Prochem Ninja warrior 1200PSI NWCU1312N User manual

86399130-A 02/03/15
Ninja Warrior 1200 PSI
Extractor
Operating Instructions (ENG)
MODEL: NWCU1312N
10070700
From Serial Number (Ref No. 1*)
* See Serial number page or
call Manufacturer.

Warranty Registration
Thank you for purchasing a Prochem Kärcher Group product. Warranty registration is quick
and easy. Your registration will allow us to serve you better over the lifetime of the product.
To register your product go to :
http://www.prochem.com/WarrantyRegistration.aspx
For customer assistance:
1-800-444-7654
286399130 Operators Manual Ninja Warrior 1200PSI
Machine Data Label
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

3
Table of Contents
Machine Data Label. . . . . . . . . . . . . . . . . . . . . . . . . .2
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . .3
How To Use This Manual . . . . . . . . . . . . . . . . . . . . .4
Safety
IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . .5
HAZARD INTENSITY LEVEL. . . . . . . . . . . . . . . . . .6
Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Grounding Instructions . . . . . . . . . . . . . . . . . . . . . . .8
Operations
Technical Specifications . . . . . . . . . . . . . . . . . . . . . .9
Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . .11
Chemicals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Solution Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Auto-Fill. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Auto Pump-Out. . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Pre-Run Inspection. . . . . . . . . . . . . . . . . . . . . . . . .12
Equipment Set-up. . . . . . . . . . . . . . . . . . . . . . . . . .12
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Maintenance
Periodic Maintenance . . . . . . . . . . . . . . . . . . . . . . .13
Daily/Regular Maintenance. . . . . . . . . . . . . . . . . . .13
Vacuum Motor Replacement . . . . . . . . . . . . . . . . .14
Solution Pump Replacement . . . . . . . . . . . . . . . . .15
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Suggested Spare Parts. . . . . . . . . . . . . . . . . . . . . .18
86399130 Operators Manual Ninja Warrior 1200PSI

4
How To Use This Manual
This manual contains the following sections:
• How to Use This Manual
•Safety
• Operations
• Maintenance
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 on the back of the machine.
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
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.
Model:
Date of Purchase:
Serial Number:
Dealer:
Address:
Phone Number:
Sales Representative:
86399130 Operators Manual Ninja Warrior 1200PSI

5
Safety
IMPORTANT SAFETY INSTRUCTIONS
When using this machine, basic precaution
must always be followed, including the following:
READ ALL INSTRUCTIONS BEFORE USING THIS MACHINE.
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.
86399130 Operators Manual Ninja Warrior 1200PSI

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
manufacturer approved replacement parts.
86399130 Operators Manual Ninja Warrior 1200PSI

7
Safety
Safety Labels
NOTE: These drawings indicate the location of safety labels on the machine. If at any time the labels become
illegible, promptly replace them.
Label Warning
86244300
Label Circuit Interrupter
86200570
86399130 Operators Manual Ninja Warrior 1200PSI

8
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.
This appliance is for use on a nominal 120-volt circuit,
and has a grounded plug that looks like the plug in "Fig.
A". A temporary adapter that looks like the adapter in
"Fig. C" may be used to connect this plug to a 2-pole
receptacle as shown in "Fig. B", if a properly grounded
outlet is not available. The temporary adapter should
be used only until a properly grounded outlet (Fig. A)
can be installed by a qualified electrician. The green
colored rigid ear, lug, or wire extending from the
adapter must be connected to a permanent ground
such as a properly grounded outlet box cover.
Whenever the adapter is used, it must be held in place
by a metal screw.
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.
USING AN ADAPTOR
GROUNDING CONNECTION
Note: Adaptors are not allowed in Canada.
Outlet
Tab for Grounding
Outlet Box
FIGURE C
Grounded
FIGURE A
Adaptor
Screw
FIGURE B
Adaptor
Metal Screw
Grounded
Grounding Pin
86399130 Operators Manual Ninja Warrior 1200PSI

9
Operations
Technical Specifications
This appliance is not intended for use by persons (including children) with reduced physical, sensory or
mental capabilities, or lack of experience or knowledge, unless they have been given supervision or
instruction concerning use of the appliance by a person responsible for their safety
MODEL ITEM MEASURE
10070700
Electrical 115 Volt, 60 hz, 15A
Solution Pump 1200 psi
Pump-Out Pump 5.0 GPM Diaphragm
Solution Capacity 13 Gal
Recovery Capacity 11 Gal
Height 43 inches
Length 30 inches
Width 22 inches
Vacuum Motor Single 3 Stage
Weight- Empty 151 lbs
Weight-Full Solution 275 lbs
Power cord 2 X 25 feet
86399130 Operators Manual Ninja Warrior 1200PSI
Height
Length
Width

10
Operations
Controls
1. Vacuum Accessory Tool Hook-up
2. Breaker for Vacuum
3. Vacuum Switch
4. Solution Pump Switch
5. Pump-Out Switch
6. Pump-Out Fitting
7. Solution Auto-Fill Fitting
8. Adjustable Unloader Valve
9. Pressure Gauge
10. Solution Accessory Tool Hook-up
86399130 Operators Manual Ninja Warrior 1200PSI
134567
8
9
10
2

11
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 floor cleaning chemicals. But
they are susceptible to chemical attack from some
cleaning substances, such as hydrocarbon solvents
and chlorinated bleaches.
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 machine run unattended.
Solution Pump
The solution pressure is adjustable by turning the
unloader valve on the control panel.
Do not let pump run dry.
Auto-Fill
When a water supply is connected to the auto fill fitting
the solution tank will fill to a preset level. The auto-fill
float in the solution tank will maintain this water level
during operation.
Auto Pump-Out
The auto pump-out system uses a run-dry diaphragm
pump. The pump will run whenever the pump-out
switch is turned on. The primary strainer is located in
the recovery tank. A secondary strainer is attached to
the pump head to protect the pump from a damaged or
improperly installed primary strainer.
Do not turn on auto pump-out with cap attached to
the pump-out fitting. Pump-out system damage
may occur from excessive pressure.
86399130 Operators Manual Ninja Warrior 1200PSI

12
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 cords from machine into properly
grounded wall outlet. Power cords must be on
separate circuits.
2. Connect fresh water supply hose to auto-fill fitting
on control panel. Do not use water over 130°F.
Turn on water to supply hose. The solution tank will
fill to float level.
3. Connect pump-out hose to pump-out fitting on
control panel. Place opposite end of pump-out
hose in an appropriate drain area.
4. Connect vacuum hose to machine. Slide the swivel
cuff over the outlet on the tank.
5. 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.
6. Turn solution pump, vacuum, and pump-out
switches to the on position.
Cleaning
1. Prior to cleaning, make certain that the floor tool is
functioning properly.
2. When cleaning, keep the floor tool flat on the
surface being cleaned.
3. The float shutoff inside the recovery tank will
impede the vacuum flow when the vacuum tank is
full. If this occurs, disconnect power from machine,
drain recovery tank, and clean pump-out strainer.
When using a powder cleaner, pre-mix with hot water in
a clean container before adding to the solution tank.
86399130 Operators Manual Ninja Warrior 1200PSI

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 yourmachine. Frayed or crackedhoses
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.
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. Inspect and clean pump-out strainer in recovery
tank.
4. Flush pumping system with 1 to 2 gallons of clean
water.
5. 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.
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 pump-out strainer and run clean water through pump-out system. *
Clean out solution tank and remove and clean vacuum intake screen *
Clean outside of all tanks and check for damage *
Run vacuum 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 vacuum motor carbon brushes *
86399130 Operators Manual Ninja Warrior 1200PSI

14
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.
86399130 Operators Manual Ninja Warrior 1200PSI
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
Solution Pump Replacement
Only qualified maintenance personnel are to perform the following repairs.
86399130 Operators Manual Ninja Warrior 1200PSI

16
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
Vacuum 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
Vacuum motor seals leaking Replace
Floor tool vacuum 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.
Solution 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
Solution 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
Solution Pump will not
run Faulty switch Replace
Loose wiring Repair or replace
86399130 Operators Manual Ninja Warrior 1200PSI

17
Maintenance
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 vacuum 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
Auto-fill does not
control water level Faulty Auto-fill float Replace float
Pump-out system has
no flow
Faulty Pump-out switch Replace Pump-out switch
Faulty Pump-out pump Replace Pump-out pump
Blown fuse Replace fuse
Pump-out system has
low flow Clogged primary strainer Clean primary strainer
Clogged secondary strainer Clean secondary strainer
86399130 Operators Manual Ninja Warrior 1200PSI

18
Suggested Spare Parts
86399130 Operators Manual Ninja Warrior 1200PSI
86135320 BRUSH SET
VACUUM
86309790 WHEEL
86308370 VALVE & SEALS KIT 1200
86308380 CAM & BEARING KIT 1200
86001660 HUBCAP SHAFT
86007970 STRAINER
PUMP
86308360 PLUNGER & SEAL KIT 1200
86334490 DECK PLATE
86010730 WASHER
86300070 HUBCAP
86199430 CASTOR

19
Notes
86399130 Operators Manual Ninja Warrior 1200PSI

86399140-A 02/03/15
Spare Parts List
(1.007-070.0)
Ninja Warrior 1200 PSI
From Serial Number (Ref No. 1*)
* See Serial number page or
call Manufacturer.