ESAB Warrior 500 User manual

MODELS:
WARRIOR 500
WARRIOR 500-10
WARRIOR 500-05
Operating instructions (ENG)
Read these instructions before using the machine.
500 PSI
760-173

2
Machine Data Log / Overview
OVERVIEW
The Ninja Warrior is an electric 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:

3
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 . . . . . . . . . . . . . . . . . . . . . . . . .10
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

4
How to Use This Manual
This manual contains the following sections:
• How to Use This Manual
•Safety
• Operations
• Maintenance
•PartsList
The HOW TO USE THIS MANUAL section will tell you
how to find important information for ordering correct
repair parts.
Parts may be ordered from authorized dealers. When
placing an order for parts, the machine model and
machine serial number are important. Refer to the
MACHINE DATA box which is filled out during the
installation of your machine. The MACHINE DATA box
is located on the inside of the front cover of this manual.
The model and serial number of your machine is
located approximately where shown.
Model:
Date of Purchase:
Serial Number:
Dealer:
Address:
Phone Number:
Sales Representative:
Serial Number
Tag
The SAFETY section contains important information
regarding hazardous or unsafe practices of the
machine. Levels of hazards are identified that could
result in product damage, personal injury, or severe
injury resulting in death.
The OPERATIONS section is to familiarize the operator
with the operation and function of the machine.
The MAINTENANCE section contains preventive main-
tenance to keep 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 illustration.
•PART NO. – column lists the part number for
the part.
•PRV NO. – reference number.
•QTY – column lists the quantity of the part used
in that area of the machine.
•DESCRIPTION – column is a brief description
of the part.
•SERIAL NO. FROM – If this column has an (*)
and a Reference number, see the SERIAL
NUMBERS page in the back of your manual. If
column has two asterisk (**), call manufacturer
for serial number. The serial number indicates
the first machine the part number is applicable
to. The main illustration shows the most current
design of the machine. When a boxed illustra-
tion is shown, it displays the older design.
•NOTES – column for information not noted by
the other columns.
NOTE: If a service or option kit is installed on your
machine, be sure to keep the KIT INSTRUCTIONS
which came with the kit. It contains replacement parts
numbers needed for ordering future parts.
NOTE: The manual part number is located on the
lower left corner of the front cover.

5
Safety
IMPORTANT SAFETY INSTRUCTIONS
When using an electrical appliance, basic precaution
must always be followed, including the following:
READ ALL INSTRUCTIONS BEFORE USING THIS MACHINE.
This machine is for commercial use.
To reduce the risk of fire, electric shock, or injury:
Connect to a properly grounded outlet. See Grounding Instructions.
Do not leave the machine unattended. Unplug machine from outlet when not in use and before mainte-
nance or service.
Use only indoors. Do not use outdoors or expose to rain.
Do not allow machine to be used as a toy. Close attention is necessary when used by or near children.
Use only as described in this manual. Use only manufacturer's recommended components and attach-
ments.
Do not use damaged electrical cord or plug. Follow all instructions in this manual concerning grounding
the machine. If the machine is not working properly, has been dropped, damaged, left outdoors, or
dropped into water, return it to an authorized service 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 openings blocked. Keep openings free of debris that may reduce
airflow.
This machine is intended for cleaning carpet only.
Do not vacuum anything that is burning or smoking, such as cigarettes, matches, or hot ashes.
This machine is not suitable for picking up health endangering dust.
Turn off all controls before unplugging.
Machine can cause a fire when operating near flammable vapors or materials. Do not operate this
machine near flammable fluids, dust or vapors.
This machine is suitable for commercial use, for example in hotels, schools, hospitals, factories, shops
and offices for more than normal housekeeping purposes.
Maintenance and repairs must be done by qualified personnel.
If foam or liquid comes out of machine, switch off immediately.
SAVE THESE INSTRUCTIONS

6
Safety
The following symbols are used throughout this guide as indicated in their descriptions:
HAZARD INTENSITY LEVEL
There are three levels of hazard intensity identified by signal words -WARNING and CAUTION and FOR SAFETY.
The level of hazard intensity is determined by the following definitions:
WARNING - Hazards or unsafe practices which COULD result in severe personal injury or death.
CAUTION - Hazards or unsafe practices which could result in minor personal injury or product or property damage.
FOR SAFETY: To Identify actions which must be followed for safe operation of 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 machine operating personnel.
FOR SAFETY:
DO NOT OPERATE MACHINE:
Unless Trained and Authorized.
Unless Operation Guide is Read and understood.
In Flammable or Explosive areas.
In areas with possible falling objects.
WHEN SERVICING MACHINE:
Avoid moving parts. Do not wear loose clothing; jackets, shirts, or sleeves when working on the machine.
Use only manufacturer approved replacement parts.

7
Safety
Grounding Instructions
THIS PRODUCT IS FOR COMMERCIAL
USE ONLY.
ELECTRICAL:
In the USA this machine operates on a standard 15
amp 115V, 60 hz, A.C. power circuit. The amp, hertz,
and voltage are listed on the data label found on each
machine. Using voltages above or below those
indicated on the data label will cause serious damage
to the motors.
EXTENSION CORDS:
If an extension cord is used, the wire size must be at
least one size larger than the power cord on the
machine, and must be limited to 50 feet (15.5m) in
length.
GROUNDING INSTRUCTIONS:
This appliance 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-
nances.
Improper connection of the equipment-grounding
conductor can result in a risk of electric shock.
Check with a qualified electrician or service person
if you are in doubt as to whether the outlet is
properly grounded. Do not modify the plug
provided with the appliance - if it will not fit the
outlet, have a proper outlet installed by a qualified
electrician.

8
Operations
Technical Specifications
M O D E L
I T E M
M E A S U R E
ALL
Electrical
115Volt, 60HZ, 15A
Soluon Pump
500PSI
Soluon capacity
13 Gal
Recovery Capacity
11 Gal
Height
43 inches
Length
30 inches
Width
22 Inches
WARRIOR
500
Vacuum Motor
Dual 2-Stage
Weight - Empty
127 LBS
Weight-Full Soluon
232 LBS
Power Cord
1 x 25 Feet
WARRIOR
500-10
Vacuum Motor
Dual 2-Stage
Weight - Empty
134 LBS
Weight-Full Soluon
239 LBS
Power Cord
2 x 25 Feet
Heater
1850 Was
WARRIOR
500-05
Vacuum Motor
Dual 3-Stage
Weight - Empty
129 LBS
Weight-Full Soluon
234 LBS
Power Cord
2 x 25 Feet
Height
Length
Width

9
Operations
Controls
1. Vacuum Accessory Tool Hook-up
2. Solution Pump Switch
3. Vacuum 1 Switch
4. Vacuum 2 Switch
5. Heater Switch with On Light (Units w/Heat Only)
6. Pressure Gauge
123456
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

10
Operations
Machine Operation
Care must be exercised in the use of all chemicals.
Chemicals are poisonous and can pose a health risk.
Read and follow manufacturers instructions regarding
dangers and correct usages.
The internal parts of the pump used in the machine are
suitable for use with most carpet cleaning chemicals.
But they are susceptible to chemical attack from some
cleaning substances, such as hydrocarbon solvents
and chlorinated bleaches. These non-compatible
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 for use with this
machine. Use of non-compatible chemicals may cause
machine damage and will not be covered under the
warranty. Carefully read ingredients on manufacturer’s
label before using any product in this machine.
Do not let pump run dry.
Do not let pump run unattended.

11
Operations
Pre-Run Inspection
1. Check all fittings and connectors for proper
assembly.
2. Check all hoses for leaks. Repair or replace any
damaged hoses.
3. Check power cord(s) for any damage. If damaged,
replace.
Equipment Set-up
1. Plug power cord from machine into properly
grounded wall outlet.
2. Turn vacuum motor switch on and off to make sure
there is electrical power at machine.
3. Using a clean container, fill the solution tank with
clean hot water. Do not use water over 130°F. Mix
in a non-foaming cleaning concentrate for use in
hot water extraction machines, following the manu-
facture's instructions printed on container.
4. Connect priming hose to solution fitting on
machine. Turn on pump and run for 30 seconds or
until a steady flow of water is coming out of priming
hose. Turn off pump and disconnect priming hose.
5. Connect vacuum hose to machine. Slide the swivel
cuff over the outlet on the tank.
6. Connect the hose to your machine and wand. Pull
back the knurled collar 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
extremely hot during operation. Allow sufficient
time to cool, or run solution through the machine
with the heater turned off before disconnecting or
performing any maintenance on the heater.
Plug the two power cords into separate grounded
circuits. The heater draws 15 amps of current.
Turn the solution pump ON. Fully prime the solution
system before turning heater on.
Turn the heater switch on. The red light on the heater
switch will be on when the heater switch is on. The red
heater temperature light will be on when the heater is
active and will turn off when the heater reaches
maximum temperature.
On initial start-up the heater will take a few minutes to
reach operating temperature.
When turning the pump and heater OFF, make certain
that you turn the heater off FIRST.

12
Operations
Cleaning
Always use defoamer if foaming occurs. Foam will
suspend large particles that may damage
vacuum(s) as well as allow liquid into the vacuum
motor(s) without activating the float shutoff.
1. Prior to cleaning, make certain that the nozzle is
functioning properly.
a. To check, hold the wand about one foot above
the surface to be cleaned and open the wand
valve. A full spray should be observed from the
nozzle.
b. If the nozzle is not showing a full spray pattern,
adjust nozzle for 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 open.
4. The shutoff float inside the vacuum tank will
impede the vacuum flow when the vacuum tank is
full. When this occurs, empty the vacuum tank by
opening the dump valve and dispose of the waste
in a proper manner.
5. Once the vacuum tank has been emptied, you may
once again proceed with cleaning

13
Maintenance
Periodic Maintenance
Twice a month, flush a white vinegar solution (one
quart vinegar to two gallons of water) or anti-browning
solution (mixed as directed) through the machine. This
will prevent build-up of alkaline residue in the system.
Periodically inspect all hoses, electrical cables and
connections on your machine. Frayed or cracked hoses
should be repaired or replaced to eliminate vacuum or
solution pressure loss. The electrical cable must be
well insulated and cable connector screw kept tight. If
the cable insulation is broken or frayed, repair or
replace immediately. Don't take chances with electrical
fire or shock.
SERVICE SCHEDULE DAILY WEEKLY QUARTERLY
Check machine for cord damage *
Check recovery dome and gasket for damage and cleanliness *
Check hoses for wear, blockages, or damage *
Check handles, switches, and knobs for damage *
Run one gallon of water through solution system *
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 if
necessary *
Check and clean solution screen *
Check cables for fraying *
Check overall performance of machine *
Check vac motor carbon brushes *
Daily/Regular Maintenance
Before making any repairs or adjustments to the
machine, disconnect the power cords from the
electrical source.
1. Empty unused cleaning solution from the solution
tank.
2. Inspect and clean filter screen in solution tank.
3. Flush pumping system with 1 to 2 gallons of clean
water.
4. After each use, rinse tank with fresh water. Periodi-
cally inspect the recovery tank and decontaminate
if necessary, using a Hospital Grade Virucide or a
10-1 bleach to water solution. Waste water should
be disposed of properly.
Do not allow machine to freeze.

15
Maintenance
Only qualified maintenance personnel are to
perform the following repairs.
Vacuum Motor Replacement
1. Turn off all switches and unplug machine.
2. Remove hardware under front of machine to
access component compartment.
3. Remove vacuum motor cover and disconnect
motor wires.
4. Remove the vacuum motor.
5. Reverse process to install vacuum motor.
Vacuum Motor Carbon 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 damage motor if brushes are allowed to wear
away completely.
Periodically check the length of the carbon brushes.
Replace both carbon brushes when either is less than
3/8" (9.5mm) long.

15
Maintenance
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.

16
Maintenance
Only qualified maintenance personnel are to
perform the following repairs.
Pressure Regulator
For best results with the pressure regulator, we
recommend that you clean and lubricate the piston and
u-cup with Superlube lubricant 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 Monthly.
(GREEN 500 PSI)
REBUILD KIT
537-015

17
Maintenance
Troubleshooting
PROBLEM CAUSE SOLUTION
Loss of Power
Unit not plugged in Connect unit to 3 prong grounded outlet.
Dead electrical circuit Check building circuit breaker or fuse box.
Faulty power cord Replace
Electrical shock Receptacle not grounded Contact an electrician to check building's wiring
Internal wiring problem Have a trained service technician check
machine's wiring
Vac motor speed
varies or doesn't run
Vacuum circuit breaker tripped Reset Breaker
Faulty vacuum motor Replace
Faulty switch Replace
Loss of vacuum
Loose vacuum dome Center and seal dome over tank
Crack in dome of poor joint Replace or repair using acrylic plastic cement
only
Lint or dirt clogging vacuum screen With power off clean screen
Loose cuffs on vacuum hose Tighten cuffs turning counterclockwise
Vac motor seals leaking Replace
Floor tool vac chamber clogged Wash out with hose. Pick lint out with a wire
Vacuum hose damaged Replace
Recovery tank full / Float ball stuck in
the up position Turn off power, drain 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 problem still exists change BPR kit
Pump will not run Faulty switch Replace
Loose wiring Repair or replace
Solution hose fitting
hard to connect Corrosion on fittings. Clean with steel wool. Soak in acetic acid (white
vinegar). Lubricate lightly with silicone base
lubricant.
Carpet not getting
clean Severe soil conditions Make several passes at right angles to each
other. Use a pre-spray.
Carpet too wet Over saturation Adjust solution pressure to lower settings. Make
several passes without spray
Carpet browning Leaving carpet too wet Check for loss of vac pressure
Too much chemical Check label for correct solution concentration
Solution not flowing
properly
Solution hose connection Check for positive connection
Faulty pump Repair or replace
Faulty floor tool valve / Nozzle Repair or replace
Faulty pump switch Repair

PARTS

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

20
Control Panel
REF
PART NO
DESCRIPTION
NOTE
1
415-155
FW, 1/2 SS
2
415-156
FW, 1/2 SS (Stand/Max OD)
3
580-010
Q.C. 1/4 FEM (Close)
4
555-184
Elbow 45,Street 1/4
5
410-205
MS, 10-32 x 1/2 Panphil SS
6
305-075
Switch, SPST 2-Posion 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