically detect these input
voltages. Before connecting the battery charger to
power, check the label on the battery charger to
verify proper input power.

Determining Your Battery Type

CAUTION: DIFFERENT BATTERY TYPES HAVE
DIFFERENT CHARGING REQUIREMENTS.
FAILURE TO PROPERLY IDENTIFY YOUR
BATTERY TYPE, AND SET THE CHARGER
ACCORDINGLY WILL RESULT IN BATTERY
DAMAGE, AND VOID THE WARRANTY.

Your machine may have been ordered with batteries
installed at the NSS factory. The standard battery
type, normally supplied by NSS, is the Flooded (wet)
cell lead acid battery. Gel and AGM sealed batteries
may also be available at customer request.

Flooded (wet) batteries can be easily identified by the
removable cell caps. Removing the caps allows
inspection of the liquid electrolyte (sulfuric acid) level
in each cell.

AGM (Absorbed Glass Mat) batteries are sealed,
maintenance free batteries. They do not have cell
caps intended for removal. Look for “AGM” printed
on the tops or sides of the batteries.

Gel (gelled electrolyte) batteries are also sealed,
maintenance free batteries. They do not have cell
caps intended for removal. Look for “GEL” printed
on the tops or sides of the batteries.

Battery Charger Indicator LED’s

Your battery charger is equipped with LEDs that
indicate the following:
 Battery Type Setting. Either of these two LEDs will

be illuminated, anytime the charger is plugged in,
to signal which type(s) of batteries the charger is
configured to charge. The two options available
are:

oWet / AGM: When this LED is illuminated, the

charger is configured to charge either flooded
(wet), or AGM batteries.

oGel Cell. When this LED is illuminated, the

charger is configured to charge Gel batteries
ONLY. EXCEPTION: Crown and Trojan

AGMs are to be charged with the Gel
setting.

 State of Charge Indicators. Four additional LEDs

provide information about the charge level of the
batteries during charging.

o30%, 60%, 90% and 100%.

 Fault Indications. During charging, the charger

provides feedback about the charge process and
any problems detected. It will provide feedback
and signal the type of problem by flashing LEDs as
described below:

Changing the Battery Type Setting

The standard setting for the onboard battery charger
is Flooded/AGM. EXCEPTION: If your machine was
ordered from NSS equipped with Crown AGM or Gel
batteries, then the charger was configured for Gel
batteries at the factory.
Configuring the Charger for Gel batteries:

Top cover
screws

1. Remove the top cover.

2. Pull the jumper off the 2-pin connector (position 1),
and then move the jumper to position 2 on only
one pin of the 2-pin connector. See photo below.

3. Reinstall the top cover.

1. The green wire outputs a battery voltage when

the charger is not plugged in to AC to provide an
Interlock function.

2. Securely fasten the black ring terminal from the

charger to the negative terminal ("-", "NEG",
NEGATIVE") of the battery pack.

3. Select Charge Algorithm if battery type is other

than factory default.

Jumper
Location

Position 1
For Wet
Cell
(Default)
(Jumper on
both pins)

Position 2
For Gel Cell
(Jumper on 1
Pin of 2-Pin
Connector)

Configure the Charger for Flooded/AGM batteries

1. Remove the top cover

2. Pull the jumper from the 2-pin connector, and
install the jumper at position 1 (on both pins of 2­pin connector).

3. Reinstall the top cover.

Operating the Battery Charger

CAUTION: DIFFERENT BATTERY TYPES HAVE
DIFFERENT CHARGING REQUIREMENTS.
FAILURE TO PROPERLY IDENTIFY YOUR
BATTERY TYPE AND SET THE CHARGER
ACCORDINGLY WILL RESULT IN BATTERY
DAMAGE, AND VOID THE WARRANTY.

The battery charger is fully automatic. Simply plug
the charger into a suitable wall outlet, and the
charger will charge the batteries. The green 100%
LED will be continuously illuminated when the charge
cycle is complete.
A bubbling, or boiling sound coming from the
batteries during the last few hours of the charge is
normal. The batteries may be warm, but not too hot
to touch.
The charger will maintain the proper battery voltage
as long as it is plugged in (maintenance mode).

Equalizing the batteries (Flooded only)

The batteries should be equalized once every 30
days for maximum battery runtime and life.

To equalize the batteries:
 Plug in the charger, and fully charge the batteries

(until the green 100% LED is on continuously).

 Unplug the charger from the wall outlet, then plug it

back in.

The charger will run for 2hrs, holding the batteries at
a constant voltage, and equalizing each cell.

Opportunity Charging

Opportunity charging is charging the batteries when
an opportunity presents itself, such as during breaks,
and is done in addition to a full charge cycle.
Opportunity charging is recommended, as this extra
charging time will help raise the operating voltage of
the batteries, and will help ensure maximum runtime
and cycle life.

See Operating Battery Charger Instructions or
Monthly Maintenance for equalizing your
batteries especially if you have been opportunity
charging your machine.

Notes on LED indications per DoE compliance:

When first connected to DC (AC not connected), the
LEDs will display one or more of the following:
The LEDs will flash the charger’s ID code (this is for

PCS internal use only). Once the LEDs flash the ID,
they will only display one yellow LED. This
configuration will remain until AC is detected and a
charge cycle is in progress.

There is also a possibility the LEDs will not flash

their ID code and only show a yellow LED.

Lastly, the LEDs may not flash their ID code and

may not show any LEDs until AC is detected.

If the AC line and neutral wires are reversed, the unit
will wait 2 minutes before starting a charge. NOTE:
The 2-minute wait period will also be a factor if the

charger is being powered by anything other than
normal grid AC such as a conventional generator,
inverter, etc.

If the AC plug is disconnected during charge, the unit
will turn off as expected. The user may hear some
clicking noise, but should not be alarmed. This is the
Powered by Battery/DOE functionality checking for
AC connection.

How to read charging data from a battery charger

equipped with DeltaView® Link

DeltaView Link

DeltaView Link is a system that allows you to read
data from your battery charger using an app on your
smartphone. The battery charger transmits data to
your phone’s Bluetooth receiver.

These instructions apply to Dual Pro battery chargers
manufactured after 11/29/16. The manufacturing
date is located on the barcode tag attached to the
pigtail cord coming out of the charger. This battery
charger is found on Champ Rider Scrubbers,
Wrangler 3330, Wrangler 2730, Wrangler 2625,
some Wrangler 2016 models, and Charger battery
burnishers.

Instructions

Step 1. Download the Pro Charging Systems “DeltaView

Link” app

For Apple iPhones: Go to the app store and search for
“DeltaView Link” by Pro Charging Systems, LLC.
For Android Phones: Go to the play store and search for
“DeltaView Link” by Pro Charging Systems, LLC.

Step 2. Turn on your phone’s Bluetooth function. If your
Bluetooth is off, the app will turn it on for you when it
starts. Answer “yes” when prompted to turn on
Bluetooth.

Step 3. Locate the “DeltaView Link” icon on your phone
and press it to start the app.

Step 4. A list of all battery chargers that are connected to
AC power within range of your phone will appear. Tap on
a battery charger to select it.

Step 5. Follow the app prompts to read through the data
on your charger. You will find detailed information about
the last 100 charge cycles.

TABLE 1

BATTERY TYPES

NSS Part

Number

Crown

Part

Number

Battery Volts

System Volts

Battery Type

Setting

Amp Hour

4491061 1-1470 12 36 215 Flooded/AGM

3390361 1-1435 6

24 &

235 Flooded/AGM

36

2392111 1-1427 12 24 115 SPE CURVE 0

6393651 1-1428 12 24 130 SPE CURVE 0

2392731 1-12145 12 24 100 SPE CURVE 1

6491931 1-1437 6

24 &

36

200 GEL

2691501 1-1450 6 36 350 Flooded/AGM

TROUBLE SHOOTING CHART

Problem Cause Solution

Battery pack is not plugged into machine.

Machine will not turn on.

Brush motor will not run
or stopped running.

Brush motor will not turn
off when handles are in
neutral position.

Machine vibrates.

Run time is less than
when new.

Battery charger will not
turn on.

Battery charger is plugged into AC outlet. Unplug the battery charger.
The 2-amp fuse is missing or blown. Replace 2-amp fuse.
Circuit breaker is tripped. Reset circuit breaker.

Current over load of brush motor has exceeded
set parameters in control system.

Tilt switch failure.

Carbon Brushes worn or not making contact.

The potentiometer is set on the threshold of
neutral or potentiometer has failed.

Pad not centered or torn. Center pad. Change torn and worn pad.

Pad driver damaged and/or out of balance.

Damaged or defective battery or battery pack.

Batteries are not fully charged

Incorrect Battery Type Setting on the charger

Battery charger cord damaged.

Connection not made between battery charger
and battery pack.

The battery charger is damaged.

NOTE: Crown and Trojan AGM batteries should
be charged with the GEL setting.

The charger has been tested on batteries from
the following manufacturers:

Trojan flooded cell
US Battery flooded cell
Deka flooded cell
Crown gel
Concord gel
Discover AGM

Open the battery cover and plug the battery
pack into the machine.

Turn off all switches and then turn on the
master switch to reset the control system. If the
problem continues check battery meter for fault
code F42.

Check tilt switch operation. Replace tilt switch if
test failed.

Have an authorized NSS Service Station check
carbon brushes and replace if necessary.

Have an authorized NSS Service Station reset
the potentiometer to neutral or replace.

Check pad driver for damage and replace if
necessary.

Check for fault codes on the battery charger
during battery charging. Have an authorized
NSS Service Station check the batteries and
replace as necessary.

Charge batteries until the green LED indicates
the charge cycle is complete.

Ensure the charger is set according to the type
of batteries installed.

Check for cord damage and replace if
necessary. DO NOT try to repair it.

Check connections at battery pack for corrosion
and loose or broken wires.

Have an authorized NSS Service Station check
and replace if necessary. DO NOT try to repair
it.

y

Problem Cause Solution

Pad will not stay in the
pad change position.

Pad will turn on in the
pad changing position.

Circuit breaker trips.

Front of machine does
not move down to the
floor when turned on.

Flashing number 1
appears in battery
meter.

Flashing letter A
appears in battery
meter.

Fault code F12 appears
in battery meter.

Fault code F23 appears
in battery meter.

Fault code F26 appears
in battery meter.

TROUBLE SHOOTING CHART CONTINUED

Weak or missing gas spring(s). Check and replace if necessary.

Tilt switch failure.

Spray Buffing. DO NOT spray buff.

Pad pressure to heavy.

Pad pressure collars out of adjustment.

Spring guides sticking in slides.

Brush motor circuit closed when machine is
turned on.

Twist grip not in neutral when master switch is
turned on. Potentiometer not set properly in
neutral position.

Internal programmable parameter data is
corrupt.

Internal temperature of controller has exceeded
the set parameters.

Precharge failure when controller is turned on or
the control system has been miswired causing
an internal controller failure.

See daily maintenance for proper checking
procedure. Replace tilt switch as necessary.

Check gas springs for failure and replace as
necessary.

Readjust pad pressure collars as required by
your burnishing conditions.

Check spring guides for proper operation.
Replace if bent. Lubricate if necessary. Loosen
bolts in spring guide mounting bracket, it will
self-align, retighten bolts.

Turn off brush switch. Check tilt switch for
proper operation.

Let go of twist grip. Have an authorized NSS
Service Station reset the potentiometer to
neutral or replace.

Turn machine off and then on. If problem
continues call for service.

Turn machine off and let control system cool off.
If problem continues call for service.

Turn machine off and then on. If problem
continues call for service.

Fault code F29 appears
in battery meter.

Fault code F32 appears
in battery meter.

Fault code F37 appears
in battery meter.

Fault code F42 appears
in battery meter.

Fault code
F44/F4C/F45/F59/F60
appears in battery
meter.

Fault code F4D/F46/F61
appears in battery
meter.

Fault code F58 appears
in battery meter.

Fault code F62 appears
in battery meter.

Fault code F63 appears
in battery meter.

Wired incorrectly. Internal control system failure.

Wired incorrectly. Internal control system failure.

Potentiometer wired incorrectly. Internal control
system failure.

The brush motor is exceeding the current limit
set in the controller.

Caused by wiring short circuit in drive wiring or
shorted drive motor.

Caused by wiring short circuit in brush wiring or
shorted brush motor.

The deceleration of the brush motor or drive
motor exceeded set parameters. Example:
Tried to slow down or stop on too steep a hill.

Wired incorrectly. Internal control system failure.

Caused by wiring short circuit in contactor
wiring or contactor coil.

Check wiring. Turn machine off and then on. If
problem continues call for service.

Check wiring. Turn machine off and then on. If
problem continues call for service.

Check wiring. Turn machine off and then on. If
problem continues call for service.

Check the gas springs for wear. Check the
brush pressure set collars for proper
adjustment. Check pad driver and Flexiwall
shield for proper installation and problems. Turn
machine off and then on. If problem continues
call for service.

Check wiring and drive motor for short circuit.
Correct problem if found. If problem continues
call authorized NSS Service Station for service.

Check wiring and brush motor for short circuit.
Correct problem if found. If problem continues
call for service.

Turn machine off and then on. If problem
continues call authorized NSS Service Station
for service.

Check wiring. Turn machine off and then on. If
problem continues call for service.

Check wiring and contactor for short circuit.
Correct problem if found. If problem continues
call for service.

Repairs performed by an unauthorized company will void the machine warranty.
If

ou require assistance finding an authorized service center, contact NSS Enterprises.