ESAB Warrior 500 Operating Instructions Manual Download

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Table of Contents

Machine Data Log / Overview. . . . . . . . . . . . . . . . . . 2

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . 4

Safety

IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . .5

HAZARD INTENSITY LEVEL . . . . . . . . . . . . . . . . . .6

Grounding Instructions . . . . . . . . . . . . . . . . . . . . . . .7

Operations

Technical Specifications . . . . . . . . . . . . . . . . . . . . . .8

Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . 1

Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Pre-Run Inspection . . . . . . . . . . . . . . . . . . . . . . . . .11

Equipment Set-up . . . . . . . . . . . . . . . . . . . . . . . . . .11

Heater Operation . . . . . . . . . . . . . . . . . . . . . . . . . .11

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Maintenance

Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . .13

Daily/Regular Maintenance. . . . . . . . . . . . . . . . . . .13

Vacuum Motor Replacement . . . . . . . . . . . . . . . . .14

Solution Pump Replacement . . . . . . . . . . . . . . . . .15

Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . .16

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .17

PARTS

Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Control Panel with Heat . . . . . . . . . . . . . . . . . . . . 21

Electrical with 2 Stage Vacuum . . . . . . . . . . . . . . 23

Electrical with Heat / 3 Stage Vacuum . . . . . . . . . 25

Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Recovery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Solution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Vacuum, 2-Stage / 3-Stage. . . . . . . . . . . . . . . . . . 39

Wiring - 2 Stage Vacuum . . . . . . . . . . . . . . . . . . . 41

Wiring - 3 Stage Vacuum . . . . . . . . . . . . . . . . . . . 42

Wiring with Heat . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Warrior warranty . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Summary of Contents for Warrior 500

Page 1: ...MODELS WARRIOR 500 WARRIOR 500 10 WARRIOR 500 05 Operating instructions ENG Read these instructions before using the machine 500 PSI 760 173 ...

Page 2: ...ectric powered carpet extractor intended for commercial use This appliance applies a cleaning solution to the carpet and then vacuums the soiled water back into the recovery tank Model Date of Purchase Serial Number Dealer Address Phone Number Sales Representative ...

Page 3: ... up 11 Heater Operation 11 Cleaning 12 Maintenance Periodic Maintenance 13 Daily Regular Maintenance 13 Vacuum Motor Replacement 14 Solution Pump Replacement 15 Pressure Regulator 16 Troubleshooting 17 PARTS Control Panel 19 Control Panel with Heat 21 Electrical with 2 Stage Vacuum 23 Electrical with Heat 3 Stage Vacuum 25 Frame 27 Heater 29 Labels 31 Pump 33 Recovery 35 Solution 37 Vacuum 2 Stage...

Page 4: ... the machine and its components in good working condition They are listed in this general order Maintenance Lubrication Vacuum Motor Replacement Solution Pump Replacement Troubleshooting The PARTS LIST section contains assembled parts illustrations and corresponding parts list The parts lists include a number of columns of information REF column refers to the reference number on the parts illustra...

Page 5: ...ce center Do not pull or carry machine by electrical cord use as a handle close a door on cord or pull cord around sharp edges or corners Do not run machine over cord Keep cord away from heated surfaces Do not unplug machine by pulling on cord To unplug grasp the electrical plug not the electrical cord Do not handle the electrical plug or machine with wet hands Do not operate the machine with any ...

Page 6: ...equipment Report machine damage or faulty operation immediately Do not use the machine if it is not in proper operating condition Following is information that signals some potentially dangerous conditions to the operator or the equip ment Read this information carefully Know when these conditions can exist Locate all safety devices on the machine Please take the necessary steps to train the machi...

Page 7: ...e must be grounded If it should malfunc tion or break down grounding provides a path of least resistance for electric current to reduce the risk of electric shock This appliance is equipped with a cord having an equipment grounding conductor and grounding plug The plug must be inserted into an appropriate outlet that is properly installed and grounded in accordance with all local codes and ordi na...

Page 8: ...nches Width 22 Inches WARRIOR 500 Vacuum Motor Dual 2 Stage Weight Empty 127 LBS Weight Full Solution 232 LBS Power Cord 1 x 25 Feet WARRIOR 500 10 Vacuum Motor Dual 2 Stage Weight Empty 134 LBS Weight Full Solution 239 LBS Power Cord 2 x 25 Feet Heater 1850 Watts WARRIOR 500 05 Vacuum Motor Dual 3 Stage Weight Empty 129 LBS Weight Full Solution 234 LBS Power Cord 2 x 25 Feet Height Length Width ...

Page 9: ...cuum 1 Switch 4 Vacuum 2 Switch 5 Heater Switch with On Light Units w Heat Only 6 Pressure Gauge 1 2 3 4 5 6 7 8 9 10 11 7 Adjustable Pressure Relief Valve 8 Heater Temperature Light Units w Heat Only 9 Breaker for Vacuum 2 10 Breaker for Vacuum 1 11 Solution Accessory Tool Hook up ...

Page 10: ... materials are not of the type used for carpet cleaning Chemicals Suitable Chemicals Alkalis Detergents Hydroxides Soaps Vinegar Non Compatible Aldehydes Aromatics Hydrocarbons SP Butyls Carbon Tetrachloride Clorox Chlorinated Bleaches Chlorinated Hydrocarbons Lysol Methyl Ethel Ketone MEK Perchorethylene perc Phenolics Trichlorethylene D Limonene Registered Trademark Only use chemicals approved f...

Page 11: ...ollar on the quick disconnect coupler and push onto the connection on the chassis To avoid leaks check to be that a positive connection was made NOTE When using a powder cleaner pre mix with hot water in a clean container before adding to the solution tank 7 Turn pump and vacuum switch es to the on position Heater Operation NOTE Units with Heat Only The solution fittings on the machine will become...

Page 12: ... proper pattern clean or replace nozzle 2 Normally chemical is applied on the push stroke of the wand when cleaning Vacuuming is done on the pull stroke For heavily soiled carpets the wand may be used in a scrubbing manner applying chemical in both the push and pull stroke 3 When cleaning keep the working opening wand mouth flat on the surface being cleaned Keep the wand moving when the valve is o...

Page 13: ...Clean out recovery tank and check float valve to make sure it moves freely Clean out solution tank and remove and clean vacuum intake screen Clean outside of all tanks and check for damage Run vac motor for at least one minute to allow motor to dry Store with dome off tank to allow the tank to dry Check all gaskets for wear and leakage Check pump pressure observe spray pattern and check with gauge...

Page 14: ...Brushes Replacement 3 8 9 5mm Carbon Brushes End Cap WARNING The green ground wire must be attached for safe operation See wiring diagram If armature commutator is grooved extremely pitted or not concentric the motor will need to be replaced or sent to a qualified service center Important These brushes wear quicker as the length shortens due to increased heat Spring inside brush housing will damag...

Page 15: ...Cam Bearing Kit Plunger Seals Kit 512 555 Valve O Rings Kit both sides 512 560 Pump Replacement Kits 500 psi 512 565 Solution Pump Replacement Only qualified maintenance personnel are to perform the following repairs ...

Page 16: ...ricant monthly or when pressure drop seems excessive 1 Turn unit off before lubricating 2 Remove cap spring and spring retainer plate 3 With fingertips remove piston and u cup 4 Wipe piston and u cup clean of any film or scale 5 Lubricate the piston and u cup with Superlube 6 Reassemble regulator 7 With pump ON re adjust pressure regulator for normal operation Lubricate U Cup with Superlube Monthl...

Page 17: ... recovery tank Pump runs no solution Pump inlet screen plugged Clean inlet screen Pump not primed Prime pump with priming hose Internal or external solution line damaged and leaking Replace Pump runs loss of pressure Internal pump components wearing out Replace see pump kit components Check valves in pump head for particles or cuts in seals Take piston from BPR and lubricate with Super lube If pro...

Page 18: ...PARTS ...

Page 19: ...19 Control Panel 1 10 11 14 15 14 16 17 9 2 4 12 5 3 6 7 13 8 ...

Page 20: ...anphil SS 6 305 075 Switch SPST 2 Position Rocker 7 340 180 Boot Seal Breaker 8 845 084 Control Panel 9 475 040 Gasket 1 8 x 1 10 400 150 Locknut 10 x 32 Nylon SS 11 703 009 Decal Warrior W O Heat 12 340 162 Breaker 15A 13 360 015 1000 PSI Pressure Gauge 14 555 206 Elbow 90 1 4 FPT Extruded 15 555 072 Close Nipple 1 4 16 555 272 Hex Nipple 1 4 17 555 208 Elbow 90 1 4 Street Extruded ...

Page 21: ...21 Control Panel with Heat 18 19 1 10 11 14 15 14 16 17 9 2 4 12 5 3 6 7 13 8 ...

Page 22: ...ST 2 Position Rocker 7 340 180 Boot Seal Breaker 8 845 085 Control Panel 9 475 040 Gasket 1 8 x 1 10 400 150 Locknut 10 x 32 Nylon SS 11 703 009 Decal Warrior W O Heat 12 340 162 Breaker 15A 13 360 015 1000 PSI Pressure Gauge 14 555 206 Elbow 90 1 4 FPT Extruded 15 555 072 Close Nipple 1 4 16 555 272 Hex Nipple 1 4 17 555 208 Elbow 90 1 4 Street Extruded 18 305 120 Light Heater 19 305 076 Switch L...

Page 23: ...23 Electrical with 2 Stage Vacuum 3 8 10 9 4 7 11 6 1 2 5 ...

Page 24: ...lief 2 405 615 Bolt 1 4 x 1 2 Hex Head 3 335 005 Stain Relief 12 Gauge 4 325 015 Connector 5 Position Push Wire 5 415 125 FW 1 4 SS 6 465 084 BRKT Cord Strain Relief 7 315 015 Cord 25 Black 14 3 SJTW A 8 465 085 BRKT Cord Blank 9 345 120 Fuse Holder Inline 10 340 010 Fuse 5A 11 465 083 BRKT Electrical ...

Page 25: ...25 Electrical with Heat 3 Stage Vacuum 3 9 8 4 7 10 6 1 2 5 ...

Page 26: ... Steel Strain Relief 2 405 615 Bolt 1 4 x 1 2 Hex Head 3 335 005 Stain Relief 12 Gauge 4 325 015 Connector 5 Position Push Wire 5 415 125 FW 1 4 SS 6 465 084 BRKT Cord Strain Relief 7 315 015 Cord 25 Black 14 3 SJTW A 8 345 120 Fuse Holder Inline 9 340 010 Fuse 5A 10 465 083 BRKT Electrical ...

Page 27: ...27 Frame 1 2 3 4 5 6 7 9 8 ...

Page 28: ...455 075 Caster Swivel 4 2 455 090 Hubcap 5 8 Shaft 3 400 010 Hex Nut 1 4 x 20 Zinc 4 415 120 FW 1 4 zinc 5 415 165 FW 5 8 SS 6 455 085 Hubcap 9 5 Wheel 7 455 080 Wheel 12 x 2 25 8 845 090 Frame Base Warrior 9 405 088 Bolt 1 4 x 3 4 Carr Zinc ...

Page 29: ...29 Heater 1 TO QUICK CONNECT FROM PUMP OUT 2 4 4 TO REGULATOR 2 4 5 4 3 3 6 7 11 13 10 ...

Page 30: ...1 015 Crimp FTNG 1 4 HP Hose 1 4 MPT SVL 4 581 065 Crimp FTNG 3 8 Pulse Hose 1 4 MPT SVL 5 550 035 Check valve 1 4 FM x FM 6 490 005 Foamed Casing Round 1850W 7 425 040 Clamp 60 8 585 110 Nylon 90 Barb 1 2 x 3 8 NPT 9 415 125 FW 1 4 SS 10 405 615 Bolt 1 4 x 1 2 SS 11 465 086 Bracket Heater Mount ...

Page 31: ...31 Labels 3B 1 2 3A ...

Page 32: ...32 Labels REF PART NO DESCRIPTION NOTE 1 703 006 Decal Warrior LH 2 703 007 Decal Warrior RH 3A 703 008 Decal Warrior W Heat 3B 703 009 Decal Warrior WO Heat ...

Page 33: ...33 Pump 2 3A 3B 3C 12 1 16 6 15 16 6 13 14 7 5 7 4 8 9 11 10 7 TO SOLUTION TANK By Pass FROM SOLUTION TANK TO PRESSURE GAUGE 2 11 W O Heat To Quick Connect W Heat To Heater 17 18 ...

Page 34: ...0 PSI 5 555 002 ADPT 1 4 M x 1 4 F 6 425 005 Clamp 8 Hose 7 555 208 Elbow 90 1 4 Street Extruded 8 555 325 Hose Barb 90 1 2 Barb x 1 4 MPT 9 400 135 Locknut 1 4 x 20 Nylon Zinc 10 405 010 Bolt 1 4 x 1 SS 11 415 125 FW 1 4 SS 12 555 372 Hose Barb 1 2 Barb x 3 8 MPT 13 555 024 Bushing 3 8 M x 1 4 F 14 555 636 Tee 1 4 Street Extruded 15 512 580 Pump 500 PSI c w Motor BRKT 16 572 155 Polyspring Hose 1...

Page 35: ...35 Recovery 10 17 9 7 1 10 12 13 10 5 20 16 14 8 2 4 19 3 15 18 11 6 21 ...

Page 36: ... 7 405 615 CS 1 4 x 1 2 SS Hex HD 8 410 125 SMS 8 x 5 8 Pan Rob SS 9 415 125 FW 1 4 SS 10 415 165 FW 5 8 SS 11 415 305 FNDW 1 4 SS 12 455 070 Wheel 3 13 355 230 Vac Bolt Spacer 3 8 x 1 1 8 14 597 015 Adpt RM 30 Degree Float 2 15 495 320 Rec tank Warrior Blue 16 597 062 Float Screen Cage 2 17 465 082 BRKT Cord Mount 18 590 406 PVC Hose Barb 1 1 2 x MPT 19 410 265 MS 5 16 x 2 1 2 Pan Phil SS 20 595 ...

Page 37: ...37 Solution 1 2 3 4 5 6 7 8 9 11 12 13 14 15 16 17 18 19 10 20 1 2 4 ...

Page 38: ... 4 Allan 7 410 205 MS 10 32 x 1 2 SS 8 560 034 Strainer Acorn 9 415 120 FW 1 4 Zinc 10 415 125 FW 1 4 SS 11 415 305 FNDW 1 4 SS 12 440 015 Hinge 9 5 x 074 13 495 330 Lid Solution Tank 14 440 010 Hinge BRKT solution Tank 15 493 325 Solution Tank 16 460 015 Strap Tool Holder 17 415 187 FW 1 1 8 18 435 060 Knob 1 4 Hex Press Loc Wing 19 845 089 Plate mounting Solution 20 405 615 CS 1 4 x 1 2 SS Hex H...

Page 39: ...39 Vacuum 2 Stage 3 Stage 4 12A 12B 12A 12B 11A 11B 10 9 8 7 6 5 4 3 2 1 ...

Page 40: ... 2 RH Soc 3 425 020 Clamp 32 4 415 120 FW 1 4 Zinc 5 415 115 FW 10 SS 6 355 220 Manifold Dual Vacuum 7 475 072 Gasket Vacuum Manifold 8 405 065 6 Bolt 9 410 136 SMS 8 x 3 4 10 570 020 Vac Hose 2 11A 355 300 Vac 2 Stage 11B 355 305 Vac 3 Stage 12A 355 310 Housing Vac Motor 2 Stage 12B 355 315 Housing Vac Motor 3 Stage ...

Page 41: ...LUE RED VACUUM VACUUM PUMP SWITCHSWITCHSWITCH R O T O M R O T O M R O T O M POWER CORD BLK WHT WHT WHT WHT BLK BROWN ORANGE GRN GRN GRN GRN GRN 13AMP 13AMP 5AMP WHT BLK FROM PUMP RED FROM PUMP RED BLK RED VACUUM RECTIFIER M VACUUM M PUMP M ...

Page 42: ...42 Wiring 3 Stage Vacuum FUSE 5 AMP RED BLUE BLK BROWN ORANGE RED VACUUM VACUUM PUMP SWITCHSWITCHSWITCH MOTOR MOTOR MOTOR POWER CORD PANEL POWER CORD ...

Page 43: ...TE YELLOW WHITE HEATER GRN BLUE FUSE 5 AMP M M VACUUM M M M M VACUUM M M M PUMP VACUUM VACUUM PUMP SWITCHSWITCHSWITCH MOTOR MOTOR MOTOR POWER CORD PANEL POWER CORD HEAT SWITCH BROWN ORANGE RED YELLOW BLACK WHITE GRN GRN WHT WHT BLK BLK THERMO LIGHT GRN 13AMP 13AMP ...

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ESAB Warrior 500, Operating Instructions Manual

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