Windsor Ensign E50 User manual

Read these instructions before operating the machine
MODEL: E50
98635 01/09/07
U
CARPET EXTRACTOR
Operating Instructions (ENG)

MACHINE DATA LOG/OVERVIEW
ENSIGN 98635 04/04/03
2
For the name and address of your dealer contact: Windsor Industries
YOUR DEALER
Name: __________________________________________________________________________________________________
Address: _______________________________________________________________________________________________
Phone Number: _________________________________________________________________________________________
OVERVIEW
The Ensign 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 ______________________________
SALES REPRESENTATIVE # _____________________
DEALER NAME ________________________________
OPERATIONS GUIDE NUMBER ___________________
PUBLISHED __________________________________________

TABLE OF CONTENTS
ENSIGN 98635 03/26/04
3
Machine Data Log/Overview..........................1
Table of Contents...........................................2
HOW TO USE THIS MANUAL
How to use this Manual.................................1-1
SAFETY
Important Safety Instructions ........................2-1
Hazard Intensity Level...................................2-2
Safety Label Location....................................2-3
Grounding Instructions ..................................2-4
OPERATIONS
Technical Specifications................................3-1
Controls..........................................................3-2
Machine Operation........................................3-3
General Information....................................3-3
Pre-Run Machine Inspection......................3-3
Equipment Set-up.......................................3-3
Emptying & Cleaning Tanks.......................3-3
MAINTENANCE
Daily Maintenance.........................................4-1
Periodic Maintenance....................................4-1
Monthly Maintenance....................................4-1
Semi-annually................................................4-1
Lubrication......................................................4-1
Storage...........................................................4-1
Vacuum Motor Replacement.........................4-2
Solution Pump Replacement.........................4-3
Pump Replacement Kit..................................4-3
Machine Troubleshooting..............................4-4
GROUP PARTS LIST
Pump Group................................................5-1
Recovery Tank Group.................................5-3
Solution Tank Group ...................................5-5
Vacuum Motor Group..................................5-7
Wiring Group................................................5-9
Suggested Spare Parts ...............................5-10
Notes............................................................5-11
Warranty......................................................5-12

HOW TO USE THIS MANUAL
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This manual contains the following sections:
-HOW TO USE THIS MANUAL
-SAFETY
-OPERATIONS
-MAINTENANCE
-PARTS LIST
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 Windsor
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 on
the front of the Access Panel.
The SAFETY section contains important information
regarding hazard or unsafe practices of the
machine. Levels of hazards are identified that could
result in product or 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
maintenance 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.
-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 – column indicates
the first machine the part number is
applicable to. When the machine design
has changed, this column will indicate
serial number of applicable machine.
The main illustration shows the most
current design of the machine. The
boxed illustrations show older designs.
-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 98# on the lower left corner of the front
cover is the part number for this manual.
MODEL _____________________________________
DATE OF PURCHASE ________________________
SERIAL NUMBER ____________________________
SALES REPRESENTATIVE # ___________________
DEALER NAME ______________________________
OPERATIONS GUIDE NUMBER __________________
PUBLISHED ________________________________

SAFETY INSTRUCTIONS
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-1
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
maintenance 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
attachments.
Do not use damaged electrical cord or plug. Follow all instructions in this manual concerning grounding
the machine. If the machine isnot 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. Keepcord 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
!
WARNING:

HAZARD INTENSITY LEVEL
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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 equipment. 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.
.
!
WARNING
!CAUTION

SAFETY LABEL LOCATION
ENSIGN 98635 04/04/03 2-3
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
500009

GROUNDING INSTRUCTIONS
ENSIGN 98635 04/04/03
2-4
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
malfunction 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 ordinances.
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 adaptor that
looks like the adaptor 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 adaptor 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 adaptor must be
connected to a permanent ground such as a
properly grounded outlet box cover. Whenever
the adaptor 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.

TECHNICAL SPECIFICATIONS
ENSIGN 98635 04/04/03 3-1
ITEM MEASURE
Electrical 115 Volt, 60hz
Vacuum Motor Single 3 stage
Solution Pump 50 psi
Solution Capacity 7 gal (26 L)
Recovery Capacity 6 gal (22 L)
Weight - Empty 50 lbs (110 kg)
Weight –Full Solution 105 lbs (230 kg)
Height 35 inches (88.90 cm)
Height – (Handle Folded Down) 28.5 inches (72.39 cm)
Length 25 inches (63.50 cm)
Width 15.5 inches (39.37 cm)
Power Cord 22 feet (6.71 m)

CONTROLS
ENSIGN 98635 04/04/03
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1. Vacuum Switch
2. Pump Switch
ON
OFF OFF
ON
VAC PUMP
1 2

MACHINE OPERATION
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GENERAL INFORMATION
As the carpet is being cleaned, check to see
if there is foam building up in the recovery
bucket. Add a little defoaming compound to the
recovery tank but never to the solution tank.
For infrequent use or long periods of
storage, flush the system with a neutralizing
solution of 1 quart white vinegar mixed with 2
gallons hot water. Flush the system with clean
hot water after neutralizing.
For hose fitting lubrication, use a light silicone
lubricant which will not damage o-rings.
PROTECT THIS MACHINE FROM
FREEZING.
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. Connect vac hose to machine. Slide the
swivel cuff over the outlet on the tank.
4. Connect the hose to your machine and
wand. Pull back the knurled collar on the
quick disconnect coupler (located on the
solution tank) and push into the connection.
To avoid leaks, check to be sure that a
positive connection was made.
5. Using a clean container, fill the solution tank
with clean hot water. Mix in a non-foaming
cleaning concentrate for use in hot water
extraction machines, following the
manufacture’s instructions printed on
container.
NOTE:When using a powder cleaner, pre-mix
with hot water in a clean container before adding
to the solution tank.
6. Turn pump and vacuum switch(s) to the on
position.
7. Start cleaning.
EMPTYING AND 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. Before proceeding, 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

MAINTENANCE
ENSIGN 98635 04/04/03
4-1
Unplug power cord(s)
before servicing or
making any repairs.
DAILY MAINTENANCE
1. Flush the entire system, including floor tool,
hand tool, etc., with 1 to 3 gallons of clean, hot
water.
2. Vacuum out the solution tank.
3. Rinse tank with fresh water. Periodically
inspect the recovery tank and decontaminate if
necessary, using a Hospital Grade Virucide or
a 1-10 bleach to water solution. Wastewater
should be disposed of properly.
4. Occasionally check filter screen at the bottom
of the solution tank and rinse clean with hot
water if necessary.
5. Inspect hoses for wear. Frayed or cracked
hoses should be replaced to avoid vacuum or
solution pressure loss.
6. Inspect power cord for wear or damage. This
cable will lie on wet carpet. To prevent
electrical shock replace cords that are frayed
or have cracked insulation immediately.
7. Clean all dirt and obstructions from drain valve
and gaskets to prevent possible leakage and
premature wear.
8. Run clean water through solution pump when
work is complete.
9. Empty both tanks and rinse, run vacuum (s) for
at least one minute to dry motor(s).
10. Store with access covers removed to allow
tanks to dry. DO NOT attempt to
repair hose!
Repairing high-
pressure hoses may result in severe burns and
serious injury.
PERIODIC MAINTENANCE
1. 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 extractor, turning pump switch
on/off several times, flush with clean water.
This will prevent build-up of alkaline residue in
the system.
2. Check hoses for wear, blockages, or damage.
Frayed or cracked hoses should be repaired or
replaced to eliminate vacuum or solution
pressure.
3. Check all handles, switches, knobs, electrical
cables and connections on your machine for
damage. If the cable insulation is broken or
frayed, repair or replace it immediately. Don’t
take chances with electrical fire or shock.
4. Clean out solution tank. Remove and clean
solution screen.
5. Clean outside of all tanks and check for
damage.
MONTHLY MAINTENANCE
1. Check all bearings for noise and wear.
2. Check all gaskets for wear and leakage.
3. Check pump pressure; observe spray pattern
and check gauge if necessary.
4. Check overall performance of machine.
SEMI-ANNUALLY
1. Check vacuum motor brushes.
LUBRICATION
For hose fitting lubrication, use a light silicone
lubricant which will not damage o-rings.
STORAGE
Thoroughly clean machine if it is to be stored.
Protect this machine from freezing while in
storage.

MAINTENANCE
ENSIGN 98635 03/26/04 4-2
Only qualified
maintenance
personnel are to
perform the following repairs.
VACUUM MOTOR REPLACEMENT
1. Turn off all switches and unplug machine.
2. Remove recovery tank.
3. Locate the vacuum motor wires and
disconnect at the connector.
4. Remove the vacuum motor.
5. Reverse process to install vacuum motor.
Vacuum Motor Carbon Brushes Replacement (Windsor)
WARNING:
The green
ground wire must be
attached for safe operation.
See wiring diagram.
End Cap
Carbon
Brushes
If armature commutator is grooved, extremely pitted or not
concentric, the motor will need to be replaced or sent to a
qualifiedservicecenter.
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.
3
8[9.5mm]
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.
3/8 (9.5mm)
Vacuum Motor Carbon Brushes Replacement (Ametek)
Note:
When replacing carbon brushes loosen wire terminal
BEFOREremoving screws on bracket.
Note:
Place
stop in
groove.
Wire
Terminal
WARNING:
The green
ground wire must be
attached for safe operation.
See wiring diagram.
End Cap
Carbon
Brushes
Wire Terminal
If armature commutator is grooved, extremely pitted or not
concentric, the motor will need to be replaced or sent to a
qualifiedservicecenter.

MAINTENANCE
ENSIGN 98635 03/26/04
4-3
Only qualified
maintenance
personnel are to
perform the following repairs.
SOLUTION PUMP REPLACEMENT
1. Turn off all switches and unplug the
machine.
2. Remove recovery tank.
3. Remove solution hoses from fittings in pump.
4. Remove the screws that fasten the pump to
the frame.
5. Reverse process to install pump.
Valve Asm
84162
Diaphragm
29207
Pump Head
65188
PUMP (250-63) REPLACEMENT KIT
Pump Head
65235
Valve Asm
84191
Diaphragm
29263
PUMP (65233) REPLACEMENT KIT

TROUBLESHOOTING
ENSIGN 98635 03/26/04 4-4
PROBLEM CAUSE SOLUTION
Dead electrical circuit Check building circuit breaker or fuse box.
Loss of Power Faulty power cord Replace
Equipment not grounding Follow grounding instructions exactly
Receptacle not grounded Contact an electrician to check building’s wiring
Electrical shock Internal wiring problem Have a trained service technician check machine’s
wiring
Worn motor brushes Replace
Motor worn out Replace
Vac motor speed varies
or doesn’t run Faulty switch Replace
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
Loss of vacuum
Vac motor, hose, or dome
gasket Replace
Pump inlet screen plugged Clean inlet screen
Pump air locked Press trigger to open valve on cleaning wand to
relieve air
Pump runs no solution Internal or external
solution line damaged and
leaking Replace
Internal pump components
wearing out Replace, see pump kit components (pg 4-3)
Pump runs, loss of
pressure Check valves in pump
head for particles or cuts in
seals
Take piston from BPR and lubricate with Superlube.
If problem still exists change BPR kit
Unit not plugged in Connect unit to 3 prong grounded outlet
Pump will not run Loose wiring See dealer
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
Leaving carpet too wet Check for loss of vac pressure
Too much chemical Check label for correct solution concentration
Carpet browning Light carpet with no brown
prevention Go over carpet with browning prevent only
Solution hose connection Check for positive connection
Faulty pump Repair or replace
Faulty floor tool valve Repair or replace
Solution not flowing
properly Faulty pump switch Repair

PUMP GROUP
ENSIGN 98635 04/04/03
5-1
1
2
3
567
8
23
4

PUMP GROUP
ENSIGN 98635 01/09/07
5-2
REF PART NO. QTY DESCRIPTION SERIAL NO.
FROM NOTES:
1 39049 1 HOSE, 3/8” RUBBER X 11’
2 20042 2 CLAMP, 3/8 HOSE (D-SLOT)
3 40043 2
HOSEBARB, 3/8 MPT X 3/8 90°
4 65216 1 PUMP ASM, 115V 3ST SENSEI
5 110-22 4 GROMMET 6 GAL. PORT
6 87013 2 WASHER, 1/4 ID X 5/8 OD SS
7 70020 2 SCR, 1/4-20 X 1/2 HHCS SS NP
8 39311 1 HOSE, 3/8ID SGLBRD RBR X 14”

RECOVERY TANK GROUP
ENSIGN 98635 03/18/05
5-3
3
4
5
6
9
10
11
12
14
16
17
18
20
21
22
23
24
13
15
26
15
1
27
7
8
19
2
32 25
28
29
30
31

RECOVERY TANK GROUP
ENSIGN 98635 03/18/05 5-4
REF PART NO. QTY DESCRIPTION SERIAL NO.
FROM NOTES:
104094 1ADPTR, 1.5FS X 1.5FS PVC “U”
234408 1FLOAT SHUT-OFF TUBE W/ADPTR
3260-64A 1ACCESS COVER CLEAR 6” W/ RIM
470546 6SCR, 8 X 3/4 PFHT/S BLK ZINC
538299 1HANDLE, DK GRY
6110-14B 2CAP PLUG 5/8”
757106 3NUT, 8-32 W/STAR WASHER PLTD
887131 2WASHER, #10 FLAT W/NEOPRENE
970051 1SCR, 8-32 X ½ PPHMS NP
10 140-03A 1STRIKE FOR 140-03
11 140-03 1LATCH DRAW PULL 6 GAL.
12 70013 2SCR, 8-32 X ¾ PPHMS SS
13 15-808123 1DUMP VALVE, 2”
14 11-800444 1ELBOW, 2” 45D PVC SCH40
15 35256 2GASKET, DUMP VALVE
16 75338 1TANK, RECOVERY DK GRY
17 110-14A 3CAP PLUG 1”
18 57047 2NUT, ¼-20 HEX NYLOCK
19 70393 2SET SCR, 1/4-20 X 1.25L
20 87013 2WASHER, 1/4 ID X 5/8 OD SS
21 140-12 1KNOB 1/4-20 X 3/4 S/S CUPPOINT
22 390-24 1WASHER 1/4 X 5/8 BONDED NEOPRN
23 280-02 2RIVIT AL. 3/16 X 1/2 CLOSED
24 065-40 1BAFFLE
25 260-33 1HOSEBARB, 1.5 MPT X 1.5
26 35255 1GASKET, TANK LID
27 34380 1FLOAT, SHUT OFF
28 150-65 1HOSE BAG 24”X 36”
29 150-49 1VAC HOSE W/CUFF 16-1/2 X 1” DIA
30 39573 1HOSE ASM, 3/8 LP SLTN 16.5FT
31 47355 1KIT, HOSE ASM W/BAG ENSIGN
32 87257 1WASHER, HOSEBARB

SOLUTION TANK GROUP
ENSIGN 98635 01/09/07
5-5
*
*
PARTS INSIDE
TANK
CONNECT TO
PUMP ASM
4
5
7
8
6
6
1
2
9
10
41
6
11
12
6
14 13
15
18
19
22
20
21 17
16
23
24
28
29
30
18
31 32
33
34
35
38
37
39
39
40
36
3
26
27
25
23
42
43